Methods and apparatus for thermoplastic welding

A method for thermoplastic welding, the method comprising:

• positioning a first thermoplastic composite part at a welding position;
• positioning a susceptor along a surface of the first thermoplastic composite part to define one or more joint lines;
• positioning a second thermoplastic composite part on the first thermoplastic composite part with the susceptor between the first and second thermoplastic composite parts at the one or more joint lines;
• generating a magnetic flux using a plurality of induction coils to cause the susceptor to heat the one or more joint lines between the first and second thermoplastic composite parts;
• and
• removing the susceptor from the one or more joint lines after the heating of the one or more joint lines and prior to bonding of the first and second thermoplastic composite parts by directing a pulling force parallel to the one or more joint lines.

A system for thermoplastic welding, the system comprising:

• a tool configured to support first and second thermoplastic composite parts in a first welding position having one or more joint lines between the first and second thermoplastic composite parts;
• a magnetic field generator configured to generate magnetic flux;
• a susceptor removably positioned along the one or more joint lines, the susceptor configured to heat the one or more joint lines when exposed to the magnetic flux to bond the first and second thermoplastic composite parts along the one or more joint lines;
• and
• a susceptor removal device coupled to the susceptor and configured to direct a pulling force parallel to the one or more joint lines to remove the susceptor from the one or more joint lines during bonding of the first and second thermoplastic composite parts.