Abstract: A method for fusing thermoplastic composite structures includes placing a thermoplastic substructure on an inner surface of a skin that is laid up on a shaping surface of a tool configured to maintain the shape of an outer mold line. The method further includes applying at least one metal layer over the substructure and applying an insulation layer over edge portions of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure and applying a vacuum bag that at least partly encloses the skin, the substructure, and the metal layer. The method yet still further includes applying heat to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

Abstract: A system for peen-forming of thermoplastic composite material is provided. The system includes a tool, a heater, and a peen-forming device. The thermoplastic composite material is positioned on the tool, which supports the thermoplastic composite material as it is being process. The tool has a surface to which a portion of the thermoplastic composite material is intended to conform. The heater is configured to heat the thermoplastic composite material while it is positioned on the tool to make the thermoplastic composite material more malleable. The peen-forming device directs particles against the thermoplastic composite material positioned on the tool so that the portion of the thermoplastic composite material conforms to the surface of the tool.

Abstract: A composite part forming system for shaping a composite material blank having a plurality of plies, the composite part forming system comprising opposing tools including shape-forming features, an actuator, and a composite tensioning system. The composite tensioning system is connectable to a periphery of the composite material blank to apply tension to the composite material blank the first and second tools are moved together to cause the composite material blank to conform to the shape-forming features. The composite tensioning system is configured to apply more tension to wrinkle prone plies of the composite material blank than to non-wrinkle prone plies as the composite material blank is caused to conform to the shape-forming features.

Abstract: Tooling assembly and pressure vessel thereof for forming composite components such as aircraft stringers and the like. In addition to the pressure vessel, the tooling assembly may include a conveying apparatus and a forming tool for stacking plies on the forming tool and conveying the plies and the forming tool through the pressure vessel. The pressure vessel includes an entrance opening and an exit opening, which are sized and shaped to permit the forming tool supporting the plies to pass through the pressure vessel. The pressure vessel may further include an interior chamber housing multiple spheres. The spheres press against the plies as the forming tool is conveyed through the pressure vessel, thereby pressure treating the plies and forming the composite part.

Abstract: A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

Abstract: A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: Method of forming composite components such as aircraft stringers and the like, and tooling used to form the same. The method includes stacking plies on a forming tool and conveying the plies and the forming tool through a pressure vessel. The pressure vessel includes an entrance opening and an exit opening, which are sized and shaped to permit a forming tool supporting a plurality of plies to pass through the pressure vessel. The pressure vessel includes an interior chamber housing multiple spheres. The spheres press against the plies as the forming tool is conveyed through the pressure vessel, thereby pressure treating the plies and forming the composite part.

Abstract: A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

Abstract: A system and method for thermoplastic composite welding comprising a cooling means and a heat source. The cooling means cools a heat-side laminate so as to create a thermal gradient in the heat-side laminate. The heat source heats the heat-side laminate after the cooling step is initiated but before the thermal gradient dissipates so that a first side of the heat-side laminate closer to the heat source does not deform as faying surfaces of the heat-side laminate and another laminate farther away from the heat source are welded together.

Abstract: A system for manufacturing a composite part including a conductive flexible facesheet and an automated tape layup (ATL) machine for laying up composite tape onto the facesheet that is laid flat on a flat surface. The system also includes a curved tooling surface for transferring the facesheet with the composite material thereon to the curved tooling surface for attachment of substructures and curing into the composite part. System may also include insulation placed below the facesheet and insulation placed above the composite material, as well as a source of electricity and heat for heating the conductive facesheet to cure, melt, or fuse the composite tape and substructures without heating the tooling surface and other tooling used in the composite curing process. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to conductive wires attached at opposing ends to the facesheet.

Abstract: A system using a pressure differential to clamp welding heads on opposite sides of a joint of a thermoplastic composite structure to be welded. The heads are positioned over the joint opposite each other. Each head includes a housing defining a chamber having a lower pressure such that the pressure differential forces the head against the side. Each head includes a contour plate located in the space and against the joint, and at least one of the heads includes a heater located in the space and heating the contour plate to a welding temperature. The system may also include a first arm coupled with one of the heads and moving it along the joint so as to remain aligned with the other head, and a second arm coupled with the other head and moving it along the joint while the system welds the joint in successive overlapping sections.

