Finite element modeling of continuous induction welding of thermoplastic matrix composites

Lionetto, Francesca; Pappadà, Silvio; Buccoliero, Giuseppe; Maffezzoli, Alfonso

doi:10.1016/j.matdes.2017.02.024

Cited by 71 publications

(53 citation statements)

References 57 publications

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“…1,2 The high-efficiency assembly and connection technology of the thermoplastic composite components are becoming increasingly critical in the industrial manufacturing field. 4,5 Fusion bonding technologies of the thermoplastic composites commonly include laser welding, 6-8 induction welding, [9][10][11] ultrasonic welding, [12][13][14] resistance welding, and so on. 4,5 Fusion bonding technologies of the thermoplastic composites commonly include laser welding, 6-8 induction welding, [9][10][11] ultrasonic welding, [12][13][14] resistance welding, and so on.…”

Section: Introductionmentioning

confidence: 99%

“…3 Based on the meltable and reconsolidated capacity of the engineering plastics without losing mechanical properties, the fusion bonding of the thermoplastic composites is identified as an effective alternative technology for the mechanical joining and bonding. 4,5 Fusion bonding technologies of the thermoplastic composites commonly include laser welding, [6][7][8] induction welding, [9][10][11] ultrasonic welding, [12][13][14] resistance welding, and so on.…”

Section: Introductionmentioning

confidence: 99%

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Effect of chemical etching of resistance wire surface on the strength and failure mechanism of the resistance‐welded joint of polyetherimide composites

Xiong

Zhao

Ren

et al. 2019

J of Applied Polymer Sci

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The surface modification of stainless-steel (SS) mesh was carried out by chemical etching for different time, and then, the etched SS meshes were used as the interlayer heating element for resistance welding of glass fabric-reinforced polyetherimide (GF/PEI) composite laminates. The hydrophobicity and tensile strength of the etched and untreated SS wires and interfacial shear strength (IFSS) between SS wire and PEI resin were investigated by dynamic contact angle (DCA) analyzer and single fiber pull-out test to evaluate the influence of the degree of chemical etching on the bonding strength of PEI resin and SS surface. Tensile lap-shear strength (LSS) and scanning electron microscope (SEM) analysis were performed to investigate the welding interface strength and fracture morphologies of the resistance-welded joint of the GF/PEI laminates. The hydrophobicity and tensile strength of SS wires were increased and decreased respectively with etching time (t e ). The IFSS of SS wire/PEI resin showed an improvement with t e . The LSS was increased first and then decreased with t e , and the optimal t e was 30 min when LSS reached the maximum. Fracture analysis showed the main failure mode of the welded joints was the interlayer debonding when welding time (t w ) was insufficient. With the extension of t w , the failure mode gradually switched into the intralayer tearing of the SS implant.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effect of chemical etching of resistance wire surface on the strength and failure mechanism of the resistance‐welded joint of polyetherimide composites

Xiong

Zhao

Ren

et al. 2019

J of Applied Polymer Sci

View full text Add to dashboard Cite

show abstract

“…Existing works treat the process of induction welding for thermoplastic composite materials as a multi-physics problem and address the problem based on finite element (FE) method [1] [2] [3]. These works mainly study the induction welding by subdividing the process into multiple smaller processes, such as electromagnetic field, heat transfer, etc.…”

Section: Introductionmentioning

confidence: 99%

Process Modelling of Induction Welding for Thermoplastic Composite Materials By Neural Networks

Guo¹,

Pandher²,

Tooren³

et al. 2019

SAMPE 2019 - Charlotte, NC

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Induction welding for thermoplastic composite materials uses an alternating current flowing through a coil to induce an electromagnetic field and generate eddy current inside laminate with various fiber orientations-the generated heat causes the laminate to heat up and melt the polymer. As a pressure is applied to the induction heating zones, cohesive bonding may occur during the melting of the polymer. The welding quality of the composite materials is highly influenced by the temperature varying inside the heating zones. Thus, it is beneficial for induction welding if temperature varying during heating can be acquired given a set of welding parameters, such as current, pressure, fiber orientations, etc. Conducting practical induction heating experiments for this purpose is laborious and time consuming given the large varying space of welding parameters. In this paper, we propose to address this problem by using machine learning techniques to model the relation between the welding parameters and the temperature varying inside the heating zones. We conduct two sets of induction heating experiments for laminate welding and the collected sample temperature varying data are used to train the neural networks with input of welding parameters and output of the predicted temperature varying. Testing of the models demonstrates that process modeling of induction welding with machine learning techniques is viable.

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“…Such manufacturing techniques are viable alternatives to autoclave manufacturing and traditional methods for joining composite subassemblies. Because of these advantages, thermoplastic composites are currently replacing thermosetting composites in many applications [8].…”

Section: Introductionmentioning

confidence: 99%

“…Pressure can be applied by mechanical means via a roller [20,21], tooling [22], or drawing of a vacuum [21]. With roller pressure (generally limited to flat panels), the weld-line is initially heated by induction without the application of pressure before the consolidation roller passes over the part [8,20,23]. This means that the area heated by induction may de-consolidate locally before being re-consolidated by the roller.…”

Section: Introductionmentioning

confidence: 99%

Comparative manufacture and testing of induction- welded and adhesively bonded carbon fibre PEEK stiffened panels

Flanagan

Doyle

et al. 2018

Journal of Thermoplastic Composite Materials

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This work presents details of manufacturing and testing of a carbon fibre polyetheretherketone induction-welded hat-stiffened panel. Mechanical testing is carried out to evaluate the performance of the welded assembly and results are compared with similar testing of an adhesively bonded panel. The results show that the welded panel and the bonded panel had similar load-bearing capacity (<2% difference) and stiffness (<1% difference). Optical microscopy is used to verify the weld quality and identify manufacturing artefacts associated with induction welding. Inspection of the panel after welding shows that the induction welding process caused minor warpage, voids and delamination in the panel. The work addresses the lack of data relating to demonstrator scale welded assemblies in the literature, demonstrates that continuous induction welding is a suitable assembly technique for aerospace and automotive components under uniaxial in-plane compressive loading and identifies process-induced artefacts that may occur during induction welding.

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Finite element modeling of continuous induction welding of thermoplastic matrix composites

Cited by 71 publications

References 57 publications

Effect of chemical etching of resistance wire surface on the strength and failure mechanism of the resistance‐welded joint of polyetherimide composites

Effect of chemical etching of resistance wire surface on the strength and failure mechanism of the resistance‐welded joint of polyetherimide composites

Process Modelling of Induction Welding for Thermoplastic Composite Materials By Neural Networks

Comparative manufacture and testing of induction- welded and adhesively bonded carbon fibre PEEK stiffened panels

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