Effect of interfacial preheating on welded joints during ultrasonic composite welding

Wang, Kaifeng; Li, Yang; Banu, Mihaela; Li, Jingjing; Guo, Weihong; Khan, Haris Ali

doi:10.1016/j.jmatprotec.2017.03.014

Cited by 36 publications

(8 citation statements)

References 9 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The ultrasonic welding quality is controlled or affected by many welding parameters associated with the welding procedure. Some of the important welding parameters are the vibration amplitude, power, energy, weld time, vertical displacement during welding, applied weld force before, during and after the welding, and the hold time [83,92]. Weld energy, weld time and vertical displacement during welding are mutually exclusive as well.…”

Section: Ultrasonic Welding Parametersmentioning

confidence: 99%

See 1 more Smart Citation

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

et al. 2020

View full text Add to dashboard Cite

The ultrasonic welding (UW) technique is an ultra-fast joining process, and it is used to join thermoplastic composite structures, and provides an excellent bonding strength. It is more cost-efficient as opposed to the conventional adhesive, mechanical and other joining methods. This review paper presents the detailed progress made by the scientific and research community to date in the direction of the UW of thermoplastic composites. The focus of this paper is to review the recent development of the ultrasonic welding technique for thermoplastic composites to thermoplastic composites, and to dissimilar materials. Different ultrasonic welding modes and their processing parameters, namely, weld time, weld pressure, amplitude, type of energy directors (EDs) affecting the welding quality and the advantages and disadvantages of UW over other bonding techniques, are summarized. The current state of the ultrasonic welding of thermoplastic composites and their future perspectives are also deliberated.

show abstract

Section: Ultrasonic Welding Parametersmentioning

confidence: 99%

“…Out of these variable parameters, the parameter which significantly affects the welding quality is the amplitude of vibration, weld time and the load applied [51,83,92,94]. The welding load applied, and the vibration amplitude determines the rate at which heat is generated at the interface during welding.…”

Section: Ultrasonic Welding Parametersmentioning

confidence: 99%

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

et al. 2020

View full text Add to dashboard Cite

show abstract

“…Despite the potential advantages, the special shapes of EDs (e.g., triangular and semicircular EDs) increase the manufacturing cost, and thereafter, two alternative approaches were proposed to concentrate the welding energy through decreasing the stiffness of the welding layer: (1) softening the welding layer, i.e., heating the part interface, and (2) adding a soft layer between the part interface, which works as a flat ED. Wang et al [15] investigated the effects of preheating temperature and preheating time on the final joint quality and found that interfacial preheating could localize welding pressure and enhance the welding energy efficiency. However, the heating process was controlled manually, and it was hard to 1 maintain an accurate temperature.…”

Section: Introductionmentioning

confidence: 99%

Investigation of Ultrasonically Welded Thermoplastic Composite Joints Using Netlike Energy Directors

Wang

et al. 2021

Journal of Manufacturing Science and Engineering

Self Cite

View full text Add to dashboard Cite

This paper proposes a netlike energy director (ED) made of carbon fiber-reinforced thermoplastic (CFRP) composites to improve the ultrasonic welding energy efficiency. To explore the benefits of using netlike EDs, the joint qualities with flat EDs and without EDs are included for references. Also, the influence of the netlike ED geometry (i.e., hexagonal nets with different side lengths and thicknesses) on weld attributes and joint quality are investigated in terms of joint cross-sectional microstructure, fracture morphology, and maximum shear load. It is found that for both the netlike and flat EDs, the welding process can be accelerated compared to the one without EDs, which is caused by the concentration of welding energy into the expected welding region and the avoidance of welding edges introduced by surface curvature. Meanwhile, compared with flat EDs, the maximum shear loads of the joints with netlike EDs are improved, introduced by the decrease of the contact area and consequent higher cyclic strain, resulting in more melted materials during the ultrasonic welding process. However, with the increasing of the netlike ED thickness, more porosities are generated in the welding layer leading to reduced bonded region and decrease of the maximum shear load. From the joint fracture morphology analysis, it is found that the netlike EDs introduces carbon fibers in the welding layer, and the fracture modes include fiber-matrix debonding and fiber pull-out in addition to polymer fracture, confirming the feasibility of improving joint quality by introducing CFRP netlike EDs.

show abstract

“…25 On the other hand, the ultrasonic consolidation of thermoplastic composites is promising because it is distinguished by low energy consumption, rapid bonding, and ease of automation. [26][27][28][29][30] During ultrasonic consolidation, composites are heated by molecular chains of friction under pressure, and low amplitude (typically 1-100 μm) and high frequency (typically 10-40 kHz) ultrasonic vibration. Continuous GF/polypropylene, GF/high-density polyethylene (HDPE), and CF/polyethylene terephthalate (PET) have been fabricated by auto fiber placement (AFP) using ultrasonic consolidation.…”

Section: Introductionmentioning

confidence: 99%

“…On the other hand, the ultrasonic consolidation of thermoplastic composites is promising because it is distinguished by low energy consumption, rapid bonding, and ease of automation 26–30 . During ultrasonic consolidation, composites are heated by molecular chains of friction under pressure, and low amplitude (typically 1‐100 μm) and high frequency (typically 10‐40 kHz) ultrasonic vibration.…”

Section: Introductionmentioning

confidence: 99%

Ultrafast printing of continuous fiber‐reinforced thermoplastic composites with ultrahigh mechanical performance by ultrasonic‐assisted laminated object manufacturing

Chang

Parandoush

et al. 2020

Polymer Composites

View full text Add to dashboard Cite

Additive manufacturing (AM) of continuous fiber-reinforced thermoplastic composites (CFRTPCs) has drawn increasing interest and great attention in academic and industrial communities due to its capability of manufacturing complex lightweight structures with high strength at a low cost. In this study, we proposed a novel AM technique to fabricate CFRTPCs using carbon fiber prepreg sheets based on a novel method: ultrasonic-assisted laminated object manufacturing (UA-LOM). The prepreg sheets were first cut into 2D shapes, then every eight layers of the sheets were successively consolidated by an ultrasonic-vibration roller to fabricate one 3D composite part at a faster speed than conventional AM processes where materials are deposited layer by layer. Samples with controlled fiber alignments were prepared for mechanical tests. The post-processing hot press was carried out to further improve mechanical properties of the additively manufactured components. Results showed that the unidirectional composite samples displayed an ultra-high tensile strength of 1760.2 (±71.7) MPa and a tensile modulus of 105.7 (±7.2) GPa. The proposed method exhibited superior mechanical performance compared to state-of-theart AM techniques. The hot-press-treated AM composite parts in this work approached the benchmark mechanical properties provided by the prepreg manufacturing company using traditional fabrication methods. Overall, the proposed AM methods of CFRTPCs show great potential applications in aerospace and transportation industries.

show abstract

Effect of interfacial preheating on welded joints during ultrasonic composite welding

Cited by 36 publications

References 9 publications

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

Investigation of Ultrasonically Welded Thermoplastic Composite Joints Using Netlike Energy Directors

Ultrafast printing of continuous fiber‐reinforced thermoplastic composites with ultrahigh mechanical performance by ultrasonic‐assisted laminated object manufacturing

Contact Info

Product

Resources

About