Abstract: A method for manufacturing a composite part by laying up courses of composite tape using an automated tape layup (ATL) machine onto a conductive flexible facesheet laid flat on a flat surface, and then transferring the facesheet with the composite material thereon to a curved tooling surface for attachment of substructures and curing into the composite part. The method may also include applying insulation below the facesheet and above the composite material, then heating the conductive facesheet to cure the composite tape and fuse the composite tape to the substructures without heating the tooling surface or any other items used to compress and cure the composite material into the composite part. Heating of the facesheet may be performed using joule heat provided by a single turn transformer inducing current to a plurality of conductive wires attached at opposing ends to the facesheet.

Abstract: A system and method for forming an integral flange in an end portion of a composite laminate structure, such as an aerospace or other vehicle structure. First and second tool components cooperate to support the structure during a layup process, with the second tool component imparting an initial angle to the end portion. A third tool component includes a male radius positioned at an apex of the initial angle. A heater heats a succession of localized areas along the end portion to lower a viscosity of the resin. A roller applies pressure to the succession of localized areas after each is heated so as to push them around and against the third tool component to form a flange angle and the integral flange. The heater and the roller may make multiple passes along the end portion, with the roller angle increasing with each pass until the flange angle is achieved.

Abstract: A system and method for forming an integral flange in an end portion of a composite laminate structure, such as an aerospace or other vehicle structure. First and second tool components cooperate to support the structure during a layup process, with the second tool component imparting an initial angle to the end portion. A third tool component includes a male radius positioned at an apex of the initial angle. A heater heats a succession of localized areas along the end portion to lower a viscosity of the resin. A roller applies pressure to the succession of localized areas after each is heated so as to push them around and against the third tool component to form a flange angle and the integral flange. The heater and the roller may make multiple passes along the end portion, with the roller angle increasing with each pass until the flange angle is achieved.

Abstract: A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.

Abstract: A stiffening element comprises a tension and compression member, a shear member, an attachment member, and a plurality of beads. The tension and compression member is positioned spaced apart from the skin and configured to bear tension or compression forces that stiffen the skin and prevent the skin from buckling or bending. The shear member is connected to the tension and compression member and configured to bear shear forces between the skin and the tension and compression member. The attachment member is connected to the shear member and is configured to connect to the skin. The beads each create out-of-plane feature that is positioned in at least one of the shear member and the attachment member. The beads permit the stiffening element be reshaped to adjust a longitudinal curvature of the stiffening element.

Abstract: An improved composite stiffener and methods and tooling used to form the same. The stiffener includes one or more base flanges, a composite rod extending in an axial direction, a bulb cap surrounding the composite rod, and an upright web extending from the one or more base flanges to the base cap. The upright web includes a non-linear profile in the axial direction providing the improved lateral stiffness. The method includes providing tooling including a first compression tool extending in the axial direction and including a first web portion having a non-linear profile, and a second compression tool extending in the axial direction and including a second web portion having a non-linear profile. Plies are placed within the tooling and compressed such that at least a portion of plurality of plies are compressed in the web forming portion thereby forming a web of the bulb stiffener having a non-linear profile.

Abstract: A system and method for thermoplastic composite welding comprising a cooling means and a heat source. The cooling means cools a heat-side laminate so as to create a thermal gradient in the heat-side laminate. The heat source heats the heat-side laminate after the cooling step is initiated but before the thermal gradient dissipates so that a first side of the heat-side laminate closer to the heat source does not deform as faying surfaces of the heat-side laminate and another laminate farther away from the heat source are welded together.

Abstract: Method of forming composite components such as aircraft stringers and the like, and tooling used to form the same. The method includes stacking plies on a forming tool and conveying the plies and the forming tool through a pressure vessel. The pressure vessel includes an entrance opening and an exit opening, which are sized and shaped to permit a forming tool supporting a plurality of plies to pass through the pressure vessel. The pressure vessel includes an interior chamber housing multiple spheres. The spheres press against the plies as the forming tool is conveyed through the pressure vessel, thereby pressure treating the plies and forming the composite part.