A rotor blade for a wind turbine may generally include a first blade component formed from a first fiber-reinforced composite including a first thermoplastic resin material and a second blade component configured to be coupled to the first blade component at a joint interface. The second blade component may be formed from a second fiber-reinforced composite including a second thermoplastic resin material. The second fiber-reinforced composite may include a low fiber region and a high fiber region, with the low fiber region having a fiber-weight fraction that is less than a fiber-weight fraction of the high fiber region. In addition, the first thermoplastic resin material of the first fiber-reinforced composite may be welded to the second thermoplastic resin material contained within the low fiber region of the second thermoplastic composite to form a welded joint at the joint interface between the first blade component and the second blade component.

A method for manufacturing a joined body according to an embodiment of the present disclosure is a method for manufacturing a joined body in which composite materials in which fibers are impregnated with resins are heated and joined to each other. The method includes: a step of aligning the composite material with each of a plurality of molding dies, heating the molding dies, and semi-curing the resins of the composite materials; and a step of joining the composite materials to each other by combining and heating the molding dies with which the composite materials are aligned after semi-curing the resins of the composite materials. The molding dies used when semi-curing the resins of the composite materials and the molding dies used when joining the composite materials to each other are the same.

A method and apparatus is presented. Layers of composite material are laid down on a forming tool. A respective bend is formed in each of the layers to form the composite filler comprising bent layers on the forming tool. The composite filler comprising the bent layers is placed into a gap formed by at least one composite structure.

The invention provides a wind turbine blade comprising a first shell, having a first bonding region, and a second shell having a second bonding region, wherein the second bonding region of the second shell is bonded to the first bonding region of the first shell; and a temperature sensor positioned between the first bonding region and the second bonding region. Having a temperature sensor positioned within the turbine blade, in the region at which the two shells of the turbine blade are bonded together, allows for accurate determination and control of the temperature of the critical bonding regions during blade manufacture. The temperature sensor may be used during the service life of the wind turbine blade to detect delamination of the wind turbine blade.

A composite radius filler material is provided. The composite radius filler includes a resin, a first group of fibers dispersed within the resin, and a second group of fibers dispersed within the resin. The first group of fibers has a first length configured to facilitate orientation in a longitudinal direction. The second group of fibers has a second length that is shorter than the first length, with the second group of fibers configured to facilitate random orientation in a transverse direction.

A system for depositing a composite filler material into a channel of a composite structure includes an end-effector configured to extrude a bead of the filler material into the channel. The filler material can comprise a first group of relatively long fibers, a second group of relatively short fibers and a resin. A drive system is configured to move the end-effector relative to the channel, and a position sensor is configured to detect the position of the bead relative to the channel. A controller is configured to operate the drive system in response to the detected position and to operate the end-effector to heat and compress the filler material so as to orient the longer fibers in a substantially longitudinal direction relative to the channel and the shorter fibers in substantially random directions relative to the channel when the bead is extruded into the channel.

Composite layup tools for aircraft fuselage barrels, methods of assembling the layup tools, and aircraft fuselage barrels formed utilizing the layup tools are disclosed herein. A method of assembling the layup tools includes aligning an adaptor mating surface of a splice adaptor with a mandrel mating surface of a layup mandrel and initially attaching the splice adaptor to the layup mandrel at an initial attachment point. The methods further include attaching a lower lobe of the splice adaptor to a lower lobe of the layup mandrel. A method of forming a fuselage barrel assembly includes providing two fuselage barrel sections and a splice ring, aligning the two fuselage barrel sections, locating the splice ring within the two fuselage barrel sections, and attaching both fuselage barrel sections to the splice ring. The systems include a layup tool that is formed using the methods.

Installation fittings for use with induction weldable pipe connectors for assembling multi-layer pipe fluid distribution systems. Induction welding pipe connectors including a major central pipe connector section and a minor lateral pipe connector section pair having reduced thickness relative to the major central pipe connector section. Induction welding pipe connectors with 5 integral solder flow barrier for assembling fluid distribution systems. Electromagnetic induction coil reverse action pliers for use with induction weldable pipe connectors for assembling fluid distribution systems.

Methods are provided for joining a composite component, such as a rotor blade of a wind turbine. Accordingly, a first blade segment is provided and a bladder assembly is positioned thereon. Additionally, an adhesive element is positioned in a first position on the first blade segment. A second blade segment is positioned with the first blade segment so as to define an inner cavity therebetween. The inner cavity contains the adhesive element and the bladder assembly, but the adhesive element does not contact the second blade segment while in the first position. The bladder assembly is inflated to transition the adhesive element to a second position in contact with both the first blade segment and the second blade segment. With the adhesive element in contact with both blade segments, the adhesive element is allowed to cure in order to secure the blade segments to one another.

A method is provided during which a thermoplastic rib is arranged with a thermoplastic spar. A first flange of the thermoplastic rib is abutted against the thermoplastic spar. The first flange of the thermoplastic rib is ultrasonic welded to the thermoplastic spar using a tilted ultrasonic horn. A centerline of the tilted ultrasonic horn is angularly offset from the first flange of the thermoplastic rib by an acute angle during the ultrasonic welding.