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.

Riveted assemblies are provided that can include a substrate extending between two ends to define opposing substrate surfaces having a first opening extending between the opposing substrate surfaces; a metal-comprising substrate extending between two ends to define opposing metal-comprising substrate surfaces having a second opening extending between the opposing metal-comprising substrate surfaces. The riveted assemblies can further provide that the first and second openings complement one another when the substrate and metal-comprising substrate are engaged; and a rivet shaft extends through the openings and engages the substrate with the rivet head and the metal-comprising substrate with the rivet stop head, at least a portion of the stop head being mixed with, and forming a metallurgical bond with the metal-comprising substrate. Assemblies are provided that can include a rivet stop head mixed with, and metallurgically bonded with a metal-comprising substrate. Methods for affixing substrates to one another are also provided. The methods can include providing a substrate defining an opening configured to receive a rivet shaft; providing a metal-comprising substrate defining a complimentary opening; operatively engaging the substrates with the rivet shaft; and forming a stop head from the rivet shaft to affix the substrates. The method further includes that the stop head mixes with, and forms a metallurgical bond with the metal-comprising substrate. Methods for mixing materials to form a metallurgical bond are also provided. The methods can include forming a metallurgical bond between a stop head of a rivet and a metal-comprising substrate.

An apparatus for fastening a pair of gas vessels includes: a plurality of first units formed of a composite material, spaced apart from each other in parallel with each other in a length direction of the gas vessel, and having the pair of gas vessels seated on both sides thereof; a second unit formed of a composite material and extending in the length direction of the gas vessels to integrally connect the plurality of first units; and a plurality of fastening units each of which extending along a circumference of the gas vessels to enclose the gas vessels seated on the first units and having both ends connected to the first units.

Embodiments are directed to systems and methods for two or more cured composite assemblies that are bonded together to form a tubular composite structure, wherein each of the cured composite assemblies do not have a tubular shape. The tubular composite structure may form a spar for an aerodynamic component, for example. The two or more cured composite assemblies may comprise carbon or fiberglass composite materials or a combination of materials. Each of the cured composite assemblies may further comprise axial edges that are configured to be bonded to another of the cured composite assemblies, wherein the axial edges have a sloped shape. An adhesive agent may be applied on the axial edges for bonding two cured composite assemblies. Alternatively, or additionally, one or more fasteners may be used to attach the axial edges of at least two cured composite assemblies.

A riveting system, for use in mechanically linking adjacent workpieces, including a rivet having a height greater than a sum of thicknesses, measured along a line of riveting, of the workpieces being linked, so that the rivet can pass fully through the workpieces. The system also includes a riveting die, which may be a separate product. The die includes a protrusion extending from a peak toward a transition point; and a trough having a trough surface. The trough surface includes a trough inner wall, extending from the transition point to a trough bottom, and a trough outer wall, extending from the trough bottom to a trough outer edge. The technology also includes computerized systems for comparing a load-displacement profile of riveting to a pre-set profile to determine whether the riveting was performed properly.

Disclosed embodiments provide an electrofusion pipe coupler with mechanical support. The electrofusion pipe coupler comprises a coupler housing. A wire is configured and disposed within the housing. Electrodes are affixed to the coupler housing and in electrical contact with the wire. A threaded pattern is formed in an outer surface of the coupler housing. Gripping wedges are affixed to the coupler housing. Each gripping wedge extends from the coupler housing. A nut is attached to the coupler housing, engaging with the threaded pattern, and compressing the wedges against the connecting pipes. This serves to provide axial load transfer from the connecting pipes to the coupler housing via the wedges, thereby providing improved mechanical stability for such pipe assemblies.

A method of manufacturing a lightweight building element assembly is disclosed. The assembly firstly comprises a first object (1) being a lightweight building element that has a first outer building layer (11) and an interlining layer (13). The assembly further comprises a second object (2) secured to the first object. The method comprises firstly providing the first object, wherein the first object has an indentation (19) formed by the first outer building layer. The indentation may form a blind opening or a through opening in the first object. The method further comprises providing the second object (2), wherein the second object comprises an outer surface portion of a thermoplastic material, wherein the outer surface portion is a lateral outer surface portion with respect to an axis. The second object is brought in contact with the first object so that the lateral outer surface is in physical contact with the sidewall (14), and mechanical energy is coupled into the second object so as to cause energy absorption due to friction between the lateral outer surface and the lateral wall, until a flow portion of the thermoplastic material becomes liquefiable and flows relative to the lateral wall. After re-solidification of the thermoplastic material, the flow portion secures the second object to the first object.

A junction structure includes a first metallic material, a second material different in type from the first metallic material, and a welding wire as a third material similar to the first metallic material. The second material is stacked on the first material. The molten metal of the third metallic material is deposited by arc welding into the through part of the second material so as to form a flanged or tapered bead, so that the first and third metallic materials and the second material are fixed together.

The method of bonding a first object (1) to a second object (2) uses a connector, the connector having a first sheet portion and a second sheet portion (32). The first sheet portion has at least one outwardly protruding first attachment portion (33), and the second sheet portion has at least one outwardly protruding second attachment portion (34). The connector (3) further has a spacer between the first and second sheet portions. For bonding, the first and second objects (1, 2) and the connector (3) are positioned relative to each other so that the connector is placed between the first and second objects. Then the first and second objects (1, 2) are pressed against each other while mechanical vibration energy impinges on the first and/or second object until a first flow portion of thermoplastic material of the first object in contact with the first attachment portion(s) and a second flow portion of thermoplastic material in contact with the second attachment portion(s) become flowable allowing the respective attachment portions (33, 34) to be pressed into material of the first and second object, respectively. After re-solidification of the flow portions, a positive-fit connection between the first and second objects via the connector results. The spacer defines a width (w) of a gap between the first and second objects (1, 2) after bonding.

An article is formed by joining two or more layers in a stable structure, containing at least one composite layer that can be melted, with tensile and shear strength. The article is assembled by one or more mechanical fasteners and melt adhesion regions.