Parallel Welding of Thermoplastic Composites Using Continuous Ultrasonic Welding

The effect of creating parallel welds in a single overlap using continuous ultrasonic welding on the weld quality has been investigated, with the goal of creating three high-quality parallel welds. To achieve this, multiple aspects were examined to understand the creation of high-quality parallel welds. The weld quality is highly influenced by a...

Repairing impacted thermoplastic composites using ultrasonic welding to restore the compressive strength

This research project investigates the potential use of ultrasonic welding as a tool to repair impact damage inside thermoplastic composites to restore the compressive strength. Compared to the already existing method, hot-pressing, ultrasonic welding could offer faster processing times, no need for dedicated tooling, smaller and lighter...

Through the thickness heating in the ultrasonic welding of unidirectional thermoplastic composites

Research and development of thermoplastic composites has been ever increasing owing to the advantages brought by it over conventional materials such as metals and thermoset composites. Higher processing rates, automation, the possibility to recycle, weldability and better mechanical and chemical properties are some of them. Fusion bonding of...

The effect of the adherends' thickness on static ultrasonic welding of thermoplastic composites

Fiber-reinforced polymer composites have gained relevance in the aerospace industry due to their great potential for weight reduction. This, thanks to their outstanding specific properties and ability to be tailored to different applications. Developing efficient composite joining techniques is a challenge that requires great attention as it is...

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...

Fatigue Behavior of Multi-Spot Welded Joints in Thermoplastic Composites: Effects of Spot Arrangement in a Four-Spot Joint

Welding is a joining method for thermoplastic composites (TPCs) that offers multiple advantages over the more traditional methods of mechanical fastening and adhesive bonding. A particularly promising welding technique is ultrasonic welding, which features very short process times as a result of the high heating rates that can be achieved. This...

Effect of consolidation parameters on (de)consolidation in ultrasonic welding of thermoplastic composites

Thermoplastic composites are gaining prominence in the aerospace industry owing to their higher damage tolerance, cost-efficient means of manufacturing, and the possibility to be recycled. One of the major benefits of thermoplastics compared to thermosets is their ability to be welded, and one of the most promising welding techniques for...

Investigating the Degree of Crystallinity in Ultrasonically Welded Thermoplastic Composite Joints

Ultrasonic Welding is a fusion bonding method that can create high-strength thermoplastic composite joints at very fast speeds. This makes it a very promising method for use in the aerospace industry, though further research is required to mature it. One topic of interest is how the crystallinity of the polymer matrix in the joint is affected by...

Investigating the use of Fused Deposition Modeling as Energy Director application method for Ultrasonic Welding of Thermoplastic Composites

The joining of high performance Thermoplastic Composite (TPC) structures by Ultrasonic Welding (USW) is considered a promising alternative for mechanical joining or adhesive bonding methods. The process is fast, clean, and highly automated. In the USW process, an intermediate, unreinforced polymer layer is required at the weld interface to...

Ultrasonic Plastic Welding of Dissimilar Materials: Experimental investigation of metal/carbon fiber reinforced thermoplastic joints

Due to EU regulations on fuel consumption, reducing the weight of vehicles has become one of the most important goals of car manufacturers in Europe. Among them, Toyota Motor Europe is one of the worldwide leaders in the research for a sustainable future. Materials like fiber-reinforced plastics and aluminum play a significant role in the...