In an example, a method of sealing a bond cavity is described. The method comprises placing an adhesive around a perimeter of a first structure to be joined to a second structure. The method also comprises positioning the first structure relative to the second structure such that the adhesive is disposed between the first structure and the second structure. The method also comprises merging the first structure and the second structure until the first structure and the second structure are separated by a desired gap for bonding. The method also comprises heating the perimeter to at least partially cure the adhesive to form a leak-proof bond cavity perimeter between the first structure and the second structure.

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 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 method of creating a weld between a liner of a section of lined pipe and an electrofusion fitting. The fitting comprises at least one heating element, which is suitably disposed on or in an outer surface of the electrofusion fitting and is electrically isolated from an inner surface of the fitting. The method comprises locating an end of the electrofusion fitting within an end of the section of lined pipe, locating an induction coil within a bore of the electrofusion fitting in the vicinity of the at least one heating element, and supplying electrical power to the induction coil to energise the at least one heating element by electromagnetic induction.

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.

A system for controlled induction welding of at least one weld seam area (A) of at least two surfaces of at least one workpiece is provided. The system comprises an inductor configured to be arranged in conjunction with the at least one workpiece, a processing means configured to generate an electromagnetic field by applying an alternating voltage to the inductor so as to inductively heat at least one of the surfaces so that the weld seam area (A) is welded together, simultaneously measure at least one parameter (P) of the at least one workpiece at least based on the generated electromagnetic field, detect a change of the at least one parameter (P), and determine a temperature estimation of the at least one workpiece based on said detected change.

A fuselage structure of an aircraft includes a fuselage skin, and a plurality of frame elements spaced apart from one another in a direction parallel to the aircraft longitudinal axis for supporting the fuselage skin. The fuselage skin includes a plurality of interconnected fiber-reinforced composite skin panels that extend between each pair of frame elements and are connected thereto. The composite skin panels further comprise a stiffener integrally formed in each composite skin panel. A method for manufacturing the fuselage skin. The composite skin panels may be interconnected and/or connected to a frame element through an induction welded connection.

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 tooling for use in a method for electromagnetic welding of two contacted surfaces of molded parts. The tooling includes a rubber body and pressurizing means for pressurizing the rubber body and applying pressure to the contacted surfaces. The rubber body includes an embedded stiff body shaped such as to define different rubber body thicknesses in different directions, which causes a different pressure build-up in the different directions. A method for manufacturing the tooling. The tooling may be used in electromagnetic welding of two contacted surfaces of molded parts by moving a joining inductor along the contacted surfaces, generating an electromagnetic field in an induction-sensitive component of the molded parts to heat a thermally activated coupling means of the molded parts to above a melting temperature of the coupling means.

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.