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: 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: 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: 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 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: 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: A composite part layup is cured using a set of tools adapted to hold the layup and which include at least one tool face contacting the layup. Means are provided for heating the tool face to cure the part layup, and for selectively cooling sections of the tool face.

Abstract: A system for inductively heating a workpiece may include an induction coil, at least one susceptor face sheet, and a current controller coupled. The induction coil may be configured to conduct an alternating current and generate a magnetic field in response to the alternating current. The susceptor face sheet may be configured to have a workpiece positioned therewith. The susceptor face sheet may be formed of a ferromagnetic alloy having a Curie temperature and being inductively heatable to an equilibrium temperature approaching the Curie temperature in response to the magnetic field. The current controller may be coupled to the induction coil and may be configured to adjust the alternating current in a manner causing a change in at least one heating parameter of the susceptor face sheet.

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 heating system includes a structure to be heated, and a heating apparatus disposed to heat the structure. The heating apparatus includes a housing member, a plurality of resonant frequency power sources, and a plurality of associated controls. The plurality of resonant frequency power sources are attached to the housing member. The plurality of associated controllers is configured to separately operate the plurality of resonant frequency power sources at resonant frequencies matching heating requirements of the structure.

Abstract: A panel includes a structural substrate and a damping element including a viscoelastic material (VEM) layer coupleable to the structural substrate of the aircraft, and a constraining layer coupled to the VEM layer. The VEM layer is configured to dampen a vibration of the structural substrate. The constraining layer is configured to apply a shear force to the VEM layer.

Abstract: A heating system includes a structure to be heated, and a heating apparatus disposed to heat the structure. The heating apparatus includes a housing member, a plurality of resonant frequency power sources, and a plurality of associated controls. The plurality of resonant frequency power sources are attached to the housing member. The plurality of associated controllers is configured to separately operate the plurality of resonant frequency power sources at resonant frequencies matching heating requirements of the structure.

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: A system for inductively heating a workpiece may include an induction coil, at least one susceptor face sheet, and a current controller coupled. The induction coil may be configured to conduct an alternating current and generate a magnetic field in response to the alternating current. The susceptor face sheet may be configured to have a workpiece positioned therewith. The susceptor face sheet may be formed of a ferromagnetic alloy having a Curie temperature and being inductively heatable to an equilibrium temperature approaching the Curie temperature in response to the magnetic field. The current controller may be coupled to the induction coil and may be configured to adjust the alternating current in a manner causing a change in at least one heating parameter of the susceptor face sheet.

Abstract: A method of fabricating a thermoplastic component using inductive heating is described. The method includes positioning a plurality of induction heating coils to define a process area for the thermoplastic component, wherein the plurality of induction heating coils comprises a first set of coils and a second set of coils. The method also includes controlling a supply of electricity provided to the plurality of inductive heating coils to intermittently activate the coils. The intermittent activation is configured to facilitate prevention of electromagnetic interference between adjacent coils.

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 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 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 composite induction consolidation apparatus includes a base mandrel and a ferromagnetic base mandrel facesheet having a specific Curie temperature carried by the base mandrel. The base mandrel facesheet is adapted to support a composite part and allow ambient air pressure to compact the composite part against the base mandrel facesheet. At least one magnetic induction coil is provided in the base mandrel.

Abstract: Described herein is a method of forming a heat-treated material includes positioning the heat-treated material between first and second susceptors. Each of the first and second susceptors includes a tool face shaped according to a desired shape of the heat-treated material. The method also includes applying a low-strength magnetic field to the first and second susceptors to heat the first and second susceptors. Further, the method includes compressing the heat-treated material between the first and second susceptors to form the heat-treated material into the desired shape. The method additionally includes applying a high-strength magnetic field to the heat-treated material before compressing the heat-treated material between the first and second susceptors.