Abstract: Disclosed herein are induction heating cells and methods of using these cells for processing. An induction heating cell may be used for processing (e.g., consolidating and/or curing a composite layup having a non-planar portion. The induction heating cell comprises a caul, configured to position over and conform to this non-planar portion. Furthermore, the cell comprises a mandrel, configured to position over the caul and force the caul again the surface of the feature. The CTE of the caul may be closer to the CTE of the composite layup than to the CTE of the mandrel. As such, the caul isolates the composite layup from the dimensional changes of the mandrel, driven by temperature fluctuations. At the same time, the caul may conform to the surface of the mandrel, which can be used to define the shape and transfer pressure to the non-planar portion.

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: A structure is heated in a tool. The structure is quenched in the tool such that a shape of the structure is maintained, in which quenching is performed by contacting the structure with a quenching medium.

Abstract: Disclosed herein is a method of forming a multi-layered metallic part. The method comprises forming a plurality of ductile layers made of a metallic material having a first ductility. The method also comprises forming at least one high-strength powder layer made of a powdered metallic material having a second ductility higher than the first ductility. The method further comprises assembling the plurality of ductile layers and the at least one high-strength powder layer in an alternating and stacked formation to form a multi-layered metallic assembly. The method additionally comprises oscillating a crystallographic phase of the powdered metallic material of the at least one high-strength powder layer between a first crystallographic phase and a second crystallographic phase.

Abstract: A processing apparatus such as a heating and/or debulking apparatus that may be used to debulk a plurality of uncured composite layers to form an article such as an aircraft component may include a plurality of interconnected smart susceptor heater blankets. The plurality of smart susceptor heater blankets may be connected in series or in parallel, and may be controlled to uniformly heat the component during formation.

Abstract: An apparatus for thermoplastic welding includes at least one tool configured to support first and second thermoplastic composite parts in a first welding position having one or more joint lines between the first and second thermoplastic composite parts. The tool includes a plurality of induction coils. The apparatus further includes a susceptor removably positioned along the one or more joint lines. The susceptor is configured to heat the one or more joint lines when exposed to a magnetic flux generated by the plurality of induction coils to bond the first and second thermoplastic composite parts along the one or more joint lines. The apparatus also includes a susceptor removal device coupled to the susceptor and configured to remove the susceptor during bonding of the first and second thermoplastic composite parts.

Abstract: A smart susceptor assembly including an electromagnetic flux source such as one or more inductors, a geometrically complex-shaped susceptor having one or more contours, and a cladding on or over the susceptor. The cladding can alter both the thermal performance and the electrical operation of the smart susceptor assembly. With regard to thermal performance, the cladding can function as a passive heat exchanger to dissipate thermal energy across the surface of the susceptor. With regard to electrical operation, the cladding can provide a current path after portions of the susceptor heat and become low or non-magnetic.

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: 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: 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: Cookware, and an induction cooking system including the cookware, can include a container, a base layer, and a susceptor layer. The container and the base layer can be 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, thereby decreasing a range of temperatures 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 fiber placement system including a fiber placement station at a first location, the fiber placement station including a tool and a fiber placement assembly configured to construct a reinforcement layup on the tool, the first fiber placement assembly including a compaction roller rotatable about an axis of rotation, the compaction roller at least partially defining a nip, a thermoplastic composite ply extending through the nip and a heating unit positioned to heat the thermoplastic composite ply proximate the nip, and a consolidation station at a consolidation location, the consolidation location being different from the first location, the consolidation station including a consolidation tool and a consolidation system configured to consolidate a reinforcement layup assembly that includes the reinforcement layup.

Abstract: A method of manufacturing a rotor blade includes (1) assembling a first blade module that defines a first-module span axis and includes a first-module skin and a first- module spar, and each of the first-module skin and the first-module spar includes a first thermoplastic polymer and reinforcement material; (2) assembling a second blade module that defines a second-module span axis and includes a second-module skin and a second- module spar, and each of the second-module skin and the second-module spar includes a second thermoplastic polymer and reinforcement material; (3) transporting the first blade module and the second blade module to a field location; (4) aligning, at the field location, the first-module span axis with the second-module span axis to define an aligned pair of modules; and (5) heating a portion of the aligned pair of modules to form a weld joint between the first-module spar and the second-module spar.

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: Systems and methods are provided for molding systems that have a low thermal mass. One embodiment is a first tool that includes a first frame. The first frame includes a first set of plates of magnetically permeable material, and a material disposed between plates of the first set. The first tool also includes a first set of induction coils that are disposed within the first frame and that generate a first electromagnetic field, and a first susceptor that extends from the first set of plates. The first susceptor generates heat in response to the first electromagnetic field. The first tool further includes a mold that extends from the first susceptor and receives heat via conductive heat transfer from the first susceptor. Each plate of the first set is thinner than a skin depth at which the first electromagnetic field would generate an electrical induction current.

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 panel comprises a first face sheet and a second face sheet spaced apart from the first face sheet. The panel further comprises a core sheet intercoupled between the first face sheet and the second face sheet. Each of the first and second face sheets is made of a material having a thermal expansion that is different from the thermal expansion of the other face sheet.

Abstract: A smart susceptor assembly includes a plurality of susceptor elements and a plurality of conductor elements. Each susceptor element can be paired with one conductor element to form a susceptor tab. When exposed to a magnetic flux field, the plurality of susceptor elements heat to a leveling temperature. During the heating, the plurality of conductor elements alter both a thermal performance and an electrical operation of the smart susceptor assembly and, more particularly, the susceptor elements. Various configurations of the susceptor elements and conductor elements are described.

Abstract: Methods and systems for heating forming dies by an induction coil, including a pair of electromagnetic (EM) field stabilizers, each EM field stabilizer configured to be adjacent one end of the forming die while the forming die is within the induction heating coil.

Abstract: A radius filler includes a plurality of fibers encapsulated in resin and braided into a braided radius filler. The braided radius filler has a substantially triangular shape with concave radius filler side surfaces and a substantially planar radius filler base surface.