Induction welding of thermoplastic composites—an overview

Ahmed, Tousif; Stavrov, Darko; Bersee, H.E.N.; Beukers, Adriaan

doi:10.1016/j.compositesa.2005.10.009

Cited by 212 publications

(149 citation statements)

References 22 publications

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“…A complete weld is achieved when the weld interface reaches the polymer melting temperature everywhere but does not reach the polymer degradation temperature anywhere. 7,9 On the other hand, welding times longer than 90 s would promote deformation of the adherends.…”

Section: Induction Weldingmentioning

confidence: 99%

“…UD reinforcement also provides the composite with high strength and stiffness, making these materials ideal candidates for many aerospace applications. As Bayerl et al 6 and Ahmed et al 7 reported, very few studies have focused on thermoplastic composites IW based on a HE. Therefore, a study on welding of UD carbon fiber thermoplastic composites with an HE is needed and relevant.…”

Section: Introductionmentioning

confidence: 99%

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Modeling and experimental investigation of induction welding of thermoplastic composites and comparison with other welding processes

O'Shaughnessey

Dubé

Villegas

2016

Journal of Composite Materials

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A three-dimensional finite element model of the induction welding of carbon fiber/polyphenylene sulfide thermoplastic composites is developed. The model takes into account a stainless steel mesh heating element located at the interface of the two composite adherends to be welded. This heating element serves to localize the heating where it is needed most, i.e. at the weld interface. The magnetic, electrical, and thermal properties of the carbon fiber/polyphenylene sulfide composite and other materials are identified experimentally or estimated and implemented in the model. The model predicts the temperature–time curves during the heating of the composite and is used to define processing parameters leading to high-quality welded joints. The effect of the heating element size and input current on the thermal behavior is investigated, both experimentally and using the developed model. The welds quality is assessed through microscopic observations of the weld interfaces, mechanical testing, and observations of the fracture surfaces. A comparison with two other welding processes, namely resistance welding and ultrasonic welding is finally conducted.

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Section: Induction Weldingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Modeling and experimental investigation of induction welding of thermoplastic composites and comparison with other welding processes

O'Shaughnessey

Dubé

Villegas

2016

Journal of Composite Materials

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“…Examples of processes currently under investigation which have the potential to be used in conjunction with thermoforming for the manufacture of complex components include thermofolding [10] and thermoplastic welding [10,11].…”

Section: Continuous Fibre-reinforced Thermoplastic Laminatesmentioning

confidence: 99%

“…Although higher levels of raw material processing results in a corresponding higher cost, the pre-consolidated laminate sheets offer production benefits as they can be readily processed using a number of derivatives of the thermoforming family of processes, such as matched die forming, rubber thermoforming, diaphragm forming etc. Eliminating the need for layup processes in the production environment, also improves quality levels and reduces the potential for variability in finished pieces.Examples of processes currently under investigation which have the potential to be used in conjunction with thermoforming for the manufacture of complex components include thermofolding [10] and thermoplastic welding [10,11].In this work PPS was chosen for its material properties and for its emergence as a leading thermoplastic matrix material for aerospace components [7]. The chemical structure of PPS consists of para-phenylene units alternating with sulphide linkages, such an arrangement leads to a very rigid macromolecular chain, which exhibits superior physical and mechanical properties [12].…”

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confidence: 99%

Thermoforming carbon fibre-reinforced thermoplastic composites

McCool

Murphy

Wilson

et al. 2012

Proceedings of the Institution of Mechanical Engineers, Part L:

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The use of carbon fibre composites is growing in many sectors but their use remains stronger in very high value industries such as aerospace where the demands of the application more easily justify the high energy input needed and the corresponding costs incurred. This energy and cost input is returned through gains over the whole life of the product, with for example, longer maintenance intervals for an aircraft and lower fuel burn. Thermoplastic composites however have a different energy and cost profile compared to traditional thermosets with notable differences in recyclability, but this profile for thermoplastics is not well quantified or documented. This study considers the key process control parameters and identifies an optimal window for processing thermoplastic composites, along with the effect this has on the final characteristics of the manufactured parts. Interactions between parameters and corresponding sensitivities are extracted from the results. Keywords:Thermoforming, continuous fibre-reinforced thermoplastic, whole life modelling, composite material recycling-reuse. * Corresponding author:Tel.: +44 (0) 28 9097 4178; fax: +44 (0) 28 9066 1729.E-mail address: m.price@qub.ac.uk (Mark Price).Page 2 of 24 Introduction Designing with new materialsThe introduction of new materials, particularly for aerospace products, is not a simple, quick or cheap task. New materials and associated processes require extensive and high cost qualification and must meet challenging manufacturing, strength, stiffness, durability, inspection and maintenance requirements, as well as emerging recycling-reuse targets, obligations and directives. Considering the structural design process, a design is traditionally conceived using experience in combination with highly idealized performance models. This is true for the simplest of components and for the complete vehicle structure. Given commercial pressures for reduced time to market and available data within early design, the ability to fully explore and assess the potential design space is highly constrained. Consequently designs and materials tend to be limited to the most feasible of a few considered, or limited to a known and previously used design and material combination. Moreover, in cases were new materials have been selected, the structural design may not initially maximise the material potential. A good example of this is the introduction of thermosetting composite structures in aerospace which were initially designed as if they were traditional metal materials with isotropic properties. Such design constraints can only be overcome with new understanding and the adoption of new design methods which account for the range of materials, and material to part processes available, as well as the complex interactions between the materials and the ultimate whole life structural performance.In the case of composites this whole life aspect is fundamental in understanding the balance of energy and cost for a product. Each step in the manufacturing process consumes ene...

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“…In general, thermoplastic composites with continuous fibers are produced with less processing cycles, and can be hot pressed, thermoformed, pultruded, consolidated in autoclave or by automated methods on multiple complex shapes of large size [14][15][16][17][18][19][20] . Besides, they can be welded to other structures by electrical resistance, ultrasonic and induction technologies, for example [21][22][23][24][25] . Despite the advantages provided by polymeric composite materials, defects and damages may be present in the laminated structure, caused by different variables, which may occur during the processing of the component or during its useful life.…”

Section: Introductionmentioning

confidence: 99%