Systems and methods are provided for composite part fabrication. One embodiment is a method that includes placing a laminate onto a base of a mandrel between side walls of the mandrel, placing edge dams between the side walls and the laminate that each abut the laminate and abut one of the side walls, each edge dam having a Coefficient of Thermal Expansion (CTE) greater than a CTE of the mandrel, the CTE of the mandrel being greater than a CTE of the laminate, heating the laminate, edge dams, and mandrel, and during the heating, thermally expanding the edge dams an amount that corresponds with a difference in thermal expansion between the laminate and the mandrel.

Fluid flow conduits and apparatus and methods for joining the conduits, preferably in a sterile manner, are disclosed. Each conduit has a polymeric open end that is sealed by a sealing member that may include a heating element. The polymeric end material is melted, the sealing members are moved to expose the melted open ends of the conduits and the ends are brought together to form a fused or welded connection between the conduits.

A method and an apparatus for welding a first object to a second object, wherein the first object is produced from a thermoset and comprises a thermoplastic material outer layer, wherein the second object comprises at least one thermoplastic material outer layer. In addition, a layer of carbon nanotubes is applied to the thermoplastic material outer layer of the first object, and the second object is placed onto the first object. At least some of the thermoplastic material outer layer of the second object lies atop the applied layer of carbon nanotubes. In addition, a potential is applied to the layer of carbon nanotubes, such that an electrical current flows through the carbon nanotubes, wherein the thermoplastic material outer layer of the first object and the thermoplastic material outer layer of the second object are heated and are welded to one another.

A method for joining primary and secondary members includes providing a primary member, a secondary member and a heating element which is joined to one of the primary and secondary members. The heating element includes an electrically insulating matrix material and an electrically conductive reinforcing clement extending through the matrix material. The method further includes bringing the other of the primary and secondary members and the heating element into engagement and controlling a flow of electrical current in the reinforcing element so as to resistively heat and fuse at least some of the matrix material of the heating element with a matrix material of the other of the primary and secondary members. The method may be used to join a primary member such as a composite tubular and a secondary member such as a component for terminating the composite tubular.

Provided is a method for producing a joined body obtained by joining a base material A, a film containing an amorphous thermoplastic resin, which is at least one of a thermoplastic epoxy resin and a phenoxy resin, as a main component, and a resin B in this order. The method includes a first joining step of joining the base material A and the film by melting and then solidifying the film in a state in which the film is in contact with the base material A, and a second joining step of joining the base material A and the resin B by melting and then solidifying the film in a state in which the film joined to the base material A is in contact with the resin B. The base material A is at least one of a metal and an inorganic substance, an epoxy equivalent of the amorphous thermoplastic resin is 1,600 g/eq. or more, or the amorphous thermoplastic resin does not contain an epoxy group, and a heat of fusion of the amorphous thermoplastic resin is 15 J/g or less.

Systems and methods are described for applying a self-heating structural adhesive to components of aircraft or other structures. A conductive scrim can be placed in between layers of adhesive for use in joining two components together. Leads can be provided to apply an electrical current to the scrim, which can raise the temperature of the system and cure the adhesives, creating a strong bond with a conductive layer there between.

Composite joints and methods of forming composite joints are presented. A composite joint comprising: a first composite component formed of one of a thermoset material or a first thermoplastic material; a second composite component formed of a thermoset material or a third thermoplastic material; a thermoplastic joining film formed of a second thermoplastic material between the first composite component and the second composite component, the second thermoplastic material different from the thermoset material, first thermoplastic material, and third thermoplastic material; and a carbon conductive layer in the thermoplastic joining film.

A method and an apparatus for welding together a first object and a second object. The method comprises applying a layer of carbon nanotubes onto a surface of the first object and bringing the first object and the second object into contact, such that the layer of carbon nanotubes on the surface of the first object is in contact with a surface of the second object. The method further comprises applying a voltage to the layer of carbon nanotubes, such that an electrical current flows through the layer of carbon nanotubes, wherein material of the first object adjacent to the layer of carbon nanotubes and material of the second object adjacent to the layer of carbon nanotubes is heated and melted by the electrical current and thereby welded together. Further, an apparatus for welding together a first object and a second object is presented.

An implant for electric resistance welding of elements made of composites, with a frame of thermoplastic materials, reinforced with conductive fibres, in a flat multilayered structure with an upper and lower surface, and includes an electrically resistant layer of a flat sheet with openings, made of a conductive material, additional layers made of the frame material, one of which covers the electrically resistant layer from the top, and the other one from the bottom. The implant includes porous insulating layers made of an electrically nonconductive material, one covers the implant from the top, contacting the upper layer of the frame material, and the other covers the implant from the bottom, contacting the lower layer of the frame material. The layers are merged with each other in a flat, multilayered inset placed between the welded elements, and the electrically resistant layer has electrical connections for connecting a source of electrical current.

Composite joints and methods of forming composite joints are presented. A composite joint comprising: a first composite component formed of one of a thermoset material or a first thermoplastic material; a second composite component formed of a thermoset material or a third thermoplastic material; a thermoplastic joining film formed of a second thermoplastic material between the first composite component and the second composite component, the second thermoplastic material different from the thermoset material, first thermoplastic material, and third thermoplastic material; and a carbon conductive layer in the thermoplastic joining film.