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

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,...

On differences and similarities between static and continuous ultrasonic welding of thermoplastic composites

Continuous ultrasonic welding is a promising high-speed and energy-efficient joining method for thermoplastic composite structures. Our aim was to identify and understand differences between the static and continuous ultrasonic welding process for thermoplastic composites. In particular, melting of the interface, consumed power and energy...

Continuous ultrasonic welding of thermoplastic composites: Enhancing the weld uniformity by changing the energy director

Continuous ultrasonic welding is a high-speed joining method for thermoplastic composites. Currently, a thin film energy director is used to focus the heat generation at the interface. However, areas of intact energy director remain in the welded seam, which significantly lowers the weld strength, and result in a non-uniformly welded seam. To...