Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: A method and apparatus for joining parts. A plurality of conformable induction coils embedded in a number of elastomeric sheets is positioned relative to a first composite part of the parts and a second composite part of the parts. A magnetic field is generated with the plurality of conformable induction coils. The magnetic field is configured to generate heat in a magnetically permeable material at a joint location. The heat joins the first composite part and the second composite part to each other.

Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: A method for forming a shim. A liquid shim material with a magnetically permeable material is applied in a location for the shim between a plurality of composite parts. A magnetic field is applied to the magnetically permeable material in the location. The magnetic field is configured to heat the liquid shim material to a temperature to cause the liquid shim material to become solid and form the shim.

Abstract: A method and apparatus is presented. A method may comprise positioning a metallic bladder within a tool, the tool having a number of die liners that generate heat when exposed to a magnetic field; applying the magnetic field to the number of die liners to heat the metallic bladder; and pressurizing the metallic bladder.

Abstract: A method and apparatus for joining parts. A plurality of conformable induction coils embedded in a number of elastomeric sheets is positioned relative to a first composite part of the parts and a second composite part of the parts. A magnetic field is generated with the plurality of conformable induction coils. The magnetic field is configured to generate heat in a magnetically permeable material at a joint location. The heat joins the first composite part and the second composite part to each other.

Abstract: A method and apparatus for welding a thermoplastic structure. The apparatus comprises a base, a cover, and a channel. The base is formed of a material that is magnetically opaque to a frequency in a range of 30 KHz to 350 KHz. The cover is formed of the material. The channel extends between the base and the cover.

Abstract: A method and apparatus for forming a sandwich structure is presented. A sandwich structure comprises a metallic core layer and a thermoplastic layer on a first side of the metallic core layer. The thermoplastic layer is consolidated against the first side of the metallic core layer.

Abstract: An enclosure for heating a three dimensional structure. The enclosure comprising a body defining a cavity therein. The cavity sized to receive a three dimensional structure. A plurality of heating blankets configured to heat the three dimensional structure to a substantially uniform temperature. At least one of the plurality of heating blankets comprises a conductor for receiving current and generating a magnetic field in response thereto, a first susceptor wire comprising an alloy having a first Curie temperature point and a second susceptor wire. The second susceptor wire comprising a second Curie temperature point that is different than the first Curie temperature point of the first susceptor wire.

Abstract: A wire conductor for receiving alternating current and generating a magnetic field in response thereto. The wire conductor comprises a plurality of wire conductors in a parallel configured circuit extending between a first side of the wire conductor towards a second side of the wire conductor. A first layer of the plurality of wire conductors running in parallel from a first edge of the wire conductor to a second edge of the wire conductor. A second layer of parallel wire conductors residing above the first layer of the plurality of wire conductors, the second layer of parallel wire conductors running in parallel from the first edge of the wire conductor to the second edge of the wire conductor. The first layer of parallel wire conductors make a 180 degree turn along the first edge of the wire conductor. The first layer of parallel wire conductors make the 180 degree turn along the first edge of the wire conductor by first turning 90 degrees towards the second side of the parallel wire conductor.

Abstract: A susceptor wire array. The array includes a first susceptor wire comprising an alloy having a first Curie temperature point and a second susceptor wire comprising an alloy having a second Curie temperature point, the second Curie temperature point is different than the first Curie temperature point of the first susceptor wire. In one susceptor wire arrangement, the second Curie temperature point of the second susceptor wire is lower than the first Curie temperature point of the first susceptor wire. In another susceptor wire arrangement, the array further comprises a third susceptor wire, the third susceptor wire comprising an alloy having a third Curie temperature point. The third Curie temperature point of the third susceptor wire may be different than the first Curie temperature point of the first susceptor wire.

Abstract: A method of fabricating a thermoplastic composite tubular structure for use as a wind turbine blade is presented using a combination of induction heating with smart susceptors to consolidate a wrapped mandrel.

Abstract: An apparatus and method are presented. An apparatus comprises a composite structure, a plurality of cavities extending into the composite structure, and a plurality of mandrels located within the plurality of cavities. The composite structure comprises a thermoplastic material that is consolidated. The plurality of mandrels comprises a first material that is configured to generate heat in response to a magnetic field.

Abstract: A composite part is cured out-of-autoclave using an inductively heated, stand-alone tooling. The part in placed on a tool and is covered by a heating blanket. One side of the part is heated by inductive coil circuits in the tool, and the other side of the part is heated by inductive coil circuits in the blanket.

Abstract: A susceptor welding tape for use in thermoplastic welding. The susceptor welding tape comprising a thermoplastic film and a plurality of non-continuous susceptor conductors imbedded within the thermoplastic film. The plurality of non-continuous susceptor conductors allow a resulting thermoplastic weld formed by the susceptor weld tape to be tuned to a desired engineering characteristic. For example, the plurality of conductors allow the resulting thermoplastic weld formed by the susceptor weld tape to be tuned to a desired conductivity, a desired residual stress and/or a desired moisture barrier of the resulting thermoplastic weld.

Abstract: A coaxially arranged smart susceptor conductor, comprising a smart susceptor core comprising an alloy having a first Curie temperature point and a first smart susceptor shell coaxially arranged around the smart susceptor core. The first smart susceptor shell comprising a second Curie temperature point that is different than the first Curie temperature point of the smart susceptor core. In one arrangement, the second Curie temperature point of the first smart susceptor shell is lower than the first Curie temperature point of the smart susceptor core. In another arrangement, the smart susceptor conductor further comprises a second smart susceptor shell disposed about the first smart susceptor shell. The second smart susceptor shell comprising a third Curie temperature point.

Abstract: The thermal cycle time for curing a thermoset composite part in an autoclave is reduced by placing a heating blanket in proximity to an area of the composite part that is slow-to-heat, and inductively heating the area of the composite part that is slow-to-heat using the heating blanket.

Abstract: A composite part is cured out-of-autoclave using an inductively heated, stand-alone tooling. The part in placed on a tool and is covered by a heating blanket. One side of the part is heated by inductive coil circuits in the tool, and the other side of the part is heated by inductive coil circuits in the blanket.

Abstract: Manufacturing a thermoplastic composite tubular structure embedded with a first load fitting comprising the steps of braiding a first plurality of inner layers of thermoplastic composite material around a soluble, expandable mandrel. A first load fitting is positioned on the first plurality of inner layers of thermoplastic composite material. A second plurality of outer layers of thermoplastic composite material is braided around the first load fitting and the mandrel so as to form an overbraided mandrel embedded with the first load fitting. The overbraided mandrel is installed into a matched tooling assembly and heated at a specified heating profile in order to consolidate the first plurality of inner layers of thermoplastic composite material and the second plurality of outer layers of thermoplastic composite material with the first load fitting so as to form a thermoplastic composite tubular structure embedded with the first load fitting.

Abstract: A method and apparatus for forming a stiffened thermoplastic panel is presented. The method may comprise placing a number of forming tools within a number of concave areas of a thermoplastic preform. The method may also place the thermoplastic preform with the number of forming tools within the number of concave areas on a thermoplastic lay-up to form a workpiece. The method may also position the workpiece within a tool. The tool may have a number of die liners configured to generate heat in response to a magnetic field. The method may also consolidate the workpiece to form the stiffened thermoplastic panel. Consolidating may comprise applying a magnetic field to the number of die liners to heat the workpiece to a consolidation temperature.