Double-Pulse Ultrasonic Welding of Carbon-Fiber-Reinforced Polyamide 66 Composite

Zhi, Qian; Li, Yongbing; Shu, Peng; Tan, Xinrong; Tan, Caiwang; Liu, Zhongxia

doi:10.3390/polym14040714

Cited by 16 publications

(13 citation statements)

References 28 publications

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“…The thermoplastic composite has outstanding characteristics, which are different from the traditional thermosetting composite, such as high toughness, high strength, fast forming, and recyclability [ 13 , 14 , 15 , 16 , 17 , 18 ]. It is a new type of composite material with high performance, low cost, and environmental protection and becomes an ideal material for civil aircraft structure components manufacturing, which can reduce weight effectively and improve processing efficiency [ 19 , 20 ].…”

Section: Introductionmentioning

confidence: 99%

Research on Void Dynamics during In Situ Consolidation of CF/High-Performance Thermoplastic Composite

et al. 2022

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Automated fiber placement (AFP) in situ consolidation of continuous CF/high-performance thermoplastic composite is the key technology for efficient and low-cost manufacturing of large thermoplastic composites. However, the void in the in situ composite is difficult to eliminate because of the high pressure and the short consolidation time; the void content percentage consequently is the important defect that determines the performance of the thermoplastic composite parts. In this paper, based on the two-dimensional Newtonian fluid extrusion flow model, the void dynamics model and boundary conditions were established. The changes of the void content percentage were predicted by the cyclic iteration method. It was found that the void content percentage increased gradually along the direction of the layers’ thickness. With the increasing of the laying speed, the void content percentage increased gradually. With the increasing of the pressure of the roller, the void content percentage gradually decreased. When the AFP speed was 11 m/min and the pressure of the compaction roller reached 2000 N, the void content percentage of the layers fell below 2%. It was verified by the AFP test that the measured results of the layers’ thickness were in good agreement with the predicted results of the model, and the test results of the void content percentage were basically equivalent to the predicted results at different AFP speeds, which indicates that the kinetic model established in this paper is representative to predict the void content percentage. According to the metallographic observation, it was also found that the repeated pressure of the roller was helpful to reduce the void content percentage.

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Section: Introductionmentioning

confidence: 99%

Research on Void Dynamics during In Situ Consolidation of CF/High-Performance Thermoplastic Composite

et al. 2022

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“…Quality of UWed joint can be affected by many factors, such as material properties, welding parameters, contact condition among horn, welding part and fixture [13][14][15]. Our previous studies [16][17][18] have systematically investigated the influence of imperfect contacts, such as horn misalignment, gaps between workpiece, and fixture, on the weld quality of UWed joints.…”

Section: Introductionmentioning

confidence: 99%

“…Experimental results showed the imperfect conditions affect the joint Polymers 2022, 14, 2650 2 of 16 strength severely and produce discrepant welds [18][19][20][21]. Although these discrepant joints can be repaired by application of the secondary ultrasonic pulse and other processes [22,23], the additional pulse is time-consuming and the cosmetic quality of joints is deteriorated. It is known that the ultrasonic energy transmission during UW is closely related to the contact condition among the horn, upper workpiece and lower adherend.…”

Section: Introductionmentioning

confidence: 99%

“…In production, when the warped upper sheet is placed upon lower sheet for joining, a gap is usually presented between the sheets. The gap between the workpieces can result in the poor contact condition, which is detrimental to the ultrasonic propagation during UW and weld formation [17,22,23]. At this context, a preload welding method is proposed to improve the contact condition between upper and lower workpieces.…”

Section: Introductionmentioning

confidence: 99%

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Effect of Preload on the Weld Quality of Ultrasonic Welded Carbon-Fiber-Reinforced Nylon 6 Composite

et al. 2022

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Ultrasonic welding (UW) of polymeric composites is significant in automobile industry; however, maintaining the perfect contact condition between workpieces is a great concern. In this study, effect of preloading and welding pressure on strengths of UWed 2.3-mm-thick short carbon fiber reinforced nylon6 (Cf/PA6) joints with poor contact between workpieces was investigated through stress simulation and energy dissipation at the faying interface. Results showed the application of preloading can increase the strength of normal joint by 18.7% under optimal welding parameters. Gaps between upper and lower workpieces decreased the joint strength significantly, especially for gaps greater than 1.5 mm. Preloading improved the strengths of the joints with gaps remarkably, where the strength of joints with 1.5 mm gap recovered to 95.5% of that the normal joint. When combining the weld nugget evolution, stress-deformation simulation during UW, and ultrasonic vibration transmission analysis, the improvement mechanism of the joint under preloading was mainly because the preloading compacted the contact between workpieces, which favored the energy transmission at faying interface.

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“…The entire process can take just seconds. Zhi et al [4] investigated the relations among the loss modulus of carbon-fiber-reinforced polyamide 66 composite and time for obtaining stable weld areas. It was found that peak load, weld area, and endurance limit of the double-pulse ultrasonic welding process weld joint increased by about 15%, 23%, and 59%, respectively.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

Kuo

Tsai

et al. 2022

Polymers

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Ultrasonic welding (UW) is a joining of plastics through the use of heat generated from high-frequency mechanical motion, which is known as an efficient process in many applications, such as textile, packaging, or automotive. UW of thermoplastics has been widely employed in industry since no polymer degradations are found after UW. However, the trial-and-error approach is frequently used to study optimum UW process parameters for new 3C plastic power cases in current industry, resulting in random efforts, wasted time, or energy consumption. In this study, Taguchi methods are used to study optimum UW process parameters for obtaining high weld strength of a plastic power case. The most important control factor influencing the weld strength is amplitude, followed by weld pressure, hold time, and trigger position. The optimum UW process parameters are amplitude of 43.4 µm, weld pressure of 115 kPa, hold time of 0.4 s, and trigger position of 69.95 mm. Finally, the confirmation experiments are performed to verify the optimum process parameters obtained in this study.

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Double-Pulse Ultrasonic Welding of Carbon-Fiber-Reinforced Polyamide 66 Composite

Cited by 16 publications

References 28 publications

Research on Void Dynamics during In Situ Consolidation of CF/High-Performance Thermoplastic Composite

Research on Void Dynamics during In Situ Consolidation of CF/High-Performance Thermoplastic Composite

Effect of Preload on the Weld Quality of Ultrasonic Welded Carbon-Fiber-Reinforced Nylon 6 Composite

Optimization of Ultrasonic Welding Process Parameters to Enhance Weld Strength of 3C Power Cases Using a Design of Experiments Approach

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