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.

A joining method and assembly for an aircraft. To improve the characteristics or permit hitherto impossible connections between thermoplastic and thermoset components, a multi-material joining method is disclosed in which a thermoplastic connecting region is formed on the thermoplastic component. The connecting region is connected to the thermoset component by interdiffusion. For this purpose, the uncured second component is brought into contact with the connecting region and heat is supplied. An interdiffusion layer is formed which fixedly connects the second component and the connecting region to one another and thus joins the first component to the second component.

A system and process for bonding involves a pocket made into one article is used to secure that article to another using a flowable, curable material (e.g., resin) which during saturation enters through a passageway and at least partially fills the void. When the article is cured, the article is bonded to another article to which resin has also been applied since the void (now containing cured material) is larger than the passageway.

A plastic component having a core that has a thermoset matrix and an add-on part anchored to the core. At least the securing region of the add-on part can be formed from a thermoplastic and is secured by the securing region to the core of the plastic component, the securing region being attached to the core or inserted or pressed into the core, bonding, in a fusible state produced by the application of energy, in particular by ultrasonic vibrations, with the core and being anchored thereto or therein after solidification, in particular, as a connection anchor.

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 composite assembly with a laminate of fibre plies impregnated with a laminate matrix material is disclosed having pad of fibre plies impregnated with a pad matrix material, and a part with a body with protrusions which extend from the body and penetrate at least some of the fibre plies of the pad. The pad is bonded to the laminate by a stepped lap joint or a scarf joint. The assembly is manufactured by pressing the protrusions into the pad, and after the protrusions have been pressed into the pad, curing a pad matrix material impregnating the pad, and bonding the pad to the laminate.

The invention relates to the use of a low Tg compatible resin as an adhesive layer for the welding of a thermoplastic composite structure to a thermoplastic or thermoset structure. The invention is especially good for the welding of large parts, such as wind turbine halves and spar caps. A useful thermoplastic composite is one formed by the infusion and curing of long fibers by a reactive acrylic liquid resin system, such as ELIUM® resin systems from Arkema.

A composite vehicle driveshaft assembly includes a composite tube and a yoke bonded to one of the ends of the tube. The yoke has an inner sleeve that is concentrically received in the end of the tube. The sleeve has an outer peripheral surface that faces the inner peripheral surface of the tube with a cavity formed therebetween. An adhesive injection passage is formed in the yoke and extends at an acute angle from an inlet that is formed in an axial surface of the yoke to an outlet that is formed in the outer peripheral surface of the sleeve and that opens into the cavity. Also disclosed is a method of bonding a yoke of such a driveshaft assembly to a composite tube.

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.

A system for consolidating materials, comprising a sonotrode configured to direct ultrasonic energy into materials to be consolidated, wherein the materials to be consolidated have both a glass transition temperature and a melting temperature; a non-rigid consolidating material in proximity to the sonotrode, wherein the non-rigid consolidating material and sonotrode define a region therebetween for receiving the materials to be consolidated, and wherein the non-rigid consolidating material has a glass transition temperature that is higher than the glass transition temperature of the materials to be consolidated and a melting temperature that is higher than the melting temperature of the materials to be consolidated.