A system and method for fusing at least two thermoplastic composite components together may include placing faying surfaces of the thermoplastic composite components in contact with each other, placing a separation layer over and against one of the thermoplastic composite components, and placing a multi-layer composite pressure pad over and in contact with the separation layer. The method may also include placing an activated inductor against the multi-layer composite pressure pad for induction welding the two thermoplastic composite components to each other. The thermoplastic composite components may comprise conductive fibers while the multi-layer composite pressure pad may comprise a first layer and a second layer with non-conductive fibers. The first layer may at least partially melt during induction welding of the two thermoplastic composite components while the second layer may remain rigid throughout this welding.

An assembly to repair a thermoplastic composite. The assembly includes a heating device positioned on opposing sides of the thermoplastic composite. The heating device includes one or more susceptor with a Curie temperature to heat the thermoplastic composite. A pressure device applies a compressive force to the heating device. A pressure distribution device is positioned between the heating device and the thermoplastic composite. The pressure distribution device distributes the compressive force from the pressure device over areas of the opposing sides of thermoplastic composite.

An assembly to repair a thermoplastic composite. The assembly includes a heating device positioned on opposing sides of the thermoplastic composite. The heating device includes one or more susceptor with a Curie temperature to heat the thermoplastic composite. A pressure device applies a compressive force to the heating device. A pressure distribution device is positioned between the heating device and the thermoplastic composite. The pressure distribution device distributes the compressive force from the pressure device over areas of the opposing sides of thermoplastic composite.

A bonding system includes a supporting jig having a mounting surface on bonding substrates which are mounted, a bonding device that sandwiches and welds the bonding substrates between itself and the mounting surface, an articulated robot to which the bonding device is attached, and a control unit that controls the articulated robot and the bonding device.

A bonding system includes a supporting jig having a mounting surface on bonding substrates which are mounted, a bonding device that sandwiches and welds the bonding substrates between itself and the mounting surface, an articulated robot to which the bonding device is attached, and a control unit that controls the articulated robot and the bonding device.

A method comprising providing a polymeric substrate having a melting point of from about 130° C. to about 190° C., and locating a material layer onto the substrate, wherein the material layer comprises one or more polymeric materials that liquefy upon exposure to temperatures of at least about 100° C., to blend with a softened portion of the polymeric substrate. Upon exposure of one or more of the substrate and the material layer to a stimulus, the temperature is increased in a predetermined temperature zone of one or more of the substrate and material layer to cause blending of the one or more polymeric materials of the material layer with the softened portion of the polymeric substrate.

A welding apparatus for a fibre reinforced resin based material comprises an elongate flexible heat conductive strip and an elongate heat sink extending around at least a portion of the perimeter of the conductive strip. The elongate heat sink is divided into a plurality of segments wherein adjacent segments can move relative to one another.

A welding apparatus for a fibre reinforced resin based material comprises an elongate flexible heat conductive strip and an elongate heat sink extending around at least a portion of the perimeter of the conductive strip. The elongate heat sink is divided into a plurality of segments wherein adjacent segments can move relative to one another.

A fusion bonding process for polymeric components and welding heads for use in the process are described. Methods and devices can be utilized to weld polymer-based structural components to one another by use of an enhanced friction stir welding technology that combines heating, pressure, and polymer agitation to form a highly secure joint between polymeric structural components and a short fiber reinforced thermoplastic connection element.

A fusion bonding process for polymeric components and welding heads for use in the process are described. Methods and devices can be utilized to weld polymer-based structural components to one another by use of an enhanced friction stir welding technology that combines heating, pressure, and polymer agitation to form a highly secure joint between polymeric structural components and a short fiber reinforced thermoplastic connection element.