Thermal Welding by the Third Phase Between Polymers: A Review for Ultrasonic Weld Technology Developments

Qiu, Jianhui; Zhang, Guohong; Sakai, Eiichi; Liu, Wendi; Zang, Limin

doi:10.3390/polym12040759

Cited by 26 publications

(11 citation statements)

References 126 publications

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“…The goal of welding thermoplastic polymeric materials is to form a welded seam that has almost the same mechanical properties as the material to be welded. 9 Welding quality generally depends on several process parameters, namely input energy, welding time, and the compression force exerted on the material layers at the weld zone.…”

Section: Welding Techniquesmentioning

confidence: 99%

Study of the compression properties of welded seams formed using hot wedge, hot air, ultrasonic, and high-frequency welding techniques

Marcelić

Geršak

Rogale

et al. 2022

Textile Research Journal

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The compression properties of welded seams depending on welding parameters using the hot wedge and hot air welding technique, ultrasonic welding technique, and high-frequency welding technique were studied. The compression properties, expressed by parameters such as compressional energy WC, compressional resilience RC, linearity LC, and compressibility C, are important information about the welded seam quality in terms of touch, voluminosity, stiffness, and flexibility of the welded seam. KES-FB and FAST measurement systems were used to test the compression properties of the welded seams. Based on the analysis of the results obtained, the influence of the welding parameters on the compression properties of the welded seam was determined. The results of the investigation showed that improperly selected welding parameters, such as the supply or introduction of too much heat into the material to be welded or too long exposure of the material in the weld zone to heat, result in welded seams with expressive extrusion edges, which affects the quality of the welded seams. These welded seams have very low values of compressional resilience RC and very high values of compressional energy WC and compressibility C.

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Section: Welding Techniquesmentioning

confidence: 99%

Study of the compression properties of welded seams formed using hot wedge, hot air, ultrasonic, and high-frequency welding techniques

Marcelić

Geršak

Rogale

et al. 2022

Textile Research Journal

View full text Add to dashboard Cite

show abstract

“…The topography of the material layer from the plate-type part is analyzed. Qiu et al [11] reviewed the advances of applying ultrasonic thermal welding by the third phase for thermoplastic materials to provide guidance for using ultrasonic thermal welding by the third phase in polymers. Jongbloed et al [12] studied heating in the continuous ultrasonic welding of thermoplastic composites.…”

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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“…In addition to continuous fiber or fabric reinforced polymer laminates, US welding is applied to join particulate polymer composites, the strength properties of which are much lower than those of reinforced polymer laminates [ 27 , 28 , 29 , 30 , 31 , 32 ]. Regardless of the particular type of adherends, an increased LSS can be attained by embedding reinforcing fabric between the components to be welded.…”

Section: Introductionmentioning

confidence: 99%

Optimizing Ultrasonic Welding Parameters for Multilayer Lap Joints of PEEK and Carbon Fibers by Neural Network Simulation

2022

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The aim of this study is to substantiate the use machine learning methods to optimize a combination of ultrasonic welding (USW) parameters for manufacturing of multilayer lap joints consisting of two outer PEEK layers, a middle prepreg of unidirectional carbon fibers (CFs), and two energy directors (EDs) between them. As a result, a mathematical problem associated with determining the optimal combination of technological parameters was formulated for the formation of USW joints possessing improved functional properties. In addition, a methodology was proposed to analyze the mechanical properties of USW joints based on neural network simulation (NNS). Experiments were performed, and threshold values of the optimality conditions for the USW parameters were chosen. Accordingly, NNS was carried out to determine the parameter ranges, showing that the developed optimality condition was insufficient and required correction, taking into account other significant structural characteristics of the formed USW joints. The NNS study enabled specification of an extra area of USW parameters that were not previously considered optimal when designing the experiment. The NNS-predicted USW mode (P = 1.5 atm, t = 800 ms, and τ = 1500 ms) ensured formation of a lap joint with the required mechanical and structural properties (σUTS = 80.5 MPa, ε = 4.2 mm, A = 273 N·m, and Δh = 0.30 mm).

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Thermal Welding by the Third Phase Between Polymers: A Review for Ultrasonic Weld Technology Developments

Cited by 26 publications

References 126 publications

Study of the compression properties of welded seams formed using hot wedge, hot air, ultrasonic, and high-frequency welding techniques

Study of the compression properties of welded seams formed using hot wedge, hot air, ultrasonic, and high-frequency welding techniques

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

Optimizing Ultrasonic Welding Parameters for Multilayer Lap Joints of PEEK and Carbon Fibers by Neural Network Simulation

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