Numerical Study of Contact Behavior and Temperature Characterization in Ultrasonic Welding of CF/PA66

Yang, Yuanduo; Liu, Zhiwei; Wang, Yuefang; Li, Yang

doi:10.3390/polym14040683

Cited by 15 publications

(9 citation statements)

References 25 publications

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“…The mechanical oscillation of the UPW works perpendicular to the workpieces, which is beneficial for the flowing and spreading of the molten thermoplastics [ 28 ]. UPW has several significant advantages compared to other joining methods, such as a fast, flexible, and effective joining process, minimum top surface damage compared to friction stir joining, high structural reliability, minimum contamination risk of charred particles, and friendly to the environment [ 29 ]. Significantly, it can reduce costs and is more feasible for the industry’s application [ 30 ].…”

Section: Materials and Experimental Methodsmentioning

confidence: 99%

Study on the SPCC and CFRTP Hybrid Joint Performance Produced with Additional Nylon-6 Interlayer by Ultrasonic Plastic Welding

2022

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Due to the high degree of dissimilarity in physicochemical properties between metal and carbon fiber, it presents a tremendous challenge to join them directly. In this paper, cold rolled steel (SPCC) and carbon fiber reinforced thermoplastic (CFRTP) chopped sheet hybrid joints were produced with the addition of Nylon 6 (PA6) thermoplastic film as an intermediate layer by the ultrasonic plastic welding method. The effect of ultrasonic welding energy and preheating temperature on the hybrid joint microstructure and mechanical behavior was well investigated. The suitable joining parameters could obtain a strong joint by adding the PA6 film as an intermediate layer between the SPCC and bare carbon fibers. Microstructural analysis revealed that the interface joining condition between the PA6 film and the SPCC component is the primary reason for the joint strength. The crevices generated at the interface were eliminated when the preheating temperature arrived at 200 °C, and the joint strength thus significantly increased. The lap shear test results under quasi-static loading showed that the welding energy and preheating temperature synergistically affect the joint performances. At 240 °C, the joint strength value reached the maximum. Through the analysis of the microstructure morphology, mechanical performance, and the failure mechanism of the joint, the optimized joining process window for ultrasonic plastic welding of SPCC-CFRTP by adding an intermediate layer, was obtained.

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Section: Materials and Experimental Methodsmentioning

confidence: 99%

Study on the SPCC and CFRTP Hybrid Joint Performance Produced with Additional Nylon-6 Interlayer by Ultrasonic Plastic Welding

2022

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“…Notably, the welded components showcased superior mechanical prowess when juxtaposed with three-dimensional printed counterparts of congruent geometry. Yang et al [13] delved into temperature characterization and contact dynamics during welding, employing the harmonic balance method. Both simulation and experimental results underscored the significant impact wielded by welding duration and amplitude on the interface temperature.…”

Section: Introductionmentioning

confidence: 99%

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Kuo,

Liang,

Huang

et al. 2024

Polymers

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Polylactic acid (PLA) stands out as a biomaterial with immense potential, primarily owing to its innate biodegradability. Conventional methods for manufacturing PLA encompass injection molding or additive manufacturing (AM). Yet, the fabrication of sizable medical devices often necessitates fragmenting them into multiple components for printing, subsequently requiring reassembly to accommodate the constraints posed by the dimensions of the AM platform. Typically, laboratories resort to employing nuts and bolts for the assembly of printed components into expansive medical devices. Nonetheless, this conventional approach of jointing is susceptible to the inherent risk of bolts and nuts loosening or dislodging amid the reciprocating movements inherent to sizable medical apparatus. Hence, investigation into the joining techniques for integrating printed components into expansive medical devices has emerged as a critical focal point within the realm of research. The main objective is to enhance the joint strength of PLA polymer rods using rotary friction welding (RFW). The mean bending strength of welded components, fabricated under seven distinct rotational speeds, surpasses that of the underlying PLA substrate material. The average bending strength improvement rate of welding parts fabricated by RFW with three-stage transformation to 4000 rpm is about 41.94% compared with the average bending strength of PLA base material. The average surface hardness of the weld interface is about 1.25 to 3.80% higher than the average surface hardness of the PLA base material. The average surface hardness of the weld interface performed by RFW with variable rotational speed is higher than the average surface hardness of the weld interface performed at a fixed rotating friction speed. The temperature rise rate and maximum temperature recorded during RFW in the X-axis of the CNC turning machine at the outer edge of the welding part surpassed those observed in the internal temperature of the welding part. Remarkably, the proposed method in this study complies with the Sustainable Development Goals due to its high energy efficiency and low environmental pollution.

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“…On the other hand, ultrasonic welding is widely used to bond similar and dissimilar polymers, metals, and woods [7][8][9][10][11]. When an ultrasonic welding device composed of converter, booster and sonotrode is used to bond two pieces of materials such as thermoplastics, thermoplastic elastomer, and thermosets, mechanical energy generated by ultrasound wave will be propagated, amplified and finally localized to the interface between two pieces of adherends [12][13][14]. Localization of stress wave energy will lead to thermal energy accumulated around the interface of adherends.…”

Section: Introductionmentioning

confidence: 99%

Digest Ultrasonic Welding I: Localized Heating and Fuse Bonding

Yang¹,

Yang²

2023

Preprint

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This paper reports a new insight on the principle of ultrasonic welding process. Physics of ultrasonic welding process is considered to be an inverse process of shear band formation. Both ultrasonic welding and shear band formation involve temperature rising due to localized plastic deformation. During shear band formation, heat will lead to damage of materials, e.g., initiation of cracks inside materials. But heat generated in ultrasonic welding process will bond two pieces or repair the cracks inside materials [1]. Energy directors used in ultrasonic welding process act as a trigger of localized plastic deformation. Mathematically, We found out that heating generation during ultrasonic welding process is similar to heating generation by electric current.

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Numerical Study of Contact Behavior and Temperature Characterization in Ultrasonic Welding of CF/PA66

Cited by 15 publications

References 25 publications

Study on the SPCC and CFRTP Hybrid Joint Performance Produced with Additional Nylon-6 Interlayer by Ultrasonic Plastic Welding

Study on the SPCC and CFRTP Hybrid Joint Performance Produced with Additional Nylon-6 Interlayer by Ultrasonic Plastic Welding

Enhancing the Weld Quality of Polylactic Acid Biomedical Materials Using Rotary Friction Welding

Digest Ultrasonic Welding I: Localized Heating and Fuse Bonding

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