System and method for welding thermoplastic components to create composite structure

A system for welding a first thermoplastic component to a second thermoplastic component along an interface to create a composite structure, the system comprising:

• a plate element having a heated portion configured to be positioned between a portion of a first faying surface of the first thermoplastic component and a second faying surface of the second thermoplastic component, wherein the heated portion is configured to be joule heated to an operating temperature which is sufficient to melt the portion of the first and second faying surfaces,
• wherein at least the heated portion of the plate element is in physical contact with the portion of the first and second faying surfaces, and melts the portion of the first and second faying surfaces through conduction;
• and
• a manipulator mechanism configured to move the plate element along the interface from between the portion of the first and second faying surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second faying surfaces, and thereby weld the first thermoplastic component to the second thermoplastic component along the interface to create the composite structure.

A system for welding a first thermoplastic component to a second thermoplastic component along an interface to create a composite structure, the system comprising:

• a plate element having a heated portion configured to be positioned between a portion of a first faying surface of the first thermoplastic component and a second faying surface of the second thermoplastic component, wherein the heated portion is configured to be joule heated to an operating temperature which is sufficient to melt the portion of the first and second faying surfaces,
• wherein at least the heated portion of the plate element is suspended between and not in physical contact with the portion of the first and second faying surfaces, and melts the portion of the first and second faying surfaces through radiation and convection;
• and
• a manipulator mechanism configured to move the plate element along the interface from between the portion of the first and second faying surfaces, which then cool and bond together, to between a series of subsequent portions of the first and second faying surfaces, and thereby weld the first thermoplastic component to the second thermoplastic component along the interface to create the composite structure.