Susceptor integration into reinforced thermoplastic composites

DETAILED DESCRIPTION We incorporate a thermoplastic welding susceptor into a detail part or precured strip for alignment along the faying surfaces defining the bond line to simplify alignment of parts prior to welding.
With the susceptor incorporated into the detail part, assembly (especially of complexly curved assemblies) avoids tricky and difficult positioning of a separate, conventional susceptor.
We incorporate the susceptor into the detail part by: (a) applying a sheet of thermoplastic resin on a prefabricated part or prepreg layup to make the surface resin rich in the location of the intended bond line; (b) overlaying a susceptor on the thermoplastic sheet; and (c) curing the assembly under suitable heat and pressure to form the detail with the desired, integral bond line susceptor in a resin rich zone.
RTM manufacture is possible for making these integrated susceptor detail parts.
We prepare welded or bonded composite assemblies using the integrated susceptor detail parts.
The integrated susceptors are compatible with Z-pin reinforcement in the weld and with moving coil or fixed coil heating processes or even with resistance heating processes.
Integrating the susceptor onto the faying surface of the detail part fixes its location spatially.
Doing so, simplifies the welding of complex curvatures, because the susceptor is accurately secured at a predetermined location as a feature of the detail part.
With the part-to-part location of the susceptor identified, it is easier to plan for Z-pin reinforcement in the weld and to automate the welding process.
Not only are there fewer parts, but alignments greatly simplified, since the relative position of the susceptor to one detail part is fixed.