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.

Abstract: A smart susceptor assembly, including a smart susceptor, and a cladding disposed on at least a portion of the smart susceptor, wherein the cladding includes an electrically conductive material.

Abstract: A co-consolidation tool, including a heating assembly to receive one or more thermoplastic parts and to apply a consolidation temperature to the one or more thermoplastic parts, a pressure bladder to apply a consolidation pressure to the one or more thermoplastic parts, and a support insert shaped and configured to support and at least partially surround at least one of the one or more thermoplastic parts, wherein at least one of heating assembly and the pressure bladder is shaped to receive and support the support insert.

Abstract: A heating blanket includes an interlaced heating layer having a fabric thread and a heat-generating thread interlaced with the fabric thread to form the interlaced heating layer. The heat-generating thread includes a conductor wire configured to generate a magnetic field in response to an electrical current applied to the conductor wire, and a susceptor wire formed of a susceptor material configured to inductively generate heat in response to the magnetic field of the conductor wire when a temperature of the susceptor wire is below a Curie point of the susceptor wire. Methods of forming the heating blanket and methods of heating a contoured surface using the heating blanket are also disclosed.

Abstract: A composite sandwich panel includes a first composite part and a second composite part. A plurality of stiffeners extend between the first and second composite parts. A fiberglass composite perimeter edge closeout is positioned along one or more edges of the first and second composite parts. The fiberglass composite perimeter edge closeout controls a magnetic flux to bond the first and second composite parts to the plurality of stiffeners.

Abstract: A system for manufacturing a rotor blade comprises a first tooling, positioned at a factory location and configured to assemble a first blade module, comprising a first-module skin and a first-module spar, each comprising a first thermoplastic polymer and a first reinforcement material. The system also comprises a second tooling, configured to assemble a second blade module, comprising a second-module skin and a second-module spar, each comprising a second thermoplastic polymer and a second reinforcement material. The system further comprises a first support, positioned at a field location and configured to receive the first blade module, and a second support, positioned at the field location and configured to receive the second blade module. The system also comprises a spar welding assembly, positioned at the field location and configured to join the first-module spar with the second-module spar.

Abstract: Thermoplastic welding apparatus and related methods are disclosed. An example method includes providing a smart susceptor between composite parts that are to be joined via thermoplastic welding. The example method includes positioning the composite parts and the smart susceptor on a tooling surface within a cavity of a tooling apparatus and applying a seal to the composite parts and the tooling surface to form a vacuum chamber between the composite parts and the tooling surface at a welding joint of the composite parts; producing a magnetic field at the welding joint. The example method includes providing a vacuum in the vacuum chamber during a welding operation.

Abstract: A method and apparatus for forming a composite structure. An inner tooling, a stackup, and an outer tooling are held in place together using a load constraint. A bladder and a plurality of stringer bladders in the stackup are pressurized to cause expansion of the bladder and the plurality of stringer bladders, thereby pushing together an overbraided thermoplastic skin and a plurality of overbraided thermoplastic members in the stackup. The overbraided thermoplastic skin and the plurality of overbraided thermoplastic members are co-consolidated while the bladder and the plurality of stringer bladders are pressurized to form the composite structure.

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 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.

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 assembly to repair a thermoplastic composite. The assembly includes a heating device positioned on opposing sides of the thermoplastic composite. The heating device includes one or more susceptor with a Curie temperature to heat the thermoplastic composite. A pressure device applies a compressive force to the heating device. A pressure distribution device is positioned between the heating device and the thermoplastic composite. The pressure distribution device distributes the compressive force from the pressure device over areas of the opposing sides of thermoplastic composite.

Abstract: A shim assembly includes a shim material configured to be positioned between a first component and a second component. A wire is in contact with the shim material. The wire is configured to heat the shim material to above a predetermined temperature, and the shim material becomes moldable above the predetermined temperature such that the shim material is able to conform to the first component and the second component.

Abstract: An assembly to repair a thermoplastic composite. The assembly includes a heating device positioned on opposing sides of the thermoplastic composite. The heating device includes one or more susceptor with a Curie temperature to heat the thermoplastic composite. A pressure device applies a compressive force to the heating device. A pressure distribution device is positioned between the heating device and the thermoplastic composite. The pressure distribution device distributes the compressive force from the pressure device over areas of the opposing sides of thermoplastic composite.