A method is provided for controlling an induction welding operation. The method includes sweeping electrical current through an induction welding coil at an initial position of the induction welding coil along a weld path of a material; monitoring a response of the material to the swept electrical current using at least one electromagnetic field (EMF) sensor; calibrating an electrical current value for the induction welding operation using the monitored response; and performing the induction welding operation along the weld path using the calibrated electrical current value.

A method for joining moulded parts by electromagnetic welding. A joining inductor is moved along contact surfaces of the moulded parts, generating an electromagnetic field in an induction-sensitive component of the moulded part(s) to heat a thermally activated coupling means of the moulded part(s) to above a melting temperature of the coupling means. The strength of the electromagnetic field suitable for joining is determined by previously moving a sensing inductor along the contact plane, generating a relatively weak electromagnetic field to slightly heat the thermally activated coupling means to a sensing temperature, measuring the field strength generated by the sensing inductor in the moulded part(s), determining a discrepancy between the measured field strength of the sensing inductor and the field strength suitable for joining, and adjusting the field strength suitable for joining to close the discrepancy. A device for carrying out the method.

Systems and methods are provided for fabricating a hybrid composite part. A method includes braiding a first set of fibers to form a weave having a closed cross-sectional shape, braiding a second set of fibers into the weave that are chemically distinct from the first set of fibers, impregnating the weave with a resin, and hardening the resin within the weave to form a hybrid composite part.

A method for joining moulded parts by electromagnetic welding. A joining inductor is moved along contact surfaces of the moulded parts, generating an electromagnetic field in an induction-sensitive component of the moulded part(s) to heat a thermally activated coupling means of the moulded part(s) to above a melting temperature of the coupling means. The strength of the electromagnetic field suitable for joining is determined by previously moving a sensing inductor along the contact plane, generating a relatively weak electromagnetic field to slightly heat the thermally activated coupling means to a sensing temperature, measuring the field strength generated by the sensing inductor in the moulded part(s), determining a discrepancy between the measured field strength of the sensing inductor and the field strength suitable for joining, and adjusting the field strength suitable for joining to close the discrepancy. A device for carrying out the method.

A method and installation for joining a cover layer to an object in a continuous process. Joining is effected with the aid of a joining material having thermoplastic properties, wherein the joining material is arranged between the cover layer and the object and is liquefied using ultrasonic vibration energy. Before application of the ultrasonic vibration energy, the joining material is preheated in a contactless manner with the aid of electromagnetic induction in the region of the glass transition temperature of the joining material or above this glass transition temperature. The object is in particular a chip board and the cover layer an edge strip to be joined to an edge of the chip board.

A method of induction welding a first thermoplastic composite (TPC) to a second thermoplastic composite (TPC) includes inductively heating a weld interface area between the first TPC and the second TPC, and cooling a surface of the first TPC opposite the weld interface area while inductively heating the weld interface area.

A heat sink for use in induction welding includes a flexible backing and a number of tiles disposed on the flexible backing in a single layer, wherein the tiles are electrically non-conductive and thermally conductive.

A heat sink for use in induction welding includes a number of tiles, where the tiles are electrically non-conductive and thermally conductive, a joint flexibly joining the tiles together, and a fluid path formed through the heat sink for communicating a coolant therethrough.

A method of dissipating heat from a surface of a first thermoplastic composite (TPC) being inductively welded with a second thermoplastic composite (TPC) includes flexing a heat sink during placement to conform to the surface of the first TPC, cooling the heat sink, applying inductive heat to a weld interface area between the first TPC and the second TPC, and drawing off heat via the heat sink from the surface of the first TPC.

A method of induction welding a first carbon fiber thermoplastic composite (TPC) to a second carbon fiber thermoplastic composite (TPC) using an induction coil includes aligning the first TPC with the second TPC to form a weld interface area, flexing a heat sink onto a surface of the first TPC between the weld interface area and the induction coil, and inductively heating the weld interface area with the induction coil.