Provided a composite material forming method capable of easily using a composite material that is formed by causing a resin to react in a state where it is joined to another member; and a composite material. The composite material forming method includes a first material preparation step (magnetic field circuit forming material preparation step S11), a second material preparation step (magnetic field circuit non-forming material preparation step S12), a material assembly step S13, and a first heating step (magnetic field heating step S14). In the first material preparation step, a first material including a first resin is prepared. In the second material preparation step, a second material including a second resin is prepared. In the material assembly step S13, the first material and the second material are assembled to each other.

A method for assembling a shear web assembly of a wind turbine includes providing at least one spar cap. The method also includes forming a spar connecting member of a thermoplastic material via additive manufacturing. Further, the method includes securing the spar connecting member to the spar cap. Moreover, the method includes providing a shear web, forming a web connecting member of a thermoplastic material via additive manufacturing, and securing the web connecting member at a first end of the shear web. In addition, the method includes interconnecting the web connecting member and the spar connecting member at a joint. Thus, the method further includes heating the joint to secure the web connecting member and the spar connecting member together.

Two composite laminates are joined together by a bondline having portions exposed to the ambient environment. The bondline contains scrim having an electrical conductivity and impedance matched to that of the laminates in order to mitigate effects of lightning strikes.

A fusion bonding process for polymeric components and welding heads for use in the process are described. Methods and devices can be utilized to weld polymer-based structural components to one another by use of an enhanced friction stir welding technology that combines heating, pressure, and polymer agitation to form a highly secure joint between polymeric structural components and a short fiber reinforced thermoplastic connection element.

A method for manufacturing a composite structure. The method includes depositing a plurality of thermoplastic particles onto at least one of a surface of a filler member and a surface of a structural member. The method further includes assembling the filler member with the structural member such that the plurality of thermoplastic particles are disposed proximate an interface between the filler member and the structural member.

Disclosed are thermoset/thermoplastic composites that include a thermoset component directly or indirectly bonded to a thermoplastic component via a crosslinked binding layer between the two. The crosslinked binding layer is bonded to the thermoplastic component via epoxy linkages and is either directly or indirectly bonded to the thermoset component via epoxy linkages. The composite can be a laminate and can provide a route for addition of a thermoplastic implant to a thermoset structure.

Systems and methods for non-destructive inspection of curved composite laminate structures using interface guided waves. In particular, if the curved composite laminate structure has a noodle, then the noodle area may be inspected using interface guided waves. The systems and methods provide a repeatable and reliable nondestructive technique for monitoring the structural health of the noodle area of an adhesively bonded curved composite laminate structure by comparing detection data acquired from an inspected curved composite laminate structure with prediction data derived using a simulated curved composite laminate structure.

A method of making a joint for a structure comprises forming a thermoplastic filler, applying an uncured first thermoset layer into direct contact with the thermoplastic filler, applying an uncured second thermoset layer into direct contact with the thermoplastic filler, and applying an uncured third thermoset layer into direct contact with the thermoplastic filler. The method additionally comprises curing the uncured first thermoset layer, the uncured second thermoset layer, and the uncured third thermoset layer at a temperature below a melting temperature of the thermoplastic material to form a cured first thermoset layer, a cured second thermoset layer, and a cured third thermoset layer and bonding together the cured first thermoset layer, the cured second thermoset layer, the cured third thermoset layer, and the thermoplastic filler.

A method and apparatus for fabricating a composite structure. The method comprises defining a shape for the composite structure with a first face sheet. The method places core sections on the shape defined by the first face sheet. The method places an adhesive in a group of joint cavities. The method places a second face sheet on the core sections placed on the first face sheet, wherein the first face sheet, the core sections, and the second face sheet, define a structural assembly in which the group of joint cavities are present. The method cures the structural assembly with the adhesive in the group of joint cavities to fabricate the composite structure in which the adhesive fills the group of joint cavities when the adhesive is cured.

A composite forming station for forming a T-profile composite part from a planar laminate. The composite forming station includes in-line rollers arranged along a forming direction, wherein a thickness and/or edge angle each roller is greater than the preceding roller, wherein the rollers gradually splay apart feet sections of the planar laminate to convert the laminate to the T-profile composite part.