Ultrasonic welding of CF/PPS composites with integrated triangular energy directors: melting, flow and weld strength development

Villegas, Irene Fernández; Palardy, Geneviève

doi:10.1080/09276440.2017.1236626

Cited by 46 publications

(43 citation statements)

References 20 publications

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“…For the welding study, thermoplastic composite laminates were also manufactured with the integrated ED of semi-circular configuration, as recommended by many researchers in the literature [24,34,60]. The below subsections will give further details regarding the entire manufacturing process.…”

Section: Manufacturing Of Energy Director (Ed) Integrated Laminatesmentioning

confidence: 99%

Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

et al. 2020

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Joining large and complex polymer-matrix composite structures is becoming increasingly important in industries such as automobiles, aerospace, sports, wind turbines, and others. Ultrasonic welding is an ultra-fast joining process and also provides excellent joint quality as a cost-effective alternative to other joining processes. This research aims at investigating the welding characteristics of novel methyl methacrylate Elium ® , a liquid thermoplastic resin. Elium ® is the first of its kind of thermoplastic resin, which is curable at room temperature and is suitable for mass production processes. The welding characteristics of Elium ® composites were investigated by optimizing the welding parameters with specially designed integrated energy directors (ED) and manufactured using the Resin transfer molding process. The results showed a 23% higher lap shear strength for ultrasonically welded composite joints when compared to the adhesively bonded joints. The optimized welding time for the ultrasonic welded joint was found to be 1.5 s whereas it was 10 min for the adhesively bonded joint. Fractographic analysis showed the significant plastic deformation and shear cusps formation on the fractured surface, which are typical characteristics for strong interfacial bonding.

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Section: Manufacturing Of Energy Director (Ed) Integrated Laminatesmentioning

confidence: 99%

Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

et al. 2020

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“…For welding study, thermoplastic composite laminates were manufactured with ED of varied configurations, namely semi-circular, triangular, and flat, as recommended by many researchers in the literature [25,34,64]. The below subsections will give further details regarding the entire manufacturing process.…”

Section: Manufacturing Of Ed Integrated Thermoplastic Composite Laminmentioning

confidence: 99%

“…Two configurations of semi-circular energy directors were manufactured, namely single semi-circular Elium ® composite laminate (SC-ELC) and double semi-circular Elium ® composite laminate (2SC-ELC), as described in Table 2. the literature [25,34,64]. The below subsections will give further details regarding the entire manufacturing process.…”

Section: Mold Designmentioning

confidence: 99%

“…Subsequently, the laminate injection pressure was kept at 2bar pressure, but the outlet was kept at a partial vacuum of 505 mbar with a view to remove the entrapped air in the mould before injection, but the manufactured ED integrated laminate still showed small bubble content. The inlet condition was changed, and the resin was injected at 5-bar the literature [25,34,64]. The below subsections will give further details regarding the entire manufacturing process.…”

Section: Manufacturingmentioning

confidence: 99%

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Ultrasonic Welding of Novel Carbon/Elium® Thermoplastic Composites with Flat and Integrated Energy Directors: Lap Shear Characterisation and Fractographic Investigation

et al. 2020

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The current research work presents a first attempt to investigate the welding attributes of Elium® thermoplastic resin and the fusion bonding using ultrafast ultrasonic welding technique. The integrated energy director (ED) polymer-matrix composites (PMCs) panel manufacturing was carried out using the Resin Transfer Moulding (RTM) technique and the scheme is deduced to manufacture a bubble-free panel. Integrated ED configurations and flat specimens with Elium® film of different thickness at the interface were investigated for ultrasonic welding optimization. Optimised weld time for integrated ED and flat Elium® panels with film (0.5 mm thick) configuration was found to be 1 s and 5.5 s, respectively. The ED integrated configuration showed the best welding results with a lap shear strength of 18.68 MPa. The morphological assessment has shown significant plastic deformation of Elium® resin and the shear cusps formation, which enhances the welding strength. This research has the potential to open up an excellent and automated way of joining Elium® composite parts in automotive, wind turbines, sports, and many other industrial applications.

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“…There are considerable research literatures on the USW process for thermoplastic materials at the coupon level [125][126][127][128][129][130][131][132][133][134][135]. The welded condition parameters including welding time, welding pressure, and vibration amplitude, were investigated and the relationship between the welded ability and the parameters were reported.…”

Section: New Ultrasonic Welding Application For Polymersmentioning

confidence: 99%

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

et al. 2020

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Ultrasonic welding (USW) is a promising method for the welds between dissimilar materials. Ultrasonic thermal welding by the third phase (TWTP) method was proposed in combination with the formation of a third phase, which was confirmed as an effective technology for polymer welding between the two dissimilar materials compared with the traditional USW. This review focused on the advances of applying the ultrasonic TWTP for thermoplastic materials. The research development on the ultrasonic TWTP of polycarbonate (PC) and polymethyl methacrylate (PMMA), polylactic acid (PLA) and polyformaldehyde (POM), and PLA and PMMA are summarized according to the preparation of the third phase, welded strength, morphologies of rupture surfaces, thermal stability, and others. The review aimed at providing guidance for using ultrasonic TWTP in polymers and a basic understanding of the welding mechanism, i.e., interdiffusion and molecular motion mechanisms between the phases.

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Ultrasonic welding of CF/PPS composites with integrated triangular energy directors: melting, flow and weld strength development

Cited by 46 publications

References 20 publications

Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

Ultrasonic Welding of Novel Carbon/Elium® Thermoplastic Composites with Flat and Integrated Energy Directors: Lap Shear Characterisation and Fractographic Investigation

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

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