Resistance welding of thermoplastic composites skin/stringer joints

Dubé, Martine; Hubert, Pascal; Yousefpour, Ali; Denault, J.

doi:10.1016/j.compositesa.2007.07.014

Cited by 69 publications

(53 citation statements)

References 13 publications

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“…In addition, different wire diameters and opening areas of these two metal meshes provide different areas of mesh in contact with the resin, which could influence the qualities of mechanical interlocking. Since the mechanical interlocking between metal wires and polymer has been found more important than the interfacial bonding for the resistance welded joints [3], a better mechanical interlocking quality is beneficial for improving the welding quality. As shown in Figure 16, there are more areas of cohesive failure and more wires torn from the resin for M24 welded sample than M200 welded sample, which indicates different mechanical interlocking qualities between M24 and M200 welded samples.…”

Section: Effect Of the Heating Elementmentioning

confidence: 99%

“…To characterize the mechanical properties of the welded joints, different testing methods like short beam shear test, lap-shear strength test, wedge-insert test, and three-point bending tests have been used [2][3][4]. Single lap joint (SLJ), usually used for the research of adhesively bonding [5], was mostly adopted for resistance welding of thermoplastic composites due to its simplicity in geometry and convenience for manufacturing.…”

Section: Introductionmentioning

confidence: 99%

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An investigation on the strain distribution of resistance welded thermoplastic composite joints

Shi¹,

Fernandez-Villegas²,

Bersee³

2012

53rd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials Conference

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In order to better understand the usefulness of single lap shear testing for the characterization of resistance welded thermoplastic composite joints, finite element method (FEM) and digital image correlation measurements (DIC) were combined to investigate the strain distributions of the joints during testing. Glass fibre reinforced Polyphenylene Sulfide (GF/PPS) was resistance welded in aid of a metal mesh. Shear and peel strain distributions were investigated at the joint overlap area. The effect of the resin fillet and metal mesh on the strain distributions and apparent shear strengths was investigated. A comparison between resistance welded and adhesively bonded GF/PPS joints was performed.

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Section: Effect Of the Heating Elementmentioning
confidence: 99%

Section: Introductionmentioning
confidence: 99%

An investigation on the strain distribution of resistance welded thermoplastic composite joints
Shi¹,
Fernandez-Villegas²,
Bersee³
2012
53rd AIAA/ASME/ASCE/AHS/ASC Structures, Structural Dynamics and Materials Conference
6
1
0
0
View full text Add to dashboard Cite

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“…The considered specimen geometry in all cases was the skin/stringer configuration with square-ended (non-tapered) flanges (Fig. 1) [15]. The skin laminate was 130 mm long and 25.4 mm wide and the flange was 50 mm long and 25.4 mm wide.…”

Section: Materials and Specimen Geometrymentioning
confidence: 99%

“…In a previous study, resistance welding of a special specimen geometry, called a skin/stringer specimen, was investigated [15]. The specimens were made of a flange laminate, representing a stringer or frame, welded onto a skin laminate.…”

Section: Introductionmentioning
confidence: 99%

“…Both the flange and skin laminates were made of quasi-isotropic APC-2/AS4 (carbon fibre/PEEK) composite. The welding parameters, mechanical performance and failure modes of the specimens were investigated [15]. The present study uses the same skin/stringer geometry and pursues two main objectives: to develop a new insulated heating element that prevents current leakage and to analyse the effects of this insulated heating element on the mechanical performance and failure modes of the welded skin/stringer specimens.…”

Section: Introductionmentioning
confidence: 99%

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Current leakage prevention in resistance welding of carbon fibre reinforced thermoplastics
Dubé
¹
,
Hubert
²
,
Yousefpour
³

et al. 2008
Composites Science and Technology
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Current leakage is a concern with resistance welding of carbon fibre reinforced thermoplastic composites. This phenomenon is particularly important when unidirectional adherends, with the carbon fibres parallel to the electrical current direction, are welded. In this investigation, a new electrically-insulated heating element consisting of a ceramic-coated (TiO 2 ) stainless steel mesh was developed to prevent current leakage. Special specimen geometry, called a skin/stringer configuration, was welded with this newly developed heating element to represent typical reinforced aerospace structures. The adherends were made of APC-2/AS4 (carbon fibre/PEEK) composites. Unidirectional specimens, which represent the most critical case, were first welded using the new heating element. The insulated heating element successfully prevented current leakage and showed great improvement in temperature homogeneity over the weld area. The impact of the new heating element on the mechanical performance of the welds was then assessed by welding quasi-isotropic specimens. The mechanical performances of quasi-isotropic specimens welded using the new insulated heating elements and conventional (non-insulated) ones were compared under short beam and three-point bending tests. No mechanical performance drawback was observed with the new heating element; however, the failure mode of the welded quasi-isotropic specimens was changed from a delamination in the skin laminate failure to a weld interface debonding failure.
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Joining: Thermoplastic Composites Fusion Bonding/Welding
Yousefpour
¹

2012
Wiley Encyclopedia of Composites
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As advanced composite structures become larger and more complex, there is a corresponding need to improve methods of joining and assembly. Current methods of joining composite materials for aerospace applications, that is, adhesive bonding and mechanical fastening, present some design and manufacturing limitations. The mechanical fastening method cannot be effectively applied to composite structures because of stress concentration, the effects of drilling on the structural integrity, and localized delamination. Poor bonding properties between adhesives and polymers make the adhesive bonding methods less desirable for most structural applications. The fact that thermoplastic materials can be remelted provides the opportunity of welding (or fusion bonding) of thermoplastic composite parts as an alternative to joining and assembly. Fusion bonding, in principle, consists of surface preparation, heating the polymer at the weld interface to a viscous state, physically causing polymer chains to interdiffuse across the interface, and cooling the polymer for consolidation. The polymer chains are intertwined across the interface during the welding process, resulting in disappearance of the bonded surface and improving the ability of transferring loads through the welded area. The quality of the welded parts is usually compared to that of autoclave consolidated or compression molded parts.

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Resistance welding of thermoplastic composites skin/stringer joints

Cited by 69 publications

References 13 publications

An investigation on the strain distribution of resistance welded thermoplastic composite joints

An investigation on the strain distribution of resistance welded thermoplastic composite joints

Current leakage prevention in resistance welding of carbon fibre reinforced thermoplastics

Joining: Thermoplastic Composites Fusion Bonding/Welding

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