Abstract: A system for attaching a phenolic panel to a metal part includes a phenolic laminate panel having (i) a phenolic panel, (ii) a ferromagnetic susceptor bonded at an inner side of the phenolic panel via higher melting point adhesive and (iii) a non-magnetic shield having an outer side bonded at an inner side of the ferromagnetic susceptor via higher melting point adhesive. A lower melting point adhesive is applied at an inner side of the non-magnetic shield opposite from the outer side of the non-magnetic shield. With the phenolic laminate panel disposed at a metal part, an electromagnetic field is generated at the phenolic laminate panel to heat the phenolic laminate panel to a temperature greater than the melting point of the lower melting point adhesive and less than the melting point of the higher melting point adhesive to bond the phenolic laminate panel to the metal part.

Abstract: A method for repairing a damaged area of a hull of a water vessel includes providing a patch assembly having (i) a first flexible outer layer, (ii) a second flexible outer layer and (iii) an inner layer of composite material sealed between the first flexible outer layer and the second flexible outer layer. When the inner layer is heated and then cures, the composite material transforms from a flexible uncured state to a fixed cured state. With the composite material in the uncured state, the patch assembly is positioned at a damaged area of a hull of a water vessel and conforms to a shape of the hull. An electric heating element is electrically operated to heat the inner layer, and when the inner layer is cured, the composite material is cured, where the shape of the inner layer is fixed relative to the shape of the hull.

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 method for densifying a material includes arranging the material in a cavity of a mold and applying pressure to the material in the mold. While applying pressure to the material in the mold, a magnetic field is applied to the material in the mold to cause the material to transform between a first allotrope phase and a second allotrope phase. Applying the magnetic field to the material includes magnetic cycling, which includes one or more iterations of adjusting the magnetic field to a first strength, and then adjusting the magnetic field to a second strength. The method includes determining a density of the material during the magnetic cycling and, responsive to determination that the determined density reaches a threshold density, stopping the magnetic cycling.

Abstract: A component forming tool for forming a component from a blank includes a die forming shell for forming the component from the blank. A first shell portion of the die forming shell is located on a first set of support elements and a second shell portion is located on a second set of support elements. The tool includes at least one induction heating coil for induction heating of a workpiece disposed within a cavity formed by the first and second shell portions. The first set of support elements include multi-material support elements having at least two layers of different materials and the second set of support elements include multi-material support elements having at least two layers of different materials.

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: Assisted magnetic forming uses a magnetic field to assist in the forming or molding of metallic and non-metallic materials. For example, such a forming process may form a blank of ferromagnetic metals like high-strength steel and high-hard armor, non-ferromagnetic metals like aluminum and magnesium, as well as non-metals like ceramics, plastics, and fiber-reinforced composites into formed or molded parts. The magnetic field is generated to partially or completely saturate the blank during the forming process, which increases the blank's formability and/or moldability while in the presence of the magnetic field.

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: 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: Disclosed are induction heating cells comprising tensioning members with non-magnetic metal cores. Also disclosed are methods of operating such cells, for example, to process composite parts. The non-magnetic metal cores of the tensioning members provide excellent tensile strength. Furthermore, the non-magnetic metal cores allow forming long tensioning members leading to large induction heating cells for processing large composite parts, such aircraft fuselage parts, wing parts, and the like. The diameter of these non-magnetic metal cores is less than the induction heating threshold for magnetic fields used during operation of the cells, which ensures limited or no interaction of the cores with the magnetic fields. The cores can be arranged into a tensioning member extending through and compressing the die of an induction heating cell. When multiple cores are used, these cores are electrically insulated from each other, e.g., using an insulating shell or spacing these cores away from each other.

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: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.

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: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.

Abstract: Provided are induction heating cells including pressure bladders used for supporting dies and methods of using these induction heating cells. A pressure bladder may be disposed between a die and a bolster of the cell. Even when the bolster is deformed during operation of the cell, the pressure bladder continues to provide uniform support to the die thereby preserving integrity of the die and prevents its cracking or braking. As such, the cell may be operated at a higher processing pressure inside the cavity formed by the die without further strengthening the bolster. The bolster is allowed to deform without compromising the integrity of the die. The deformation of the bolster is compensated by the shape change of the pressure bladder. The number and/or position of the bladders in the cell may depend on the shape of processed parts.

Abstract: A powdered material preform includes a pressed powdered metal or other powdered material, where the preform is processed and sealed so that a skin or shell is formed at the outer surface of the preform (such as via melting an outer layer or surface of the preform or via adding an outer layer around the preform or via a combination thereof), with an inner portion of the preform comprising pressed powdered material. The skinned preform may comprise a shape that is generally similar to that of a final product or part to be formed, or may simply comprise a puck or shape of approximately the same mass of the shape being formed, and the skinned preform is suitable for use in subsequent densification and/or consolidation processes or combinations thereof to form the final, fully processed part.

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 are induction heating cells comprising tensioning members with non-magnetic metal cores. Also disclosed are methods of operating such cells, for example, to process composite parts. The non-magnetic metal cores of the tensioning members provide excellent tensile strength. Furthermore, the non-magnetic metal cores allow forming long tensioning members leading to large induction heating cells for processing large composite parts, such aircraft fuselage parts, wing parts, and the like. The diameter of these non-magnetic metal cores is less than the induction heating threshold for magnetic fields used during operation of the cells, which ensures limited or no interaction of the cores with the magnetic fields. The cores can be arranged into a tensioning member extending through and compressing the die of an induction heating cell. When multiple cores are used, these cores are electrically insulated from each other, e.g., using an insulating shell or spacing these cores away from each other.

Abstract: A component forming tool for forming a component from a blank includes a die forming shell for forming the component from the blank. A first shell portion of the die forming shell is disposed at a first set of support elements and a second shell portion is disposed at a second set of support elements. The tool includes at least one induction heating coil for induction heating of a workpiece disposed within a cavity formed by the first and second shell portions. The first set of support elements may be configured to detachably engage with respective base support elements of the component forming tool, with the first set of support elements keyed to engage the base support elements to limit lateral movement of the first shell portion at the base support elements. The first set of support elements may include at least two layers of different materials.

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.