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,...

A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites

Continuous ultrasonic welding is a promising technique for joining thermoplastic composites structures together. The aim of this study was to gain further insight into what causes higher through-the-thickness heating in continuous ultrasonic welding of thermoplastic composites as compared to the static process. Thermocouples were used to measure...

On the sensitivity of ultrasonic welding of epoxy- to polyetheretherketone (PEEK)-based composites to the heating time during the welding process

This study aims at assessing the sensitivity of the ultrasonic welding process for joining epoxy- to thermoplastic-based composites sensitivity to the heating time. For that, carbon fibre (CF)/epoxy adherends with a co-cured PEI coupling layer were ultrasonically welded to CF/polyetheretherketone (PEEK) adherends at different heating times....

Thermal effects on the performance of ultrasonically welded CF/PPS joints and its correlation to the degree of crystallinity at the weldline

The effect of temperature on the lap shear strength (LSS) and failure mechanisms of ultrasonically welded carbon fibre reinforced polyphenylene sulphide (CF/PPS) joints was investigated, correlating the weld performance to the crystallinity degree of PPS at the weldline. The single-lap shear tests were carried out at temperatures ranging from...

On the sensitivity of the ultrasonic welding process of epoxy- to polyetheretherketone (PEEK)-based composites to the welding force and amplitude of vibrations

This paper addresses the sensitivity of the ultrasonic welding process for joining dissimilar composites to variations in either the welding force or amplitude of vibrations. For that, carbon fibre (CF)/epoxy specimens were welded to CF/polyetheretherketone (PEEK) specimens, through a polyetheretherimide (PEI) coupling layer co-cured with the...

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...

Ultrasonic welding of epoxy- to polyetheretherketone- based composites: Investigation on the material of the energy director and the thickness of the coupling layer

Ultrasonic welding is a highly promising technique for joining thermoplastic to thermoset composites. A neat thermoplastic coupling layer is co-cured on the surface to be welded to make the thermoset composite ‘weldable’. A reliable bond is attained when miscible thermoplastic and thermoset materials are chosen. For welding carbon fibre...

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...

Diagnostic of manufacturing defects in ultrasonically welded thermoplastic composite joints using ultrasonic guided waves

This article presents research about the propagation of ultrasonic guided waves in ultrasonically welded thermoplastic composite joints. The goal of the study was to understand the effect of weld manufacturing defects on guided wave transmission across the joint. Triangular energy-directors integrated into the lower composite adherends...

Towards robust sequential ultrasonic spot welding of thermoplastic composites: Welding process control strategy for consistent weld quality

The research in this paper is an essential part of a bigger effort on developing robust sequential ultrasonic welding of multi-spot welded joints in thermoplastic composites. It mainly focused on assessing the impact of the changes in boundary conditions on the welding process and whether it could be circumvented by using an appropriate...

Experimental assessment of the influence of welding process parameters on Lamb wave transmission across ultrasonically welded thermoplastic composite joints

One of the advantages of thermoplastic composites relative to their thermoset counterparts is the possibility of assembling components through welding. Ultrasonic welding in particular is very promising for industrialization. However, uncertainty in the fatigue and fracture behaviour of composites is still an obstacle to the full utilisation...

Mechanical behaviour of thermoplastic composites spot-welded and mechanically fastened joints: A preliminary comparison

The in-plane and out-of-plane mechanical behaviour of both ultrasonically spot-welded and mechanically fastened joints was investigated by double-lap shear and pull-through tests, respectively. Spot-welded specimens showed comparable onset failure load and significantly higher joint stiffness compared to mechanical fasteners when carrying shear...