The possibility of assembling through welding is one the major features thermoplastic composites and it positively contributes to their cost-effectiveness in manufacturing. This article presents a comparative evaluation ultrasonic, induction resistance individual carbon fibre-reinforced polyphenylene sulphide (PPS) composite samples that comprises an analysis static dynamic mechanical behaviour joints as well main process variables. used this research benefitted from conductive nature...

Ultrasonic welding is a very fast joining technique well suited for thermoplastic composites, which does not require the use of foreign materials at interface either carbon or glass fibre-reinforced substrates. Despite interesting investigations carried out by several researchers on different aspects process, ultrasonic composite parts understood yet. This article presents deep experimental analysis transformations and heating mechanisms their relationship with dissipated power displacement...

This paper presents a detailed experimental assessment of the effect thickness flat energy directors (ED) on heat generation at interface during ultrasonic welding. Power and displacement data showed clear differences caused by change thickness, related to concentration weld line process. The extent heat-affected zone was assessed welding specimens without consolidation different stages It confirmed through optical microscopy that is generated transferred bulk adherends earlier in process...

Ultrasonic welding is a very fast and energy-efficient technique for the joining of thermoplastic composites. This article looks into main aspects ultrasonic composites, namely energy directors, process parameters, in situ monitoring, dissimilar composite materials upscaling routes. From viewpoint author this paper, these are key topics deepening our insight and, eventually, enabling its future industrialization.

Abstract Ultrasonic welding is considered as one of the most promising techniques for continuous fiber‐reinforced thermoplastic composites. Intermolecular friction within bulk, resulting from application ultrasonic waves applied on surfaces, generates heat required to take place at interface joining members via so‐called “energy directors” (EDs). Energy directors consist resin protrusions or artificially produced asperities composite surfaces and play an important role both in process...

Energy directors, responsible for local heat generation in ultrasonic welding, are neat resin protrusions traditionally moulded on the surfaces to be welded. This study evaluates an alternative energy directing solution welding of thermoplastic composites based usage a loose flat layer at interface, referred as 'flat director'. Analysis dissipated power, displacement sonotrode, and time well weld strength compared more traditional solutions showed that which significantly simplify...

A three-dimensional finite element model of the induction welding carbon fiber/polyphenylene sulfide thermoplastic composites is developed. The takes into account a stainless steel mesh heating located at interface two composite adherends to be welded. This serves localize where it needed most, i.e. weld interface. magnetic, electrical, and thermal properties other materials are identified experimentally or estimated implemented in model. predicts temperature–time curves during used define...

Continuous ultrasonic welding is a promising high-speed and energy-efficient joining method for thermoplastic composite structures. Our aim was to identify understand differences between the static continuous process composites. In particular, melting of interface, consumed power energy density, temperature evolution at weld optimum conditions both types processes were investigated. This done three combinations force vibrational amplitude, parameters which are known have significant effect...

This study aims at assessing the sensitivity of ultrasonic welding process for joining epoxy- to thermoplastic-based composites heating time. For that, carbon fibre (CF)/epoxy adherends with a co-cured PEI coupling layer were ultrasonically welded CF/polyetheretherketone (PEEK) different times. Process-induced changes in meso and microstructure these welds identified correlated weld strength. Subsequently, processing interval, i.e., range times resulting less than 10% decrease strength, was...

Ultrasonic welding is a promising joining technique for thermoplastic composite parts. On the way towards upscaling and industrialisation of this technology, it crucial to understanding how affected by manufacturing tolerances. The objective research presented in paper was investigate influence that misaligned adherends have on static ultrasonic composites. Different angles were created changing clamping configuration. results showed increasing angle between decreases power consumed...

Continuous ultrasonic welding is a promising high-speed and energy-efficient joining technique for thermoplastic composite structures. However, in the current state-of-the-art research on topic numerous deconsolidation voids could be identified at interface, which results strength knock-down. The aim of this study is, therefore, to improve quality continuous ultrasonically welded joints by adding consolidation shoe setup. To determine required pressure, size shoe, its distance from sonotrode...

This paper presents a fully experimental study on melting, flow and weld strength development during ultrasonic welding of CF/PPS composites with integrated triangular energy directors. The main goal this research was assessing whether the heating time to achieve maximum could be significantly reduced as compared flat conclusion is that, in specific case under study, directors did heat up, melt collapse approximately two times faster than it took for flow. However needed not differ...

Continuous ultrasonic welding is a high-speed joining method for thermoplastic composites. Currently, thin film energy director used to focus the heat generation at interface. However, areas of intact remain in welded seam, which significantly lowers weld strength, and result non-uniformly seam. To improve uniformity continuous ultrasonically joints, we changed more compliant director. A woven polymer mesh was found give significant improvement quality. The flattened between composite...