A comparative static and dynamic behavior of thermoplastic composite joints produced using different joining techniques

Abstract

Thermoplastic composites are preferred over their thermosetting counterparts due to their high toughness, fast manufacturing cycle, and ease of recycling. Another advantage is the variety of techniques available to join these thermoplastic composites. This paper analyzes the static and dynamic behavior of glass fiber‐reinforced thermoplastic composite joints produced using different joining techniques. The composite materials were fabricated by compression molding of glass fabric and polypropylene (PP) matrix. These composites were joined using approaches like riveting, adhesive bonding, resistance welding, and hybrid joining techniques. The performance of these joints was analyzed under static and dynamic tensile loads. During the static test, the resistance welded joints showed superior performance as compared to the other joining techniques. The highest load of 2183 N was taken by the resistance welded sample, while the least (358 N) was taken by the mechanical joint. In dynamic testing, the resistance welded joints showed the least variation in the modulus during the dynamic test, showing a higher modulus as compared to the other joining techniques. The highest number of cycles to fail the joint was obtained for the mechanical joint, that is, 40,100, while a similar value was exhibited by the resistance welded joint (39,674). The static and dynamic test results showed resistance welding to be a promising approach for joining thermoplastic composites.

Multifactor optimization for induction welding of carbon fiber reinforced thermoplastic composites based on response surface methodology

“…Carbon fiber‐reinforced thermoplastic (CFRP) composites have been applied in aerospace and astronautics applications due to short forming cycles, high repair potential, and the possibility of automated joining by welding, such as elevators and rudder for the Gulfstream G650 1–7 . Owing to thermoplastic composites' remelting characteristics, many welding technologies have been developed, including resistance welding, ultrasonic welding, and induction welding 8–14 . These welding technologies can avoid shortcomings, including weight increase, stress concentration, and long production cycles in traditional joining methods 15–17 .…”

“…[1][2][3][4][5][6][7] Owing to thermoplastic composites' remelting characteristics, many welding technologies have been developed, including resistance welding, ultrasonic welding, and induction welding. [8][9][10][11][12][13][14] These welding technologies can avoid shortcomings, including weight increase, stress concentration, and long production cycles in traditional joining methods. [15][16][17] Induction welding is considered to be one of the most promising joining techniques for CFRP composites due to its high efficiency and selectivity of the heated area, which is particularly suitable for the automated manufacture of large joining structures thanks to its ability to achieve continuous welding by moving the induction coil along the specific path.…”