Continuous ultrasonic welding thermoplastic material for aerospace component repair

1 . A repair method, comprising:

arranging a thermoplastic patch on a thermoplastic aerospace component;

arranging an ultrasonic horn on the thermoplastic patch, wherein the thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn, and the thermoplastic patch contacts the ultrasonic horn; and

continuous ultrasonic welding the thermoplastic patch to the thermoplastic aerospace component using the ultrasonic horn.

2 . The repair method of claim 1 , wherein the continuous ultrasonic welding comprises continuous vertical ultrasonic welding.

3 . The repair method of claim 1 , wherein

the ultrasonic horn extends along a centerline to a face that vertically contacts the thermoplastic patch; and

the ultrasonic horn moves back and forth along the centerline during the continuous ultrasonic welding.

4 . The repair method of claim 1 , wherein the continuous ultrasonic welding includes

ultrasonic welding the thermoplastic patch to the thermoplastic aerospace component using the ultrasonic horn; and

moving the ultrasonic horn along a weld path over the thermoplastic patch during the ultrasonic welding to provide a continuous elongated weld between the thermoplastic patch and the thermoplastic aerospace component along the weld path.

5 . The repair method of claim 4 , wherein

the thermoplastic patch has a width; and

the weld path extends along the thermoplastic patch at least fifty percent of the width.

6 . The repair method of claim 4 , wherein the weld path follows a straight line trajectory from a point where the continuous ultrasonic welding begins to a point where the continuous ultrasonic welding ends.

7 . The repair method of claim 4 , wherein the weld path follows a non-straight line trajectory from a point where the continuous ultrasonic welding begins to a point where the continuous ultrasonic welding ends.

8 . The repair method of claim 1 , wherein the thermoplastic patch contacts the thermoplastic aerospace component.

9 . The repair method of claim 1 , further comprising:

arranging a thermoplastic film on the thermoplastic aerospace component;

the thermoplastic film vertically between and contacting the thermoplastic aerospace component and the thermoplastic patch; and

the thermoplastic patch continuously ultrasonic welded to the thermoplastic aerospace component through the thermoplastic film.

10 . The repair method of claim 9 , wherein the thermoplastic film consists of a thermoplastic.

11 . The repair method of claim 1 , further comprising consolidating a plurality of layers of thermoplastic material together to form the thermoplastic patch prior to arranging the thermoplastic patch on the thermoplastic aerospace component.

12 . The repair method of claim 1 , wherein the thermoplastic patch covers a damaged region of the thermoplastic aerospace component.

13 . The repair method of claim 1 , wherein

an aperture extends into the thermoplastic aerospace component from an exterior surface of the thermoplastic aerospace component; and

the arranging of the thermoplastic patch comprises disposing the thermoplastic patch in the aperture.

14 . The repair method of claim 13 , further comprising removing a damaged region from the thermoplastic aerospace component to form the aperture in the thermoplastic aerospace component.

15 . The repair method of claim 13 , wherein the thermoplastic patch covers a portion of the exterior surface of the thermoplastic aerospace component adjacent the aperture.

16 . The repair method of claim 1 , further comprising arranging the thermoplastic aerospace component on a rigid support prior to the continuous ultrasonic welding, the thermoplastic aerospace component contacting the rigid support.

17 . The repair method of claim 1 , wherein the thermoplastic patch comprises a thermoplastic matrix and fiber reinforcement embedded within the thermoplastic matrix.

18 . The repair method of claim 1 , wherein the thermoplastic aerospace component comprises a thermoplastic matrix and fiber reinforcement embedded within the thermoplastic matrix.

19 . A repair method, comprising:

disposing a thermoplastic aerospace component on a rigid support, the thermoplastic aerospace component contacting the rigid support;

disposing a thermoplastic patch on the thermoplastic aerospace component, the thermoplastic patch contacting the thermoplastic aerospace component;

arranging an ultrasonic horn on the thermoplastic patch, wherein the thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn; and

ultrasonic welding the thermoplastic patch to the thermoplastic aerospace component using the ultrasonic horn, and moving the ultrasonic horn along a weld path over the thermoplastic patch during the ultrasonic welding to provide a continuous elongated weld between the thermoplastic patch and the thermoplastic aerospace component.

20 . A repair method, comprising:

disposing a thermoplastic aerospace component on a rigid support, the thermoplastic aerospace component contacting the rigid support;

disposing a thermoplastic film on the thermoplastic aerospace component;

disposing a thermoplastic patch on the thermoplastic film, the thermoplastic film vertically between and contacting the thermoplastic aerospace component and the thermoplastic patch;

arranging an ultrasonic horn on the thermoplastic patch, wherein the thermoplastic patch is vertically between the thermoplastic aerospace component and the ultrasonic horn; and

ultrasonic welding the thermoplastic patch to the thermoplastic aerospace component through the thermoplastic film using the ultrasonic horn, and moving the ultrasonic horn along a weld path over the thermoplastic patch during the ultrasonic welding to provide a continuous elongated weld between the thermoplastic patch and the thermoplastic aerospace component.