Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints

Ultrasonic welding is a fast and promising joining technique for thermoplastic composite parts. Understanding how changing the part thickness affects the process is crucial to its future upscaling and industrialization. This article presents an initial insight into the effect of the adherend’s thickness on the near-field ultrasonic welding of CF...

Continuous Ultrasonic Welding of Thermoplastic Composites: An experimental study towards understanding factors influencing weld quality

One of the most promising welding techniques for thermoplastic composites is ultrasonic welding. It is mainly known as a spot welding technique. The relatively new technology continuous ultrasonic welding of thermoplastic composites makes it possible to obtain large fully welded seams with higher load carrying capabilities. However, at the start...

Future Plans for the Development of an Industrialized Continuous Ultrasonic Welding Process

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...

Disassembly of fusion bonded thermoplastic composite joints aided by induction heating: Effects of induction heating on disassembly force and damage patterns

Disassembly of fusion bonded joints aided by induction heating was investigated. Single-lap shear experiments were performed while heating the joint with an induction coil to research the effect on force required and damage inflicted during disassembly. Co-consolidated CF/PEEK samples with and without a metal mesh susceptor and ultrasonically...

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...

Robotic sequential ultrasonic welding of thermoplastic composites: Process development and testing

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...

Static ultrasonic welding of carbon fibre unidirectional thermoplastic materials and the influence of heat generation and heat transfer

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...

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 Thermoplastic Composites

Ultrasonic welding is a very fast and energy-efficient technique for the joining of thermoplastic composites. This article looks into main aspects of ultrasonic welding of continuous fiber-reinforced thermoplastic composites, namely energy directors, process parameters, in situ process monitoring, welding of dissimilar composite materials and...

Induction heating of uni-directional carbon-fibre PEKK composites: Multiphysics modelling

The usage of carbon-fibre reinforced composite materials in the aerospace industry has been steadily increasing due to their light weight solution with respect to their metal counterparts. Using thermoplastic resins gives rise to induction heating as a joining technique. Induction heating can be applied by utilising the inherent material...

The Degradation of Carbon Fibre-Reinforced Epoxy Composites under Fusion Bonding Conditions

In the aircraft industry there is an increasing need for cost-effective assembly methods for dissimilar thermoplastic/thermosetting composites. Fusion bonding provides a good alternative to mechanical fastening, and may be applied to thermosetting composites by using a thermoplastic interlayer. The research project ‘HyPoComp’ at Delft University...

Welding of thermoplastic to thermoset composites through a thermoplastic interlayer

Research into the fusion bonding of joints containing thermoplastic and/or thermoset composites. A thermoplastic interlayer is co-cured with the thermoset that provides a fusible surface. Depending on the type of materials the interlayer can form an adhesive interface or a gradient interphase with the thermoset. Welding of thermoset composite to...