Vibration welding fiber-reinforced composite aircraft structures

A formation method, comprising:

• providing a first component comprising a first fiber-reinforced thermoplastic composite, the first component including a base and a material buildup on a portion of the base;
• providing a second component comprising a second fiber-reinforced thermoplastic composite;
• arranging the second component with the first component, the second component abutting the material buildup;
• and
• vibration welding the second component to the first component to provide a weld joint between the first component and the second component, wherein at least a portion of the material buildup is displaced during the vibration welding,
• wherein:
• the first fiber-reinforced thermoplastic composite comprises at least thirty-five percent by unit volume continuous fibers, and/or
• the second fiber-reinforced thermoplastic composite comprises at least thirty-five percent by unit volume continuous fibers.