Disclosed is a method of resistance welding between composite articles. A conductive element is provided between faying surfaces, having a plurality of lower resistivity electrode portions spaced apart along the length of the contact area between the composite articles. The electrode portions can be used to spot weld across the electrode portions, and along a longitudinal portion of the conductive element between the electrode portions by application of an electrical current. Also disclosed are apparatus for use in the resistance welding methods and composite articles and structures and elements incorporating the conductive element.

A method for joining two objects by anchoring an insert portion provided on a first object in an opening provided on a second object. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. During the step of inserting the insert portion in the opening and/or during anchorage a clamping force is applied to opposing surfaces of the second object to prevent the second object from cracking or bulging.

A method for joining two objects by anchoring an insert portion provided on a first object in an opening provided on a second object. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. During the step of inserting the insert portion in the opening and/or during anchorage a clamping force is applied to opposing surfaces of the second object to prevent the second object from cracking or bulging.

An implantable medical device includes a first component including a first material, a second component including a second material, and a fiber matrix including a plurality of fibers. The fiber matrix joins the first component to the second component. The fiber matrix includes a first a first portion connected to the first component, and a second portion connected to the second component. The first portion of the fiber matrix is interpenetrated with, and mechanically fixed to, the first material. The first portion of the fiber matrix directly contacts the first material.

An implantable medical device includes a first component including a first material, a second component including a second material, and a fiber matrix including a plurality of fibers. The fiber matrix joins the first component to the second component. The fiber matrix includes a first a first portion connected to the first component, and a second portion connected to the second component. The first portion of the fiber matrix is interpenetrated with, and mechanically fixed to, the first material. The first portion of the fiber matrix directly contacts the first material.

A method for connecting two components. In this method, a first component and a second component, which are each formed from a thermoplastic material, are first provided. The first component has a first peel-off ply on a first surface of the first component. The first peel-off ply is removed from the first component. Once the first peel-off ply has been removed, the first surface of the first component is brought into contact with a second surface of the second component. The first component and the second component are then welded to one another at the first and second surface by ultrasonic welding.

A method for connecting two components. In this method, a first component and a second component, which are each formed from a thermoplastic material, are first provided. The first component has a first peel-off ply on a first surface of the first component. The first peel-off ply is removed from the first component. Once the first peel-off ply has been removed, the first surface of the first component is brought into contact with a second surface of the second component. The first component and the second component are then welded to one another at the first and second surface by ultrasonic welding.

Disclosed embodiments provide automated fiber placement techniques for fabrication of parts made from composite materials. A peening system with multiple pins provides compaction over irregular surfaces, providing superior performance as compared with traditional compaction rollers. The apparatus that carries out the techniques include a tape dispensing system, a heating system, a peening system, a processor and a memory coupled to the processor. The memory contains instructions that when executed by the processor perform the steps of: dispensing a first ply of thermoplastic composite tape over a mandrel; dispensing a second ply of thermoplastic composite tape on the first ply; and peening the second ply onto the first ply, such that the second ply is bonded to the first ply.

Disclosed embodiments provide automated fiber placement techniques for fabrication of parts made from composite materials. A peening system with multiple pins provides compaction over irregular surfaces, providing superior performance as compared with traditional compaction rollers. The apparatus that carries out the techniques include a tape dispensing system, a heating system, a peening system, a processor and a memory coupled to the processor. The memory contains instructions that when executed by the processor perform the steps of: dispensing a first ply of thermoplastic composite tape over a mandrel; dispensing a second ply of thermoplastic composite tape on the first ply; and peening the second ply onto the first ply, such that the second ply is bonded to the first ply.

A method for manufacturing a composite member, in which a composite member having a high joining strength can be manufactured in an inexpensive and efficient way; and the composite member. A metal member and a resin-containing member are joined together by heating the metal member while pressing the resin-containing member against a metal porous film formed on a surface of the metal member. The porous film is formed by impacting the surface of the metal member with metal powder by the cold spray process.