A laser welded structure is formed by laser welding together a resin molded body formed from a thermoplastic polymer alloy containing a crystalline resin and an amorphous resin and a metal body made of a metal. A glass transition temperature of the amorphous resin is lower than a melting start temperature of the crystalline resin.

A method for manufacturing a thrust reverser blocker door may comprise thermoforming a sandwich panel comprising a facesheet, a backsheet, and a honeycomb core. The method may further comprising overmolding a mounting structure onto the backsheet. The first thermoplastic material may comprise a continuous fiber reinforced thermoplastic composite material. The second thermoplastic material may comprise a discontinuous fiber reinforced thermoplastic composite material.

A method for manufacturing of a part made of composite material including pre-compacting to a predetermined shape of a mixture of a first thermosetting resin with discontinuous long fibers so as to form a first preform, pre-curing the first preform until an intermediate conversion stage corresponding to a solidification of said first resin, contacting the first preform with a second preform including a fiber structure of continuous fibers impregnated with a second thermosetting resin, polymerizing the first and second preforms so as to form a part made of composite material including a body made of composite material including reinforcement made of continuous fibers consolidated by an organic matrix provided with a portion made of composite material including reinforcement made of discontinuous long fibers consolidated by an organic matrix.

Mechanically attaching articles made from composites has problems due to the difference in properties of the composite in the x, y planar direction and the z perpendicular direction, this results in different properties between the composite and the attachment member such as differences in coefficients of thermal expansion which can weaken the joint further leading to differences in moisture uptake which can further reduce the strength and robustness of the joint. The invention relates to the selection of the position of a joint in order to reduce such problems and to operating the moulding process in a way that improves the provision of mechanical attachments such as bolt holes.

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.

A method for forming a hybrid heat exchanger is provided. The method includes laser-texturing a metal surface to create a plurality of microstructures and subsequently melt-bonding a plastic component to the plurality of microstructures. During melt-bonding, plastic material penetrates the plurality of microstructures and conforms to the plastic component to the metal surface. After hardening inside the microstructures, the plastic component adheres to the metal surface as a hybrid component. As a result, a fastener or snap connection is not required, and the plastic-metal joint provides a barrier to water, glycol-based fluids, air, and other fluids.

The invention first relates to a method for welding at least two parts comprising a thermoplastic material and having respective surfaces to be welded, comprising: inserting an insert between the surfaces to be welded of the two parts; generating heat via said insert; wherein the insert moves in relation to the parts to be welded in a welding direction. The invention also relates to an installation adapted for implementation of this method.

A thermoplastic seatback for a passenger seat includes a thermoplastic peripheral structural frame for attachment to a seat assembly and a thermoplastic diaphragm overmolded onto a forward face of the frame. An aircraft passenger seat and a method of constructing a passenger seatback is also disclosed.

The present technology discloses a system, for joining workpieces using energy, such as ultrasonic energy, where the energy concentrates at a location within a weld area, promoting sequential melting of a plurality of energy directors. The system can be configured so that the sequential melting begins at the center of the weld area and progresses outwards. Sequential melting may occur through use of a welding tip configured to reduce air pockets, a tapering the height of a plurality of energy directors, and/or tapering the energy directors themselves, all of which reduce the size of an energy transfer area produced by thermal energy. The present technology also includes a method for joining workpieces using energy such as ultrasonic energy that concentrates at a location within a weld area causing sequential melting of a plurality of energy directors using the aforementioned features.

A structural element that includes a central part formed of a fibrous material suspended in a thermoplastic matrix and at least one side part formed of a fibrous material suspended in a thermoplastic matrix and having at least one void therein. The central part and the at least one side part are bonded together while in a heated thermoplastic state to form a single, integral structure characterized by the absence of discontinuity across the bond plane of the structure.