Ultrasonic welding of PEEK graphite APC‐2 composites

Benatar, Avraham; Gutowski, Timothy G.

doi:10.1002/pen.760292313

Cited by 142 publications

(139 citation statements)

References 8 publications

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“…Once the temperature at the energy directors reaches the melting temperature, it flows under the application of pressure. The flowing polymer wets the interface and diffusion and entanglement of polymer chains occur across the interface, thereby resulting in a weld [28].…”

Section: Ultrasonic Weldingmentioning

confidence: 99%

“…Benatar [28] showed that the ultrasonic welding process model could be divided into five steps: (1) mechanics and vibration of the parts, fixture, and welder, (2) viscoelastic heating due to intermolecular friction, (3) heat transfer from energy directors to the composites, (4) flow of the molten energy directors and wetting of the composite surfaces, and (5) intermolecular diffusion of polymer chains across the interface and their entanglement [28]. The ultrasonic welding process model shows the potential for on-line monitoring of joint quality through measurement of the dynamic mechanical impedance of the parts during welding.…”

Section: Fusion Bonding/welding Of Thermoplastic Compositesmentioning

confidence: 99%

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Fusion Bonding/Welding of Thermoplastic Composites

Yousefpour

Hojjati²,

Immarigeon

2004

Journal of Thermoplastic Composite Materials

381

223

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Joining of thermoplastic composites is an important step in the manufacturing of aerospace thermoplastic composite structures. Therefore, several joining methods for thermoplastic composite components have been under investigation and development. In general, joining of thermoplastic composites can be categorized into mechanical fastening, adhesive bonding, solvent bonding, co-consolidation, and fusion bonding or welding. Fusion bonding or welding has great potential for the joining, assembly, and repair of thermoplastic composite components and also offers many advantages over other joining techniques. The process of fusion-bonding involves heating and melting the polymer on the bond surfaces of the components and then pressing these surfaces together for polymer solidification and consolidation. The focus of this paper is to review the different fusion-bonding methods for thermoplastic composite components and present recent developments in this area. The various welding techniques and the corresponding manufacturing methodologies, the required equipment, the effects of processing parameters on weld performance and quality, the advantages/disadvantages of each technique, and the applications are described.

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Section: Ultrasonic Weldingmentioning

confidence: 99%

Section: Fusion Bonding/welding Of Thermoplastic Compositesmentioning

confidence: 99%

Fusion Bonding/Welding of Thermoplastic Composites

Yousefpour

Hojjati²,

Immarigeon

2004

Journal of Thermoplastic Composite Materials

381

223

View full text Add to dashboard Cite

show abstract

“…1 The feasibility of using fusion bonding technology for large-scale composite joining applications was demonstrated in the assembly of an aircraft structure whereby part count, weight, and assembly time were reduced by using a thermoplastic polymer fusion bonding technique. 2 Fusion bonding techniques are classified by the method of heat generation -infrared, 3 hot plate, 4 ultrasonic, 5 resistance, 6,7 and induction. [8][9][10] Resistance welding is one of the most promising, nearterm fusion bonding techniques, as it utilizes conventional equipment to provide controllable heat generation at the joint interface.…”

Section: Introductionmentioning

confidence: 99%

Scaling issues in resistance-welded thermoplastic composite joints

McKnight

Holmes

Gillespie

et al. 1997

Adv. Polym. Technol.

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Resistance welding has been demonstrated as a viable technique for joining thermoplastic composites. Extensive research has been conducted in previous studies on the processing and postprocessing evaluation of coupon‐sized resistance welded specimens using this thermoplastic fusion bonding technique. This work focuses on the manufacturing and evaluation of large‐scale resistance welds used to join carbon fiber (CF)/polyetheretherketone (PEEK) thermoplastic composite parts. Applications using the present resistance welding technology are assessed, and potential applications of resistance welding are discussed. The sequential resistance welding process is introduced as an approach to large‐scale welding that increases joint quality and performance while maintaining modest pressure and weld power requirements. The single‐step and alternate multiple‐step (sequential) techniques are implemented for large‐scale resistance welds of CF/PEEK adherends comolded with polyetherimide (PEI) (i.e., the Thermabond® process). Nondestructive ultrasonic evaluation, mechanical testing, fractography, and microscopy show that: (1) a higher weld uniformity was obtained with the multiple‐step weld than the single‐step weld; and (2) uneven heating and overheating were minimized by reducing the heating element length within the bond region through the use of the sequential resistance welding process. The different welding techniques produce a large variation in lap shear strength; direct comparison of the weld quality and lap shear strength shows that the sequential resistance welding process yields a superior bond. With the principles developed in this investigation, resistance welding can be used to join large‐scale thermoplastic composite parts with consistent, high levels of performance and quality. © 1997 John Wiley & Sons, Inc. Adv in Polym Techn 16: 279–295, 1997

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“…3 Although the ultrasonic welding process has been developed for more than three decades, the research effort that has been devoted to this technique is limited. Benatar and his co-workers [4][5][6] completed research in both near-field and far-field welding of different thermoplastics, including polystyrene, ABS, polyethylene, polypropylene, and PEEK graphite composites. They proposed a lumped parameter model to predict the heating rates and energy dissipation of the ultrasonic welding.…”

mentioning

confidence: 99%

Optimizing the joint strength of ultrasonically welded thermoplastics

Liu

Lin

Chang

et al. 1999

Adv. Polym. Technol.

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Ultrasonic welding of thermoplastics has become an important process in industry because of its relatively low cost and its high quality joints. However, the optimization of this technique has been essentially based on a trial‐and‐error process. In this report, an L18 experimental matrix design based on the Taguchi method was conducted to optimize the joint strength of ultrasonically welded thermoplastics. For the factors selected in the main experiments, weld time and amplitude of vibration were found to be the principal factors affecting the joint property of ultrasonically welded thermoplastics. A weldability diagram was proposed based on the statistical results to give first guidelines for system optimization. In addition, amorphous polymers required less energy to be successfully welded than semicrystalline polymers. Semicircular energy directors were found to bond parts of highest strengths. © 1999 John Wiley & Sons, Inc. Adv Polym Techn 18: 125–135, 1999

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Ultrasonic welding of PEEK graphite APC‐2 composites

Cited by 142 publications

References 8 publications

Fusion Bonding/Welding of Thermoplastic Composites

Fusion Bonding/Welding of Thermoplastic Composites

Scaling issues in resistance-welded thermoplastic composite joints

Optimizing the joint strength of ultrasonically welded thermoplastics

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