A comparative evaluation between flat and traditional energy directors for ultrasonic welding of CF/PPS thermoplastic composites

Villegas, Irene Fernández; Grande, Bjørnar; Bersee, H.E.N.; Benedictus, Rinze

doi:10.1080/09276440.2015.1053753

Cited by 67 publications

(16 citation statements)

References 9 publications

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“…The design of ED plays a very important role to get a sound welding, since their shape, size, morphology and their configuration, influence the final weld quality. Different shapes of energy directors can be designed, such as semicircular, triangular, rectangular, multiple EDs and others [41,51,90]. They can also be oriented in the parallel or perpendicular direction of welded joints, and their effects could be compared.…”

Section: Energy Directormentioning

confidence: 99%

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Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

et al. 2020

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The ultrasonic welding (UW) technique is an ultra-fast joining process, and it is used to join thermoplastic composite structures, and provides an excellent bonding strength. It is more cost-efficient as opposed to the conventional adhesive, mechanical and other joining methods. This review paper presents the detailed progress made by the scientific and research community to date in the direction of the UW of thermoplastic composites. The focus of this paper is to review the recent development of the ultrasonic welding technique for thermoplastic composites to thermoplastic composites, and to dissimilar materials. Different ultrasonic welding modes and their processing parameters, namely, weld time, weld pressure, amplitude, type of energy directors (EDs) affecting the welding quality and the advantages and disadvantages of UW over other bonding techniques, are summarized. The current state of the ultrasonic welding of thermoplastic composites and their future perspectives are also deliberated.

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Section: Energy Directormentioning

confidence: 99%

“…Villegas et al, in one the investigation, has shown that flat ED has no negative impact on the welding process or quality while comparing it with traditional ED (Triangular) [90]. Influence on LSS with and without ED was investigated by Tao et al, using CF/PEEK and ED of 0.45 mm thickness [51].…”

Section: Energy Directormentioning

confidence: 99%

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

et al. 2020

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“…Applications and research activities in ultrasonic welding of TPC have been deeply reviewed and conducted by Villegas et al [ 33 , 81 , 82 , 87 , 147 , 148 , 149 , 150 , 151 , 152 ]. The size, shape, and number of energy directors affect the heat generation and resin flow.…”

Section: Tpc Joining and Repair Techniquesmentioning

confidence: 99%

Thermoplastic Composites and Their Promising Applications in Joining and Repair Composites Structures: A Review

2020

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Thermoset fiber reinforced composites, widely used in current structural applications, have complex repair procedures and generates significant amounts of scrap due to its recycling difficulties, which does not comply with the most recent environmental restrictions. These disadvantages may be overcome by using a thermoplastic matrix phase, which is very suitable to be joined and repaired by local melting, making the composite material fully recyclable. This work presents a literature review on the joining methods applicable to thermoplastic based composites and their potential applications to be used as repair procedures in structural elements. The effectiveness of selected adhesive and fusion bonding techniques for several thermoplastic composite systems is evaluated by a comparative study based on the joints’ strength and toughness results available in the literature. This work focuses on the three most promising fusion bonding techniques: Resistance welding, induction welding, and ultrasonic welding. The advantages and drawbacks for each one of these processes are discussed, as well as their suitability for several specific structural applications. In addition, several discordant aspects for each welding technique are identified and the corresponding recommendations are discussed. A compilation of analytical models for the mechanisms of heat generation and transient heat transfer modelling is also presented for each fusion bonding process in order to promote their application in numerical modelling.

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“…There are considerable research literatures on the USW process for thermoplastic materials at the coupon level [125][126][127][128][129][130][131][132][133][134][135]. The welded condition parameters including welding time, welding pressure, and vibration amplitude, were investigated and the relationship between the welded ability and the parameters were reported.…”

Section: New Ultrasonic Welding Application For Polymersmentioning

confidence: 99%

Thermal Welding by the Third Phase Between Polymers: A Review for Ultrasonic Weld Technology Developments

et al. 2020

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Ultrasonic welding (USW) is a promising method for the welds between dissimilar materials. Ultrasonic thermal welding by the third phase (TWTP) method was proposed in combination with the formation of a third phase, which was confirmed as an effective technology for polymer welding between the two dissimilar materials compared with the traditional USW. This review focused on the advances of applying the ultrasonic TWTP for thermoplastic materials. The research development on the ultrasonic TWTP of polycarbonate (PC) and polymethyl methacrylate (PMMA), polylactic acid (PLA) and polyformaldehyde (POM), and PLA and PMMA are summarized according to the preparation of the third phase, welded strength, morphologies of rupture surfaces, thermal stability, and others. The review aimed at providing guidance for using ultrasonic TWTP in polymers and a basic understanding of the welding mechanism, i.e., interdiffusion and molecular motion mechanisms between the phases.

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A comparative evaluation between flat and traditional energy directors for ultrasonic welding of CF/PPS thermoplastic composites

Cited by 67 publications

References 9 publications

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

Thermoplastic Composites and Their Promising Applications in Joining and Repair Composites Structures: A Review

Thermal Welding by the Third Phase Between Polymers: A Review for Ultrasonic Weld Technology Developments

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