To ensure safety in structural design, a method to quantify the damage in thermoplastic ultrasonic single-spot-welded Single-Lap Shear (SLS) joints is needed. This paper investigates whether detailed knowledge regarding the shape of the weld is required when using the global compliance to quantify damage. A finite element model using cohesive zone elements is developed in Abaqus to simulate single-spot SLS specimens with varying weld areas, aspect ratios, and damage growth directions, covering damage levels from 0 to 90% of the initial weld area. For each configuration, the relationship between intact weld area and global compliance is evaluated, and the numerical trends are compared to previously published experimental data from similar joints. The results show that weld size and damage growth direction have negligible influence on the relationship between global compliance and weld area, and that weld shape is also insignificant as long as the aspect ratio remains within a practical range; only very elongated welds with an aspect ratio over 4.4, which are unlikely in production, deviate significantly. Global compliance can be used as a reliable indicator of damage in single-spot ultrasonic welds that is insensitive to weld shape. This enables simplified in situ damage monitoring and reduces the need for detailed geometric characterisation during mechanical testing.

Our aim with this work was to evaluate how the thermoplastic resin used in the composite adherends and on the energy director affected the static ultrasonic welding process in both parallel and misaligned configurations. Polyetheretherketone (PEEK) and low-melt polyaryletherketone (LMPAEK) were the resins used and their thermomechanical properties were characterized via dynamic-mechanical analysis and modulated differential scanning calorimetry. With parallel adherends, neither the welding time nor the through-thickness heating in the adherends vary significantly. This similarity was attributed to a larger heat capacity of the PEEK energy director counterbalancing its higher viscoelastic heating rate. With misaligned adherends, the welding time was larger for PEEK welds than for LMPAEK welds and LMPAEK adherends presented a larger though-thickness heating. These effects were attributed to the larger bulk viscoelastic heating rate of carbon fibre reinforced/LMPAEK adherends adding up to the lower heat capacity of LMPAEK.

Structural reuse is a promising alternative to recycling of composite materials; it preserves material composition while liberating the materials for reuse in secondary applications. Thermoplastic reinforced composite materials have the potential to expand reuse opportunities by adapting their shape, or reversing them to a laminate blank. In this study, we evaluated reverse forming of glass fibre-polypropylene (GF-PP) laminates by developing a processing method, testing material properties and the effect of three design parameters: forming strain, laminate architecture and material type. Forming strain relates to the deformation mechanism of inter-ply slip, and is imposed through varying the contour depth and bending radius. Laminate architecture relates to resin redistribution, and is imposed by using an orthogonal as well as quasi isotropic layup. Finally, the material type affects both Inter-ply slip as well as resin redistribution, and is imposed by using plain and twill weaves. GF-PP blanks were prepared using a heated platen press and subsequently formed and flattened using convection heating (<165 °C) and vacuum pressure in a novel moulding process. The samples had typical values for flexural strength of 91 - 113 MPa and flexural modulus of 9–16 GPa. Using a Design of Experiments analysis the process was deemed robust for the given boundary conditions. These results demonstrate the feasibility of reverse forming for cases where inter-ply slip is the governing deformation mechanism. The presented reverse forming process and design parameters can be used to create new thermoplastic composite parts, anticipating for structural reuse through reverse forming.

In the framework of CleanSky2 (CS2)-Large Passenger Aircraft project, a consortium led by Airbus consisting of universities, research centers and industrial partners across Europe investigated various fuselage system, cabin & airframe technologies for commercial aircraft. The goal has been to strongly contribute to the environmental objectives of 20-30% CO2 reduction whereas at the same time performance increase through weight reduction and improved competitiveness through less recurring cost and industrial ramp up capabilities had to be demonstrated. In total, more than 40 different technologies have been further developed by the European consortium consisting of 14 partners in order to finally deliver an 8m large scale flagship in 2024: the Multifunctional Fuselage Demonstrator. Novel fuselage design and built concepts are demonstrated as well as thermoplastic composite material testing & modelling, elementary parts manufacture and assembly for large scale fuselage structures incl. “zero airframe customization” concepts for cabin installation. Final results and major achievements of this European funded program will be presented and discussed in this paper.

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 lies in the potential benefits of using multi-spot welded joints for increased damage tolerance and the need to prove the damage arresting and damage progression behaviour for certification. The current study focused on measuring the damage in single-spot welded Single Lap Shear (SLS) joints during fatigue test with the global specimen compliance, the local out-of-plane displacement and the local strain on the surface. Digital Image Correlation (DIC) measurements were used to obtain the local quantities. The results showed that the local quantities are better suited to obtain detailed information on the damage state. The local surface strain showed more distinct features that facilitate the recognition of damage locations. The benefits and challenges of all methods are discussed as well as the difference in the level of detail, generalization and the prior knowledge necessary to obtain the damage state.

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 approximately 4.5° in different scenarios: with higher welding force; with increased ED compliance by the use of a thicker ED and; with increased ED compliance by the use of a discontinuous ED. The most significant reduction of the effects caused by misaligned adherends was obtained when combining the use of both increased welding force and discontinuous ED. Such improvement derives from the imposed parallelism caused by the use of a higher welding force and from a more efficient concentration of heat generation at the weld line that occurs when a discontinuous ED is used.

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 adherends have on static ultrasonic welding of thermoplastic composites. Different angles were created by changing the clamping configuration. The results showed that increasing the angle between adherends decreases the power consumed and increases the process time while decreasing the weld uniformity and increasing the risk of overheating. These effects were associated to the impact of the different clamping configurations on the cyclic strain in the energy director and adherends during the welding process. Decreasing the top adherends bending stiffness by increasing the clamping distance was found to significantly reduce the adverse effects of adherend misalignment on weld quality.

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 as end-notched flexure or double cantilever beam) typically entails significant complexity in the design of the welding process. Testing of SLS joints is also uncomplicated and, even though, owing to mixed-mode loading and uneven stress distribution, it does not provide design values, it is widely acknowledged as a valuable tool for comparison. Even so, comparing different aspects of composite welded joints through their corresponding SLS strength values alone can be deceptive. This paper shows that comparison of different welding processes, adherend materials, process parameters or different types of joining techniques through SLS testing is only meaningful when strength values are combined with knowledge on other aspects of the joints such as joint mesostructure, failure modes and joint mechanics. This article is part of a discussion meeting issue 'A cracking approach to inventing new tough materials: fracture stranger than friction'.

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. Process-induced changes in the meso and microstructure of these welds were identified and correlated to the weld strength. Subsequently, a processing interval, i.e., a range of heating times resulting in less than 10% decrease of weld strength, was defined. As, expected, the dissimilar composite welded joints were more sensitive to the heating time than the CF/PEEK to CF/PEEK welded joints. However, this effect was less pronounced than expected, since a relatively wide processing interval could be obtained provided that the coupling layer had a sufficient thickness.

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 –50 °C to 120 °C on three series, one with amorphous and two with semi-crystalline weldline. The overall trend was decreasing LSS with increasing temperature and the largest LSS reduction was observed above the glass transition temperature. Fractographic analysis revealed that the main failure mechanism at –50 °C was matrix fracture while fibre/matrix debonding became more pronounced with increasing temperature. It was demonstrated that higher degree of crystallinity of PPS at the weldline was beneficial at high temperatures (90 °C and 120 °C) most likely due to the higher fibre/matrix interfacial strength compared to amorphous PPS. The amorphous weldline was shown to be advantageous at -50 °C, probably due to the higher toughness and ductility of amorphous PPS.