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Belo Gomes Brito, C. (author), Teuwen, Julie J.E. (author), Dransfeld, C.A. (author), Villegas, I.F. (author)This paper evaluates the potential of changing the welding force and the compliance of the energy director (ED) to reduce the effects caused by misaligned adherends, which were: increased through-thickness heating, reduced size of welded area and increased heating time. In the methodology that was followed, we welded adherends misaligned by...journal article 2023
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Jongbloed, B.C.P. (author), Teuwen, Julie J.E. (author), Villegas, I.F. (author)Continuous ultrasonic welding is an attractive welding technique for thermoplastic composite structures. In this process, a metallic sonotrode connected to a piezoelectric transducer and to a press moves along the parts to be welded applying ultrasonic vibrations and a static welding force on the welding overlap. Thus far, the research carried...journal article 2023
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Smeets, E.T.B. (author), Rans, C.D. (author), Castro, Saullo G.P. (author), Villegas, I.F. (author)In thermoplastic composite joints with a circular ultrasonic spot weld, the damage growth is located at the interface between the joined components. This means that any damage in these joints is invisible from the outside. This experimental study compares three different in-situ methods to measure the damage growth indirectly. The motivation...journal article 2023
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Akay, E. (author), Köhler, F. (author), Villegas, I.F. (author)Continuous ultrasonic welding (CUW) is one of the most efficient integration methods of thermoplastic composites. Researchers from our group have already utilized CUW method by using both frame based and robotic welding platforms to achieve sufficient amount of joint strength for aerospace applications [1-3]. On the other hand, the...conference paper 2022
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Jongbloed, B.C.P. (author), Akay, E. (author), Köhler, F. (author), Villegas, I.F. (author)The need for robust joining methods for thermoplastic composites increases since the usage of these materials expands steadily in the aerospace industry. Continuous ultrasonic welding has been demonstrated in the recent years as one of the most promising joining techniques for thermoplastic composites to fulfill this need. This paper presents...conference paper 2022
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Brito, B.C.Q.B. (author), Teuwen, Julie J.E. (author), Dransfeld, C.A. (author), Villegas, I.F. (author)Ultrasonic welding is a promising joining technique for thermoplastic composite parts. On the way towards upscaling and industrialisation of this technology, it is crucial to understanding how it is affected by manufacturing tolerances. The objective of the research presented in this paper was to investigate the influence that misaligned...journal article 2022
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Jongbloed, B.C.P. (author), Vinod, R. (author), Teuwen, Julie J.E. (author), Benedictus, R. (author), Villegas, I.F. (author)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,...journal article 2022
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Smeets, E.T.B. (author), Rans, C.D. (author), Alderliesten, R.C. (author), Castro, Saullo G.P. (author), Villegas, I.F. (author)Ultrasonic spot welding is a joining technique for thermoplastic composites with great potential regarding processing speed and cost. To investigate the damage tolerance and possible inherent damage arresting behavior of multi-spot welded joints, a technique is necessary to measure damage growth in the joints under cyclic loading. Visual...conference paper 2022
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Jongbloed, B.C.P. (author), Teuwen, Julie J.E. (author), Benedictus, R. (author), Villegas, I.F. (author)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...journal article 2021
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Tsiangou, E. (author), Teixeira De Freitas, S. (author), Benedictus, R. (author), Villegas, I.F. (author)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...journal article 2021
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Koutras, N. (author), Benedictus, R. (author), Villegas, I.F. (author)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...journal article 2021
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Villegas, I.F. (author), Rans, C.D. (author)Single-lap shear (SLS) joints are straightforward to manufacture. This makes them especially attractive for testing polymer composite welded joints. Owing to local heating, which is characteristic of composite welding processes, the production of more geometrically intricate joints (such as double-lap or scarfed joints) or bigger joints (such...review 2021
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Tsiangou, E. (author), Kupski, J.A. (author), Teixeira De Freitas, S. (author), Benedictus, R. (author), Villegas, I.F. (author)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....journal article 2021
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Köhler, F. (author), Villegas, I.F. (author), Dransfeld, C.A. (author), Herrmann, A. (author)Ultrasonic welding is a promising technology to join fibre-reinforced thermoplastic composites. While current studies are mostly limited to fabric materials the applicability to unidirectional materials, as found in aerospace structures, would offer opportunities for joining primary aircraft structures. However, due to the highly anisotropic...review 2021
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Choudhary, A. (author), Villegas, I.F. (author)Multi-spot sequential ultrasonic welding is a promising joining technique for fibre-reinforced thermoplastic composites structures (TPC). In existing research on the multi-spot sequential ultrasonic welding process, welds are produced through the use of a static table-top welding machine, at a coupon level. However, in order to apply this...conference paper 2021
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Jongbloed, B.C.P. (author), Teuwen, Julie J.E. (author), Benedictus, R. (author), Villegas, I.F. (author)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...journal article 2020
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Tsiangou, E. (author), Teixeira De Freitas, S. (author), Villegas, I.F. (author), Benedictus, R. (author)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...journal article 2020
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Jongbloed, B.C.P. (author), Teuwen, Julie J.E. (author), Palardy, G. (author), Villegas, I.F. (author), Benedictus, R. (author)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...journal article 2020
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Veldman, S.L. (author), Kortbeek, Peter (author), Wölcken, P.C. (author), R., Herrmann (author), Kos, J. (author), Villegas, I.F. (author)This paper discusses the development and underlying requirements of a multifunctional lower fuselage demonstrator for a new single aisle aircraft undertaken as part of the Clean Sky 2, Large Passenger Aircraft – Platform 2. The demonstrator will validate high potential combinations of airframe structures, systems, cargo and cabin technology...conference paper 2020
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Zhao, T. (author), Tsakoniatis, Ioannis (author), Rans, C.D. (author), Villegas, I.F. (author), Benedictus, R. (author)Thermoplastic composite spot welded joints are more well-suited for carrying shear load rather than peel load. However, peel load is difficult to be eliminated in single-lap joint configuration. In this paper, a series of mechanical tests were carried out to study the effects of the spot spacing and the number of welded spots on the secondary...conference paper 2020