Zero-flow

A novel approach to continuous ultrasonic welding of CF/PPS thermoplastic composite plates

Journal article (2016)

Authors

G. Palardy Structural Integrity & Composites - Aerospace Engineering
I.F. Villegas Structural Integrity & Composites - Aerospace Engineering
Research Group
Structural Integrity & Composites (Aerospace Engineering) (TU Delft)
Copyright: © 2016 F. Senders, M. van Beurden, G. Palardy, I.F. Villegas
DOI
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https://doi.org/10.1080/20550340.2016.1253968
Composites Fusion bonding Thermoplastic resin Structural joining Ultrasonic heating Continuous welding
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Published Date

2016

Language

English

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Faculty

Aerospace Engineering

Department

Aerospace Structures & Materials

Research Group

Structural Integrity & Composites

Abstract

Continuous ultrasonic welding of plastic films, fabrics, and even thermoplastic composite prepreg tape is a common industrial practice. However, continuous ultrasonic welding of stiff thermoplastic composite plates is challenging due to squeeze flow of resin at the welding interface, and significant local deformation of the welding stack, that are generally needed to achieve strong welds. This paper presents a novel approach to continuous ultrasonic welding of thermoplastic composite plates based on zero-flow welding. The proposed technique can create strong welds before any squeeze flow takes place at the interface. It is enabled by the use of very thin flat energy directors, owing to simultaneous melting of both energy director and adherends’ matrix. The results prove the feasibility and indicate the potential for high-strength welds between thermoplastic composite plates at very high speed.