Rohr, Inc.

Shyan Bob Shen

Michael Van Tooren

Daniel O Ursenbach

Jeffrey D Woods

Sarah Lohman

Paolo Ballocchi

Ryan M Robinson

James Alan Phillips

Nigel J Mckibbin

A method is provided during which a thermoplastic rib is arranged with a thermoplastic spar. A first flange of the thermoplastic rib is abutted against the thermoplastic spar. The first flange of the thermoplastic rib is ultrasonic welded to the thermoplastic spar using a tilted ultrasonic horn. A centerline of the tilted ultrasonic horn is angularly offset from the first flange of the thermoplastic rib by an acute angle during the ultrasonic welding.

Thermoplastic composite structure and methods for forming

During a formation method, a first component and a second component are provided. The first component is configured from or otherwise includes a first fiber-reinforced thermoplastic composite. The first component also includes a base and a material buildup on a portion of the base. The second component is configured from or otherwise includes a second fiber-reinforced thermoplastic composite. The second component is arranged with the first component. The second component abuts the material buildup. The second component is vibration welded to the first component to provide a weld joint between the first component and the second component. At least a portion of the material buildup is displaced during the vibration welding.

Vibration welding fiber-reinforced composite aircraft structures

A method for forming a fiber-reinforced thermoplastic hollow structure may comprise: abutting a first surface of a first flange of a shell and a second surface of a second flange of the shell with a mating component; disposing an end block laterally adjacent to the shell; applying a first load to a sidewall of the shell; applying a second load to the second flange of the shell; and vibrating one of the shell or the mating component while keeping a non-vibrating component stationary, the non-vibrating component including one of the shell or the mating component.

Vibration welding systems and methods

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San Diego, CA, United States of America

Shyan Bob Shen