A method for surface preparation of composite substrates prior to adhesive bonding. A curable surface treatment layer containing blocked isocyanate compounds is applied onto a curable composite substrate, followed by co-curing. The surface treatment layer may be a resin layer without fibers or a removal peel ply composed of resin-impregnated fabric. After surface preparation, the composite substrate is provided with a chemically-active, bondable surface that can be adhesively bonded to another composite substrate to form a covalently-bonded structure.

A primer-attached thermoplastic resin material having a thermoplastic resin material and one or plural primer layers laminated on the thermoplastic resin material, wherein at least one layer of the primer layers is an in-situ polymerizable composition layer of an in-situ polymerizable composition polymerized on the thermoplastic resin material.

An assembly to manufacture a roll of prepreg material. The assembly includes a moving system for picking a sheet of prepreg material from a stack of sheets and moving the sheet along a feed path. An alignment system aligns a leading edge of the sheets with a trailing edge of a roll of the prepreg material. A welding system connects the sheet to the roll.

An assembly to connect together first and second sheet members. The assembly includes a pressure device that applies pressure to the sheet members while the sheet members are in an overlapping arrangement and positioned on a support platform. A sensing system that includes one or more thin film pressure sensors detects the positions of the leading and trailing edges. A connection device connects the members together in an overlapping arrangement.

A method of producing a high-pressure tank including a liner and a reinforcement layer made of fiber-reinforced resin includes a process of forming at least a domed member included in the reinforcement layer. The process includes placing first fiber bundles to form a part of a protruding portion and a part of a domed main body, and placing second fiber bundles to cover the first fiber bundles. The first fiber bundles are placed, such that a fiber direction of the first fiber bundles in the protruding portion follows an axial direction of the protruding portion, and resin with which the fiber bundles are impregnated is solidified while the first fiber bundles are being placed. The second fiber bundles are placed, such that the fiber direction of the second fiber bundles intersects with the fiber direction of the first fiber bundles.

Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

Construction of a sealed connection between an elastomeric or synthetic polymer flexible pipe or hose and a metallic coupling member. The coupling member surrounds an armor layer at a free end of the flexible pipe or hose. A sealing area is defined by a recessed portion of the pipe coupling into which a sealing material is introduced. An inner liner layer of the flexible pipe or hose may extend into the sealing area where it is bonded to the sealing material. The sealing material and the inner liner layer may each be comprised of a semi-crystalline thermoplastic material. Furthermore, a reinforcement material may be provided in the inner liner layer.

Conductively coated fastening systems are disclosed herein. An apparatus includes a fastening system and a structural assembly. The structural assembly comprises a first structural element made of an electrically conductive fiber reinforced plastic and a second structural element. The first structural element comprises a first hole and the second structural element comprises a second hole. The first and second holes are separately pre-formed prior to assembly of the structural assembly. The structural assembly further comprises an electrically conductive gap filler applied to a first structural element sidewall of the first hole of the first structural element. The fastening system comprises a fastener comprising a head and a shank extending from the head. The shank is configured to be inserted into the first hole and the second hole.

Composite fabrication system and associated methods. In one embodiment, a composite fabrication system comprises a molding tool that includes a forming surface at least partially disposed within a constrained space, and a foamable material that expands inside of the constrained space to form an expanded material that presses a layup of one or more composite layers against the molding tool. The composite fabrication system further comprises a curing device configured to cure the layup to form a composite part, and a cutting wire embedded in the constrained space that is heated and configured to cut the expanded material into pieces that are removable from the constrained space.

A method of making and testing a wind turbine blade comprises providing a structural member having a web portion and a flange portion, where the flange portion extends away from the web portion and a curvilinear heel is defined between the web and flange portions. 5 A flange extender is integrated with the flange portion, where a first section of the flange extender overlies the flange portion, and a second section of the flange extender extends past the heel and away from the web portion. The flange extender is bonded to the inner surface of a wind turbine blade shell. Non-destructive test (NDT) equipment is used to assess the integrity of the bond by identifying first and second target surfaces of the 10 structural member. The target surfaces are spaced apart by an intermediate region, corresponding to the location of the heel, where it is not possible to positively identify any surface using NDT techniques. Identification of the two target surfaces indicates a good integrity bond in the intermediate region, whereas identification of only one, or neither, of the target surfaces indicates a poor integrity bond. 15