Abstract: Methods and a double vacuum processing system are presented. A method of performing a double vacuum debulk and cure on a composite laminate is presented. A composite laminate is heated to begin a double vacuum debulk of the composite laminate while vacuum is pulled in a first vacuum zone containing the composite laminate and a second vacuum zone containing the first vacuum zone. Pressure within the second vacuum zone is increased to above atmospheric pressure. Heating the composite laminate is continued to complete a cure cycle for the composite laminate while the second vacuum zone is above atmospheric pressure.

Abstract: An induction heating system and methods of forming an induction heating system are presented. The induction heating system comprises a conductor, a susceptor surrounding the conductor, and magnetic field reduction. The susceptor has a Curie temperature. The magnetic field reduction is configured to reduce magnetic fields escaping the induction heating system when the susceptor is at the Curie temperature independent of a layout of the induction heating system within an induction heating device.

Abstract: Methods and an induction curing system for curing a composite panel. The induction curing system comprises; a rigid curing tool configured to hold a composite material; a vacuum bagging material sealed to the rigid curing tool; and a dimensional control structure having a lattice and an open casing formed of a rigid material, the lattice positioned within a concavity of the open casing, the dimensional control structure sealed to at least one of the vacuum bagging material or the rigid curing tool.

Abstract: A composite forming apparatus includes an end effector, a forming feature that is coupled to the end effector, and a heating element that is coupled to the forming feature to heat the forming feature. The end effector moves the forming feature relative to a composite ply to form the composite ply over a forming tool or over a prior formed composite ply. The forming feature heats the composite ply via conduction.

Abstract: Disclosed herein is a method of forming a multi-layered metallic part. The method comprises stacking at least two metallic layers, each made of a metallic material having a ductility, to form a multi-layered metallic assembly. The method also comprises interposing a diffusion-bond preventing element directly between adjacent ones of the at least two metallic layers of the multi-layered metallic assembly. The method further comprises diffusion bonding the at least two metallic layers to each other at locations other than a location contiguous with the diffusion-bond preventing element to produce a multi-layered metallic part having a non-bonded region between the at least two metallic layers at the location of the diffusion-bond preventing element.

Abstract: Stiffened skin panels comprise alternating truss core portions and solid laminate portions sandwiched between inner and outer facesheets, all formed from a fiber reinforced thermoplastic. The components of the panels are co-consolidated using induction heating. The panels are stiffened with spars fastened to the solid laminate portions.

Abstract: A method and system for heating a material includes an induction coil, a susceptor providing a receptacle, where the receptacle is configured to receive the material, and at least one nozzle for ejecting a heated gas onto and/or into the material. During the method, the susceptor is heated by the induction coil, and thermal energy from the susceptor can be transferred to the material. In addition to being heated by heat from the susceptor, the material is also heated by the heated gas, thereby increasing a heating rate of the material to rapidly heat the material to a processing temperature. The system can include other components such as a gas source, at least one conduit that channels gas from the gas source to the at least one nozzle, and a heat source that heats the gas prior to ejecting the gas from the at least one nozzle.

Abstract: Systems and methods are provided for creating precursors for consolidating composite parts. One embodiment is a method for forming a metallic structure. The method includes forming a precursor for a pressure membrane that includes a contour having a linearized length corresponding with a linearized length of a surface of a forming tool. The method also includes affixing a perimeter of the precursor to a perimeter of a base member, leaving a volume between the base member and the precursor, altering a shape of the precursor at a superplastic temperature by forcing the precursor into complementary contact with the surface of the forming tool, and setting the shape of the precursor while the precursor is held in complementary contact.

Abstract: A composite forming apparatus includes an end effector, a forming feature that is coupled to the end effector, and a heating element that is coupled to the forming feature to heat the forming feature. The end effector moves the forming feature relative to a composite ply to form the composite ply over a forming tool or over a prior formed composite ply. The forming feature heats the composite ply via conduction.

Abstract: An apparatus includes a first electrode exhibiting a first Seebeck coefficient, a second electrode exhibiting a second Seebeck coefficient greater than the first Seebeck coefficient, and particles between the first and second electrodes exhibiting a third Seebeck coefficient between the first and second Seebeck coefficients. An alternating current power supply is electrically connected to the first and second electrodes. Heat is generated due to the Peltier effect at a junction between the first electrode and the particles and at a junction between the second electrode and the particles. Heat is removed due to the Peltier effect at the junction between the first electrode and the particles and at the junction between the second electrode and the particles. The particles are densified due to heating and cooling phase transitions between a higher-temperature solid phase and a lower-temperature solid phase while compressing the particles.

Abstract: Cookware, and an induction cooking system including the cookware, include a container, a base layer, and a susceptor layer. The container and the base layer are non-magnetic at room temperature, while the susceptor layer is magnetic at room temperature and has a Curie temperature at which the susceptor layer becomes non-magnetic. During heating of a material within the container, the base layer functions as a passive heat exchange to transfer heat across the susceptor layer. Further, during the heating, the base layer conducts an electric current when the susceptor layer approaches a leveling temperature and/or the Curie temperature of the susceptor layer, thereby decreasing an amount of heat produced and resulting in a more even heating of the material.

