A method for welding at least two parts including a thermoplastic material and having respective surfaces to be welded, including: inserting an insert between the surfaces to be welded of the two parts; generating heat via the insert; wherein the insert moves in relation to the parts to be welded in a welding direction. Also, an installation adapted for implementation of this method.

A ultrasonic welding method of joining dissimilar-material workpieces, such as sheet materials, and the joined components formed thereby. The method includes applying ultrasonic energy to a thermoplastic piece to fill a hole of a dissimilar piece to form a weld point that is made up with polymer from the thermoplastic piece. In general, the geometry of the thermoplastic piece is not altered during the process. The dissimilar piece generally has a higher melting temperate and can be metal, thermoset polymers, or other thermoplastic material. The welded pieces can be arranged in a lap, laminate, or double lap configuration. In some embodiments, the hole of the dissimilar sheet material includes undercut features that improve the mechanical interlock between the dissimilar pieces. In some embodiments, the weld point has a mushroom cap to improve mechanical interlock.

A hollow punch rivet is described having a flange and a rivet section. Furthermore, a method for the attachment of individual components to one another using a punch rivet is described, with at least one of the components being formed by a material of the composite material. The method includes the following steps: a) arrangement of the die button against one of the two components to be secured to one another, which are placed on one another, wherein the die button has a bore which is dimensioned to receive the rivet section, b) carrying out a relative movement of the punch rivet with the free end of the rivet section to the fore towards the components arranged on one another and in the direction of the die button, c) piercing of the components with the free end of the rivet section and introduction of the rivet section into the bore of the die button until the component contact surface comes into contact and the component adjacent to the flange, d) using a plunger in order to dilate the punch rivet at least locally and e) forming a rivet bead by reshaping the free end region of the rivet section.

Disclosed is a method of resistance welding between composite articles. A conductive element is provided between faying surfaces, having a plurality of lower resistivity electrode portions spaced apart along the length of the contact area between the composite articles. The electrode portions can be used to spot weld across the electrode portions, and along a longitudinal portion of the conductive element between the electrode portions by application of an electrical current. Also disclosed are apparatus for use in the resistance welding methods and composite articles and structures and elements incorporating the conductive element.

A first member formed of a thermoplastic resin molding mixed with a fiber material and a second member formed of a molding containing at least a thermoplastic resin are welded by friction stir spot welding using a double-acting tool for friction stir spot welding. An overlapping part between the first member and the second member is formed, and the tool is disposed against the overlapping part while the pin and the shoulder are rotated about the rotation axis. The pin is plunged into the overlapping part, and friction stir is performed to cause extension fibers to remain around a plunging region of the pin while the shoulder is retracted to release an overflow material. The shoulder is brought closer to the overlapping part to wrap the extension fibers into the overflow material when the overflow material is backfilled while the pin is retracted from the overlapping part.

A method for forming a fiber-reinforced thermoplastic hollow structure may comprise: abutting a first surface of a first flange of a shell and a second surface of a second flange of the shell with a mating component; disposing an end block laterally adjacent to the shell; applying a first load to a sidewall of the shell; applying a second load to the second flange of the shell; and vibrating one of the shell or the mating component while keeping a non-vibrating component stationary, the non-vibrating component including one of the shell or the mating component.

An induction welding system includes a first gantry, a second gantry, and a support structure. The first gantry includes a first frame and a first plurality of trunks. The first plurality of trunks defines a first curved inner support surface of the first gantry. The first curved inner support surface has a first curvature geometry. The second gantry includes a second frame and a second plurality of trunks. The second plurality of trunks defines a second curved inner support surface of the second gantry. The second curved inner support surface has a second curvature geometry which is different than the first curvature geometry. The support structure includes at least one tooling member defining a curved outer support surface of the support structure. The support structure is longitudinally moveable relative to the first gantry and the second gantry.

A reinforcing component for a structure of an aircraft or spacecraft has a first component region for reinforcing at least one other element, and at least one second component region, which is permanently connected to the first component region. The reinforcing component is formed using a thermoplastic plastics material in each of the first component region and the second component region. In the first component region, the thermoplastic plastics material forms a matrix in which continuous reinforcing fibres are embedded. In the second component region, the reinforcing component comprises discontinuous reinforcing fibres or is free of reinforcing fibres.

A method for preparing a pre-bond surface of a composite structure includes the steps of: (1) separating a peel ply, co-cured with a composite substrate, from the composite substrate; and (2) transferring an identifiable marking agent from the peel ply to the composite substrate upon separation of the peel ply from the composite substrate. Residue of the peel ply, transferred from the peel ply to the composite substrate upon separation of the peel ply from the composite substrate, is layered on the identifiable marking agent.

A method of bonding a second object to a first object includes: providing the first object having a thermoplastic liquefiable material in a solid state; providing the second object having a surface portion that has a coupling structure with an undercut, so that the second object is capable of making a positive-fit connection with the first object; pressing the second object against the first object with a tool that is in physical contact with a coupling-in structure of the second object while mechanical vibrations are coupled into the tool; continuing to press and couple vibrations into the tool until a flow portion of the thermoplastic material of the first object is liquefied and flows into the coupling structures of the second object; and letting the thermoplastic material re-solidify to yield a positive-fit connection between the first and second objects by the re-solidified flow portion interpenetrating the coupling structures.