A method for bonding composite substrates includes coupling a first co-cure prepreg layer having a first off-set amine to epoxide molar ratio onto a surface of a first composite substrate and coupling a second co-cure prepreg layer having a second off-set amine to epoxide molar ratio onto a surface of a second composite substrate. The first and second composite substrates are cured to the first and second co-cure prepreg layers, respectively, using a first cure cycle (including B-stage and cure temperatures) to form a first and a second co-cure prepreg layer portion. The method further includes coupling the first co-cure prepreg layer portion to the second co-cure prepreg layer portion and applying a second cure cycle to cure the first co-cure prepreg layer portion of the first composite substrate to the second co-cure prepreg layer portion of the second composite substrate to form a monolithic covalently bonded composite structure.

A wind turbine blade comprising first and second adjacent blade sections arranged end to end along the length of the blade. Each section comprises an aerodynamic fairing and a spar. Each spar comprises a shear web extending across the fairing and a pair of spar caps, one at either end of the shear web. Each spar cap in the first section has a different cross-sectional shape and/or material from the respective spar cap in the second section and wherein the spar cap in the first section is joined to the respective spar cap in the second section via a connection piece. Each connection piece is a pre-cured component extending along the length of the blade from a first inclined end configured to connect to a first complimentary inclined end of a spar cap of the first blade section and a second inclined end.

A method for assembling a box structure includes elementary parts assembled along an understructure of stiffeners and skins. The understructure and skins are made of composite material with a polymer matrix. The method includes sizing the box structure for the loads to which it is subjected and for a glued assembly. A map of the loads on the structure is obtained and a first load limit is defined depending on the probability of the structure being damaged. The understructure and the skins are assembled by gluing them. An additional layer is applied that covers the assembled elementary parts to areas of the assembled box structure where the first load limit is reached.

A method of fabricating a composite assembly may include providing a first laminate and a second laminate respectively formed of first and second composite plies, and having a respective first and second cured section and a respective first and second uncured section. The method may further include interleaving the first composite plies in the first uncured section with the second composite plies in the second uncured section to form an interfacial region. The method may additionally include curing the interfacial region to join the first laminate to the second laminate and form a unitized composite assembly.

Systems and methods for reinforcing physical structures with composite reinforcement systems are disclosed herein. According to aspects of the present disclosure, a composite reinforcement system includes a carrier formed of a plurality of fibers and a blend of at least two reagents impregnated within the carrier. The at least two reagents are chemically configured to react to form a moisture-curable prepolymer. One reagent of the at least two reagents is an isocyanate, and another reagent of the at least two reagents is an aromatic-group-containing polyol.

A method and apparatus is presented. A layer of composite material is laid up on a forming tool. A bend is formed in the layer on the forming tool to form a bent layer. A laminate stack and the bent layer are assembled to form the composite filler.

A method of manufacturing a wind turbine blade is described, the blade being formed from at least a pair of blade shells being joined together. For at least a portion of the wind turbine blade, the blade shells are joined by an overlamination applied between the edges of the blade shells, thereby substantially reducing or eliminating the need for a structural adhesive to join the blade shells, particularly in the area of the leading edge of the blade or the root region of the blade trailing edge. The overlamination can be formed from the same material as the blade shells themselves, thereby minimising the possibility of structural faults or cracks due to differences in materials or stiffness levels at the interface between the blade shells.

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. An injection device may also move behind the plate and reciprocally inject a polymer between the first and second faying surfaces to provide toughness and crack arresting properties.

A method of joining a non-metallic pipe to a metallic pipe. The pipe may be wrapped with one or more sheets of reinforcement material (e.g., pre-impregnated fiberglass, carbon fiber, or aramid fiber) and then fitted with an adapter or fitting that is connectable to a metallic pipe. The reinforcement material may be heated using a heating apparatus which allows the material to bond to the pipe to strengthen the joint.

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. The heated portion may contact the faying surfaces and melt them through conduction, or may be suspended between them and melt them through radiation and convection.