Improving the quality of continuous ultrasonically welded thermoplastic composite joints by adding a consolidator to the welding setup

Improving the quality of continuous ultrasonically welded thermoplastic composite joints by adding a consolidator to the welding setup

Jongbloed, B.C.P. (TU Delft Aerospace Structures & Computational Mechanics)
Vinod, R. (Student TU Delft)
Teuwen, Julie J.E. (TU Delft Aerospace Manufacturing Technologies)
Benedictus, R. (TU Delft Structural Integrity & Composites)
Villegas, I.F. (TU Delft Aerospace Structures & Computational Mechanics)

2022

Continuous ultrasonic welding is a promising high-speed and energy-efficient joining technique for thermoplastic composite structures. However, in the current state-of-the-art research on the topic numerous deconsolidation voids could be identified at the welding interface, which results in a strength knock-down. The aim of this study is, therefore, to improve the quality of continuous ultrasonically welded joints by adding a consolidation shoe to the welding setup. To determine the required consolidation pressure, the size of the shoe, and its distance from the sonotrode a stepwise approach was followed based on the static ultrasonic welding process. The closest consolidation distance, best representing the static welding conditions, did not improve the weld quality as significant porosity was still found in the weld line and in the adherends. However, for the furthest consolidation distance high-quality continuous welds were obtained with almost no porosity and a high strength.

Fusion bonding
Ultrasonic welding
Consolidation
Joining
CF/PPS
PPS
CF

http://resolver.tudelft.nl/uuid:19ccdf3f-2f9c-436b-b9a1-d432687e80f5

https://doi.org/10.1016/j.compositesa.2022.106808

1359-835X

Composites Part A: Applied Science and Manufacturing, 155

Institutional Repository

journal article

© 2022 B.C.P. Jongbloed, R. Vinod, Julie J.E. Teuwen, R. Benedictus, I.F. Villegas