A method for manufacturing a thermoplastic composite product includes: providing a first and second thermoplastic composite component made from a consolidated stack of thermoplastic composite plies, said first and second component having a first and second ply drop off, respectively. The first and second components are positioned such that the first ply drop off and the second ply drop off are aligned, and the first and second components are fixedly connected by means of heating. The stacks of plies for the first and second components are constructed by stacking the plies in a stacking direction wherein the plies are arranged such that plies at a different position along the stacking direction are laterally offset relative to each other for the purpose of forming the first ply drop off and the second ply drop off, respectively, before consolidating.

A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Systems and methods are provided for utilizing stringer end caps. One embodiment is a method of forming a stringer. The method includes laying up a stringer preform comprising fiber-reinforced material, placing the stringer preform onto a skin panel preform, bonding an end cap to the stringer preform and the skin panel preform, and co-curing the stringer preform and the skin panel preform while the end cap is bonded to the stringer preform and the skin panel preform, resulting in a composite part that includes the end cap.

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.

A first thermoplastic component and a second thermoplastic component including a first joint portion and a second joint portion, respectively, are provided. A least a portion of a surface area of each of the first and second joint portions include a respective first and second mating surface. The first and second mating surfaces of the respective first and second joint portions are positioned in contact with one another. The first and second joint portions are fusion joined. Fusion joining the first and second joint portions forms a fused unitary portion of the first and second thermoplastic components.

Systems and methods are provided for utilizing stringer end caps. One embodiment is a method of forming a stringer. The method includes laying up a stringer preform comprising fiber-reinforced material, placing the stringer preform onto a skin panel preform, bonding an end cap to the stringer preform and the skin panel preform, and co-curing the stringer preform and the skin panel preform while the end cap is bonded to the stringer preform and the skin panel preform, resulting in a composite part that includes the end cap.

Systems and methods are provided for fabricating composite parts. One embodiment is a method for fabricating a composite part. The method includes forming a skin panel preform comprising fiber reinforced material, disposing rigid end caps at the skin panel preform at end locations of stringer preforms that will be placed at the skin panel, locating the stringer preforms at the skin panel preform via the rigid end caps, and anchoring the stringer preforms to the skin panel preform.

The invention relates to a high-strength and permanently elastic curable adhesive for bonding at least two surfaces, of which at least one surface is a surface of a permanently elastic plastic, wherein the adhesive is an adhesive that cures in at least two different hardening mechanisms, wherein the first hardening mechanism comprises a chemical reaction to form a chemical bond including a sulphur atom, and the second hardening mechanism comprises the formation of crystalline structures from amorphous polymers. The invention also relates to a method for high-strength and permanently elastic bonding of at least two surfaces to one another, of which at least one surface is that of a permanently elastic plastic, by means of such an adhesive, said method comprising the steps of: applying the adhesive to at least a first of the surfaces to be connected, ensuring conditions under which at least the first hardening mechanism of the adhesive can take place, bringing the first surface into contact with the second surface, and ensuring conditions under which the second hardening mechanism of the adhesive can take place.

A method for repairing rivet tape includes steps of cutting portions of the rivet tape on each side of a break to define at least three aligned coplanar rivet tape edges, abutting the at least three aligned coplanar rivet tape edges to define a seam, and joining the at least three aligned coplanar rivet tape edges to one another. The seam may define a Z shape. One or more rivets may be removed to expose rivet apertures on each side of the break before the steps of cutting, abutting, and joining. The step of joining is accomplished by at least one adhesive strip disposed on a surface of the rivet tape and dimensioned to overlie the at least one or more exposed rivet apertures. Adhesive strips may be disposed on each opposed surface of the rivet tape length. In other aspects, workstations comprise devices for practicing the described methods.

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.