Thermoplastic welding apparatus and related methods

A method comprising:

• positioning a smart susceptor between a first composite part and second composite part;
• positioning the first composite part, the second composite part and the smart susceptor in a cavity defined by a tooling surface of a thermoplastic welding apparatus;
• applying a tape to a perimeter of the first composite part and the second composite part and only to a portion of the tooling surface at perimeter edges of the first composite part and the second composite part to form a gas seal over a welding joint defined by the smart susceptor and the first and second composite parts;
• applying a welding pressure only to the portions of the first composite part and the second composite part located within the perimeter defined by the tape to cause the smart susceptor to compress between the first composite part and the second composite part, wherein the applying the welding pressure includes generating a pressure differential between the cavity and the gas seal by providing a vacuum only to the tool surface located inside of the perimeter defined by the tape and providing a gas pressure outside of the perimeter defined by the tape that is greater than the vacuum;
• and
• generating a first magnetic field adjacent the smart susceptor via a first inductor provided adjacent the tooling surface.

A method comprising:

• positioning a smart susceptor between opposing surfaces of a first composite part and a second composite part;
• positioning the first and second composite parts and the smart susceptor on a tooling surface defining a cavity of a welding tool;
• sealing a perimeter of the first and second composite parts and a portion of the tooling surface adjacent the perimeter of the first and second composite parts to provide a gas seal over a welding joint, the welding joint defining a sealed portion in communication with the tooling surface and a non-sealed portion in communication with the cavity;
• applying a vacuum to the welding joint of the first and second composite parts during a welding operation;
• and
• generating a magnetic flux field oriented generally parallel to a plane of the smart susceptor during the welding operation.