Abstract: A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Abstract: A joining method is provided during which a first thermoplastic component joint section and a second thermoplastic component joint section are arranged between first tooling and second tooling. The second thermoplastic component joint section is abutted against the first thermoplastic component joint section at a joint area. The first thermoplastic component joint section is joined to the second thermoplastic component joint section to provide a unitized thermoplastic structure. The joining includes: pressing the first thermoplastic component joint section against the second thermoplastic component joint section at the joint area between the first tooling and the second tooling using a pressure device; and heating the first thermoplastic component joint section and the second thermoplastic component joint section at the joint area using a first heater configured with the first tooling. The unitized thermoplastic structure is cooled at the joint area using a first cooler configured with the first tooling.

Abstract: A method is provided for joining thermoplastic components. During this method, a skin is provided that is configured from or otherwise includes a skin fiber-reinforced thermoplastic composite. A support member is provided that is configured from or otherwise includes a support member fiber-reinforced thermoplastic composite. A shim is arranged at an interface between the skin and the support member. The shim is configured from or otherwise includes a shim fiber-reinforced thermoplastic composite. The support member is welded to the skin through the shim at the interface.

Abstract: A method for forming a fiber-reinforced thermoplastic part may comprise the steps of locating a lightning strike protection layer on a mold surface of a mold tool, locating a thermoplastic layer over the mold tool, heating the thermoplastic layer to a pliable forming temperature, conforming the thermoplastic layer to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic layer.

Abstract: A method for forming a fiber reinforced thermoplastic part may comprise the steps of locating a thermoplastic material over a mold tool, heating the thermoplastic material to a pliable forming temperature, conforming the thermoplastic material to a mold surface of the mold tool, and depositing a plurality of fiber strips over the thermoplastic material.

Abstract: A method of repairing a defect of a thermoplastic component is provided. The thermoplastic component has a thermoplastic material at the defect having a first melting temperature, and the defect has a contact surface (TC contact surface). The method includes a) providing a patch comprising a second thermoplastic material having a second melting temperature that is below the first melting temperature. The patch includes a contact surface (TP contact surface); b) disposing a portion of a heating element between the TC contact surface and the TP contact surface. The heating element is operable to heat up as a result of electrical resistance; c) forcing the TP surface toward the TC surface; and d) inputting energy into the heating element to cause the heating element to heat and maintain the TP surface at or above the second melting temperature to produce bonding between the thermoplastic component and the patch.

Abstract: A method for consolidating a thermoplastic component includes positioning a thermoplastic vacuum bagging film (e.g., PAEK or PEEK) over a thermoplastic preform (e.g., PPS or LM PAEK) to be consolidated, vacuum consolidating the thermoplastic component with the thermoplastic vacuum bagging film to form the thermoplastic component, and removing the thermoplastic vacuum bagging film from the consolidated thermoplastic component.

Abstract: A method of manufacturing a thermoplastic panel may comprise: laying up a panel preform within a consolidation assembly, the panel preform comprising a plurality of plies of material comprising thermoplastic resin and fiber; generating, via a hot bond unit, a vacuum environment within the consolidation assembly; and heating, via the hot bond unit and through a heated blanket within the consolidation assembly, the panel preform.

Abstract: A method of and system for removing a portion of a thermoplastic component is provided. The component includes a thermoplastic material having a melting temperature. The method includes: a) providing a glider that includes an electrically conductive material operable to produce thermal energy resulting from electrical resistance; b) heating a portion of the glider with electrical energy to a glider operating temperature that is equal or greater than the melting temperature; and c) removing the portion by engaging the component with the glider and translating one of the glider or the component relative to the other. The engagement of the glider and the component causes an amount of the thermoplastic material to melt, and the translation of the one of the glider or the component relative to the other removes the portion from the thermoplastic component.

Abstract: A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Abstract: A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Abstract: A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Abstract: A single bolting flange arrangement for variable inlet guide vane (VIGV) connection includes a connection arm connected to a stem of the VIGV to rotate the VIGV. The connection arm is driven by a drive pin received in a slot of the connection arm. The connection arm has a bolting flange and the stem of the VIGV is fastened to one side of the single bolting flange by a bolt/nut assembly.

Abstract: A single bolting flange arrangement for variable inlet guide vane (VIGV) connection includes a connection arm connected to a stem of the VIGV to rotate the VIGV. The connection arm is driven by a drive pin received in a slot of the connection arm. The connection arm has a bolting flange and the stem of the VIGV is fastened to one side of the single bolting flange by a bolt/nut assembly.