A method for joining two substantially planar fiber-composite structural components, includes stacking the two components on a support jig to overlap along a joining region. A lower component end section within the joining region borders a gap between the upper component and the jig, where the upper component is unsupported by the jig. The gap is bordered on an opposite side of the lower component end section by a filling portion of the upper component or a planar filler element supported by the jig. The lower component is joined to the upper component within the joining region by applying temperature and pressure to the components. A width of the gap allows the upper component to elastically deform along the gap under the pressure and bend down into the gap to abut the jig along the gap and thereby compensate thickness tolerances between the components during the pressure application.

A bonded joint for use in bonding composite materials is provided and includes a composite rib having electrically conductive properties and a composite structure having electrically conductive properties. An electrically conductive preform is provided that facilitates a bond between the composite rib and the composite structure. A mesh composition that bonds the composite rib to the preform and that bonds the preform to the composite structure is provided and is electrically conductive to conduct current between the composite rib and the composite structure.

A method for surface preparation of composite substrates prior to adhesive bonding. A curable surface treatment layer is applied onto a curable, resin-based composite substrate, followed by co-curing. After co-curing, the composite substrate is fully cured but the surface treatment layer remains partially cured. The surface treatment layer may be a resin film 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 method for joining two objects by anchoring an insert portion provided on one of the objects in an opening provided on the other one of the objects. The anchorage is achieved by liquefaction of a thermoplastic material and interpenetration of the liquefied material and a penetrable material, the two materials being arranged on opposite surfaces of the insert portion and the wall of the opening. Before such liquefaction and interpenetration, an interference fit is established in which such opposite surfaces are pressed against each other, and, for the anchoring, mechanical vibration energy and possibly a shearing force are applied, wherein the shearing force puts a shear stress on the interference fit.

A method for producing a component with a surface that is suitable for plastic welding or adhesive bonding of two parts is provided. As a preparation step prior to joining, a filler sheet comprising a thermoplastic material or adhesive is arranged on a first surface of a first component and a structuring tool is arranged on the filler sheet. Mechanical force is applied to the structuring tool and heat is applied to the filler sheet such that the filler sheet is attached to the first surface of the first component and such that the structuring tool is partially embedded in the filler sheet. The structuring tool is subsequently removed from the filler sheet to produce a plurality of protrusions in the outer surface of the filler sheet. After surface structuring the first and second components are joined using any type of welding technique or joined using of adhesive bonding.

A system for fusing thermoplastic composite structures includes a skin and a substructure on an inner surface of the skin. The system also includes a shaping surface of a tool, with the skin laid up on the shaping surface. The shaping surface is configured to maintain the shape of an outer mold line. The system further includes at least one insulation layer applied over a flange of the substructure and over exposed portions of the inner surface of the skin not in contact with the substructure, and a vacuum bag at least partly enclosing the skin and the substructure. Heat can be applied to the shaping surface to fuse the substructure to the skin such that the skin exceeds its melting point and at least a portion of a raised segment of the substructure does not exceed its melting point.

To improve a method for ultrasonic welding of parts for vehicles and/or aircraft, a method in which an energy director made of non-woven fiber material is arranged between a first fiber composite part and a second fiber composite part to be joined together. A sonotrode is used to join/weld the parts together by pressing on the parts. The energy director is compliant such that a uniform even contact is generated between the first and second fiber composite parts during the welding process.

A method for connecting the joint of two ends of at least one chassis sealing element. In order to allow a secure and quick connection of the ends and allow an additional unhindered passage of air and moisture between hollow chambers within the chassis sealing element via the joint when using a profiled hollow chamber, the ends are first arranged at a distance to each other, and a shapeless bonding agent is applied to at least one end. The bonding agent is then heated, and the ends are brought into mutual contact, whereby the ends are bonded at the joint by way of the heated bonding agent.

A joint structure includes a reinforcement portion that is formed by joining a composite material and a reinforcing material through an adhesive. The composite material includes a plate portion that is formed by laminating a plurality of fiber sheets, and a raised portion that is formed by laminating a plurality of fiber sheets in addition to the plurality of fiber sheets of the plate portion, and surfaces of the plate portion and the raised portion are covered with a single fiber sheet. The reinforcement portion includes the raised portion and the reinforcing material that is bonded to the raised portion through an adhesive. A first boundary between the plate portion and the raised portion and a second boundary between the raised portion and the reinforcing material are located at different positions in an in-plane direction of a laminated interface between the fiber sheets that are laminated.

Provided are a welding device and a welding method that can avoid occurrence of a clearance in a side region of a member and suppress occurrence of a failure of the member due to such a clearance. The embodiment includes: an electrode 11 configured to supply electricity to an electroconductive element 23 arranged between members 21, 22 and configured to generate heat by current conduction; and a pressing element 12 arranged in a side region of one member 22 of the members 21, 22 and configured to press the electroconductive element 23 while elastically being in close contact with the one member 22. Further, the pressing element 12 comes into close contact with the one member 22 by being pushed against the electroconductive element 23 and expanding in a direction orthogonal to a pushing direction.