A skin-to-core bond line mapping system and method is disclosed. Layered composite components formed by “sandwiching” multiple materials together require a continuous bond between those materials with voids below particular thresholds that can vary by application. The skin-to-core bond line mapping system can include a laminate, an adhesive, a separator film, a core, a breather, a layup tool, bagging material, sealant, and a vacuum port. By employing systems and processes that layer separator film over adhesive and applying a core proximate the adhesive, a bagging material can be disposed over the materials to facilitate vacuum compaction, thereby impressing core impressions on the adhesive to map the areas between the skin and core that have good contact. An iterative process is disclosed, in which additional adhesive can be used to build the bond line until contact is made (or engineering tolerance is reached).

A wafer bonding apparatus includes a first bonding chuck to fix a first wafer on a first surface thereof, a second bonding chuck to fix a second wafer on a second surface thereof facing the first surface, a bonding initiation member at a center of the first bonding chuck to push the first wafer towards the second surface, and a membrane member including a protrusion protruding from a center portion of the second surface towards the first surface, and a planar portion defining the protrusion on an outer region surrounding the center portion.

A method for use in ply compaction in forming a composite structure. The method includes positioning a ply of material on a forming tool having a web surface and at least one flange surface extending from the web surface, positioning a flange forming device at the ply of material on the forming tool, the flange forming device including an inflatable contact element pressurized to define a deformable contact surface, applying, by the deformable contact surface, the ply of material onto the forming tool with a predetermined pressure, wherein the deformable contact surface is moved across the forming tool, and wherein the inflatable contact element is configured to maintain the predetermined pressure as the deformable contact surface transitions from the web surface to the at least one flange surface.

A segmented rotor blade for a wind turbine includes a first rotor blade segment, a second rotor blade segment, at least one thermoplastic material, and an internal pressure source. The first rotor blade segment includes a first joint end. The second rotor blade segment includes a second joint end. The first and second joint ends are arranged together in an end-to-end orientation so as to form at least one scarf joint. The at least one thermoplastic material is arranged at each of the first and second joint ends. The first and second joint ends of the first and second rotor blade segments are bonded together via thermoplastic welding of the at least one thermoplastic material. The internal pressure source provides pressure to the scarf joint during the thermoplastic welding. The internal pressure source remains within the rotor blade after thermoplastic welding is complete.

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 number of tiles, wherein the tiles are electrically non-conductive and have a thermal diffusivity of greater than about 25 mm2/sec. A joint flexibly joins the tiles together.

A method of induction welding a first thermoplastic composite (TPC) to a second thermoplastic composite (TPC) using an induction coil includes forming a weld interface area between the first TPC and the second TPC, cooling the first TPC with a cooling apparatus before heating by the induction coil, and inductively heating the weld interface area with the induction coil after cooling the first TPC.

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.