A method for fusing thermoplastic composite structures includes placing a 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 insulation layer over a flange 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 to at least partly enclose the skin and the substructure. 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.

An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

A method for fusing thermoplastic composite structures includes placing a 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 insulation layer over a flange 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 to at least partly enclose the skin and the substructure. 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.

A method for fusing thermoplastic composite structures includes placing a 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 insulation layer over a flange 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 to at least partly enclose the skin and the substructure. 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.

A method of manufacturing a rotor blade includes (1) assembling a first blade module that defines a first-module span axis and includes a first-module skin and a first- module spar, and each of the first-module skin and the first-module spar includes a first thermoplastic polymer and reinforcement material; (2) assembling a second blade module that defines a second-module span axis and includes a second-module skin and a second- module spar, and each of the second-module skin and the second-module spar includes a second thermoplastic polymer and reinforcement material; (3) transporting the first blade module and the second blade module to a field location; (4) aligning, at the field location, the first-module span axis with the second-module span axis to define an aligned pair of modules; and (5) heating a portion of the aligned pair of modules to form a weld joint between the first-module spar and the second-module spar.

A method of manufacturing a rotor blade includes (1) assembling a first blade module that defines a first-module span axis and includes a first-module skin and a first- module spar, and each of the first-module skin and the first-module spar includes a first thermoplastic polymer and reinforcement material; (2) assembling a second blade module that defines a second-module span axis and includes a second-module skin and a second- module spar, and each of the second-module skin and the second-module spar includes a second thermoplastic polymer and reinforcement material; (3) transporting the first blade module and the second blade module to a field location; (4) aligning, at the field location, the first-module span axis with the second-module span axis to define an aligned pair of modules; and (5) heating a portion of the aligned pair of modules to form a weld joint between the first-module spar and the second-module spar.

An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

An automated fiber-placement method comprises delivering a first quantity of pulsed energy to first portions of at least one fiber-reinforced tape strip, and delivering a second quantity of pulsed energy to second portions of at least the one fiber-reinforced tape strip, alternating with the first portions. Each one of the second portions at least partially overlaps two adjacent ones of the first portions such that overlapping regions of the first portions and the second portions have a higher temperature than non-overlapping regions of the first portions and the second portions. The automated fiber-placement method further comprises laying down at least the one fiber-reinforced tape strip against a substrate along a virtual curvilinear path, such that (i) at least the one fiber-reinforced tape strip is centered on the virtual curvilinear path, and (ii) the overlapping regions are transformed into discrete tape-regions, geometrically different from the overlapping regions.

A system (100), for manufacturing a rotor blade (112), comprises a first tooling (170), positioned at a factory location (114) and configured to assemble a first blade module (116), comprising a first-module skin (118) and a first-module spar (120), each comprising a first thermoplastic polymer (122) and a first reinforcement material (124). The system (100) comprises a second tooling (172), configured to assemble a second blade module (126), comprising a second-module skin (128) and a second-module spar (130), each comprising a second thermoplastic polymer (132) and a second reinforcement material (134). The system (100) comprises a first support (160), positioned at a field location (140) and configured to receive the first blade module (116), and a second support (162), positioned at the field location (140) and configured to receive the second blade module (126). The system (100) comprises a spar welding assembly (174), positioned at the field location (140) and configured to join the first-module spar (120) with the second-module spar (130), and a skin welding assembly (176), positioned at the field location (140) and configured to join the first-module skin (118) with the second-module skin (128).