Abstract: A method and apparatus for forming a composite structure. A plurality of consolidated overbraided thermoplastic preforms are co-consolidated in a circumferential stackup that is circumferentially constrained. Fibers of the plurality of consolidated overbraided thermoplastic preforms are tensioned during co-consolidation.

Abstract: A first tooling die and a second tooling die are movable with respect to each other. The first tooling die and the second tooling die form a die cavity. The first tooling die and the second tooling die comprise a plurality of stacked metal sheets. A plurality of air gaps is defined between adjacent stacked metal sheets. A first smart susceptor material is within the die cavity and connected to the first tooling die. The first smart susceptor material has a first Curie temperature. A second smart susceptor material is within the die cavity and associated with the second tooling die. The second smart susceptor material has a second Curie temperature lower than the first Curie temperature. A flexible membrane is between the second tooling die and the first smart susceptor material. The flexible membrane is configured to receive pressure.

Abstract: An induction curing system comprises a slip sheet and a power supply. The slip sheet comprises a layup surface configured to receive a composite material, a tool interface surface configured to interface with an upper surface of a tool, a rigid body extending between the layup surface and the tool interface surface, and an induction coil circuit within the rigid body of the slip sheet. The induction coil circuit is configured to heat the layup surface to a temperature sufficient to cure the composite material. The induction coil circuit has a diameter selected to generate heat using a power supply having a frequency below 150 kHz. The rigid body is configured to support the composite material during transport of the composite material. The power supply is coupled with the induction coil circuit, the power supply is selected based on the diameter of the induction coil circuit.

Abstract: A method and apparatus for tacking and trimming a thermoplastic tow. A thermoplastic tow is received from a braiding system over a braided structure on a surface. The thermoplastic tow is tack welded to the braided structure. A portion of the thermoplastic tow is trimmed to thereby trim the thermoplastic tow received over the braided structure.

Abstract: An induction-heating system includes a susceptor located proximate to a flight surface of an aircraft. The susceptor comprises an array of wires arranged along a first axis. The array of wires is constructed of a ferromagnetic material having a selected Curie temperature. The induction-heating system also includes an electrically conductive coil including a plurality of coil windings oriented substantially perpendicular with respect to the first axis of the array of wires. The electrically conductive coil is configured to generate a magnetic field oriented substantially parallel with respect to the first axis of the array of wires. The electrically conductive coil is positioned to induce induction heating within the ferromagnetic material of the susceptor when the susceptor is below the selected Curie temperature.

Abstract: Heating apparatus and methods for thermally processing a part including improved control of temperature. A thermal management system is coupled to a back surface of a table thermally coupled to an inductive heating circuit. The thermal management system includes a chamber defining an interior space, at least one cooling fin disposed within the chamber, an inlet extending through the chamber and fluidly communicating with the interior space, and an outlet extending through the chamber and fluidly communicating with the interior space. In some applications, an air source fluidly communicates with the inlet and is selectively operable to generate an air flow through the chamber, so that the thermal management system may be selectively operated in an insulator mode and a cooling mode.

Abstract: Heating apparatus and methods for forming a part with a non-planar shape include a table formed of a thermally conductive material and defining a table surface. A tool, also formed of a thermally conductive material, has a base surface configured to engage the table surface of the table and a tooling surface opposite the base surface, wherein the tooling surface has a contoured shape that is non-planar. A heating blanket is provided above the table and defines a heating surface. The tooling surface of the tool is configured to engage a first surface of the part and the heating surface of the heating blanket is configured to engage a second surface of the part opposite the first surface of the part. The table and the heating blanket are heated to a processing temperature so that the part at least partially conforms to the tooling surface of the tool.

Abstract: A heating apparatus for thermally processing a part includes a table formed of a thermally conductive material and a table inductive heating circuit thermally coupled to the table. The table inductive heating circuit comprising a plurality of table induction coil circuits electrically coupled in parallel with each other. Each table induction coil circuit includes a table electrical conductor and a table smart susceptor having a Curie temperature. First and second table induction coil circuits have pairs of segments positioned adjacent each other that are configured to carry current in opposite directions. In some examples, the table induction coil circuits have partially nested, rectilinear hook shapes. In other examples, the table induction coil circuits overlap each other at rhombus-shaped turns.

Abstract: A method and apparatus for forming a composite structure. A stackup comprising a plurality of overbraided thermoplastic members and an overbraided thermoplastic skin is built. The stackup is placed between an inner tooling and an outer tooling. The inner tooling, the stackup, and the outer tooling are held in place together using a load constraint. The inner tooling, the stackup, the outer tooling, and the load constraint form a consolidation setup. The consolidation setup is heated to form the composite structure.