A Study of Films Incorporating Magnetite Nanoparticles as Susceptors for Induction Welding of Carbon Fiber Reinforced Thermoplastic

Abstract

Induction welding is a fast, clean, noncontact process that often uses a metal-mesh susceptor to facilitate localized controlled heating; however, the metal mesh presents various problems. In this study, the induction heating behavior of a 450 μ m thick thin-film susceptor, fabricated by mixing magnetite (Fe 3 O 4 ) nanoparticles (NPs) and PA6/carbon fiber (CF) (30%) thermoplastic resin, was examined with respect to the weight ratio of Fe 3 O 4 (50, 67, 75, and 80 wt%). The useful induction heating behavior of the 75 wt% Fe 3 O 4 susceptor suggested its suitability for additional heat treatment experiments, carried out at 3.4 kW at a frequency of 100 kHz. This susceptor attained the same maximum temperature during 10 cycles of repeated induction heating and cooling. It was then used to weld two thermoplastic composites, with 60 s of induction heating followed by 120 s of simultaneous cooling and pressing. The resulting welded joints had lap shear strength values of 36.8, 34.0, and 36.4 MPa under tensile test loads of 884, 817, and 874 N, respectively. Scanning electron microscopy images confirmed a uniform weld quality. Thus, the proposed manufacturing method, involving the incorporation of Fe 3 O 4 NPs into thermoplastic resin, should help expand the range of applications for thermoplastic composites.

Multifactor optimization for induction welding of carbon fiber reinforced thermoplastic composites based on response surface methodology

“…These welding technologies can avoid shortcomings, including weight increase, stress concentration, and long production cycles in traditional joining methods 15–17 . Induction welding is considered to be one of the most promising joining techniques for CFRP composites due to its high efficiency and selectivity of the heated area, which is particularly suitable for the automated manufacture of large joining structures thanks to its ability to achieve continuous welding by moving the induction coil along the specific path 18–20 . However, the nonuniformity of the temperature field in the weld area limits the application of induction welding.…”

“…In addition, the induced current tends to flow outwards at the surface of the material rather than penetrate the cross section with the same intensity, which is called the skin effect 26 . The heating rate near the coil is faster so that the highest temperature is achieved on the top surface rather than at the bond‐line of the composites, which results in surface overheating and degradation 19 Edge effects and skin effect are two key issues that hinder the application of induction welding.…”

Hybrid Thermoplastic Composites from Basalt- and Kevlar-Woven Fabrics: Comparative Analysis of Mechanical and Thermomechanical Performance

“…This results in prolonged impregnation time and sometimes poorly impregnated areas, which leads to mechanical failures. To overcome these issues, reactive thermoplastic resin such as PA6 was developed [ 43 , 44 , 45 , 46 , 47 ]. Several researchers have reported the mechanical advantages of thermoplastic composites produced by pultrusion and reinforced with fibrous materials [ 48 , 49 , 50 , 51 ].…”

Use of the FMVSS-214 static bending test to evaluate an automobile side door impact beam made of glass fiber-reinforced plastic

“…Ben et al experimentally and analytically investigated a hybrid beam composed of an Al alloy with a carbon fiber-reinforced plastic (CRFP) laminate 20 ; they studied bending performance with respect to the type of carbon fiber, the beam cross-section, and the bonding method, in which impact absorption was better than that of typical steel beams. Liu et al filled square CFRP tubes with an aluminum honeycomb and studied lateral fractures 21,22 ; in the side-bending test, the new tube absorbed 32% more energy than the typical steel tube. Sebaey et al examined five CFRP composite tubes filled with polyurethane foam 23 ; the energies absorbed were compared using a drop impactor in which foam-filled tubes exhibited the highest energy absorption.…”