Continuous Ultrasonic Welding of Thermoplastic Composites

An experimental study towards understanding factors influencing weld quality

Doctoral Thesis (2022)
Author(s)

Bram Jongbloed (TU Delft - Aerospace Structures & Computational Mechanics)

Research Group
Aerospace Structures & Computational Mechanics
Copyright
© 2022 B.C.P. Jongbloed
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Publication Year
2022
Language
English
Copyright
© 2022 B.C.P. Jongbloed
Research Group
Aerospace Structures & Computational Mechanics
ISBN (print)
978-94-6421-596-0
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Abstract

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 of the research conducted for this dissertation very little knowledge on the process was available. The weld quality in the state-of-the-art research was significantly lower than the weld quality of the statically welded counterpart in terms weld uniformity as unwelded and overwelded areas were present simultaneously, the single-lap strength, and the presence of voids. Hence, before continuous ultrasonic welding can be industrially applied the weld quality needs to be improved. Consequently, the main objective of this dissertation was to acquire a deeper understanding of the continuous ultrasonic welding process of thermoplastic composites to promote its development for future industrial applications.

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