Heat distribution simulation and effects of ultrasonic welding amplitude on carbon fiber/polyetherimide composite joint properties

Wang, Jing; Lü, Chang; Xiao, Cunyong; Cheng, Jian; Ren, Rong; Xiong, Xuhai

doi:10.1016/j.matlet.2023.134148

Cited by 5 publications

(4 citation statements)

References 8 publications

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“…The obtained result was superior to previously published data for the PEI-b laminates, and slightly inferior to those based on polyphenylsulfide (PPS). For exam LSS was 16.5 MPa for the US-welded PEI-based laminates [38], while it was 33.5 ± 1.4 for the PPS-based ones [3]. Figure 7 shows the LSS versus USW duration dependencies.…”

Section: Tensile Testsmentioning

confidence: 99%

“…The obtained result was superior to previously published data for the PEI-based laminates, and slightly inferior to those based on polyphenylsulfide (PPS). For example, LSS was 16.5 MPa for the US-welded PEI-based laminates [38], while it was 33.5 ± 1.4 MPa for the PPS-based ones [3]. Figure 8 shows general views of the fractured EDTecaPEI lap joints after the tensile tests, including those characterizing damage to the CF fabric-PEI laminate adjacent to the sonotrode in the USW process.…”

Section: Tensile Testsmentioning

confidence: 99%

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Effect of the Energy Director Material on the Structure and Properties of Ultrasonic Welded Lap Joints of PEI Plates with CF Fabric/PEI Prepreg

Tian,

Alexenko,

Panin

et al. 2024

J. Compos. Sci.

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To estimate the possibility of using both low-melting TecaPEI and neat PEI films as energy directors (EDs) for ultrasonic welding (USW) of carbon fiber (CF) fabric–polyetherimide (PEI) laminates, some patterns of structure formation and mechanical properties of their lap joints were investigated by varying the process parameters. The experiment was planned by the Taguchi method with the L9 orthogonal matrix. Based on the obtained results, USW parameters were optimized accounting for maintaining the structural integrity of the joined components and improving their functional characteristics. The use of the low-melting EDTecaPEI film enabled US-welding the laminates with minimal damage to the fusion zone, and the achieved lap shear strength (LSS) values of ~7.6 MPa were low. The use of EDSolverPEI excluded thermal degradation of the components as well as damage to the fusion zone, and improved LSS values to 21 MPa. With the use of digital image correlation (DIC) and computed tomography (CT) techniques, the structural factors affecting the deformation behavior of the USW lap joints were justified. A scheme was proposed that established the relationship between structural factors and the deformation response of the USW lap joints under static tension. The TecaPEI film can be used in USW procedures when very high interlayer adhesion properties are not on demand.

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Section: Tensile Testsmentioning

confidence: 99%

Section: Tensile Testsmentioning

confidence: 99%

Effect of the Energy Director Material on the Structure and Properties of Ultrasonic Welded Lap Joints of PEI Plates with CF Fabric/PEI Prepreg

Tian,

Alexenko,

Panin

et al. 2024

J. Compos. Sci.

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“…The root mean square of amplitude variation with time of R1 and R5 are smaller than other, while the root mean square of amplitude variation at R4 is the largest. Different amplitudes have different effects on the molten pool [25]. Therefore, the position with stable amplitude can promote the stable action of ultrasonic vibration on the molten pool and improve the microstructure of welded joints.…”

Section: The Distribution Characteristics Of Ultrasonic Fieldmentioning

confidence: 99%

The Effect of the Distance between Ultrasonic Horn and Torch on the Microstructure of Ultrasonic-Assisted Gas Tungsten Arc Welded Inconel 690 Alloy Joint

Xia,

Cai,

Dong

et al. 2023

Crystals

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The study focuses on investigating the relationship between the ultrasonic effect and microstructure of ultrasonic-assisted gas tungsten arc welding (UA-GTAW) Inconel690 alloy joints. The influence of ultrasonic vibrations on Inconel690 plates was examined, while also clarifying the distribution pattern of the ultrasonic effect across the plate. Furthermore, actual welding experiments were performed by varying the distance between the ultrasonic horn and the welding torch. The results revealed that there were changes in both grain growth direction within the weld zone and refinement effects achieved under different distances. The optimal refinement of primary and secondary dendrite arm spacing was observed at distances of 60 mm and 180 mm between the welding torch and ultrasonic horn. The hardness of weld zone reached 235HV1 when the distance between ultrasonic horn and welding torch is 180 mm.

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“…The USW assisted fabrication of laminates is an actual issue nowadays. It is caused by several reasons, including: a) nonstationary development of the process in time associated with the non-linear heating of the components being joined [12][13][14] (in contrast to molding in stacks); b) one-sided input of acoustic energy, converted into frictional heating of the fusion zone [15][16][17]; c) simultaneous development of the structure formation processes at several interfaces [18,19]; d) significant differences in the elastic properties of the laminate components, including those affecting the propagation pattern of ultrasonic vibrations [20], etc. One of the efficient options for solving this issue is the use of prepregs based on reinforcing fibers (or fabrics) and the thermoplastic binders [21], as noted above.…”

Section: Introductionmentioning

confidence: 99%

Ultrasonic welding of lap joints of PEI plates with PEI/CF-fabric prepregs

Alexenko,

Tian,

Panin

et al. 2024

Frattura Ed Integrità Strutturale

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In this study, ultrasonic welding (USW) of lap joints of polyetherimide (PEI) plates (adherends) with carbon fiber (CF) prepregs impregnated with PEI was investigated. No energy director (ED) was used, so binder contents were varied in the prepregs to compensate for the lack of the polymer in the fusion zone. In addition, the effect of the USW parameters on the structure and the mechanical properties of the lap-joints were analyzed. The most homogeneous macrostructure, the maintained structural integrity of both the CF-fabric in the prepregs and the lap-joined PEI adherends, as well as the maximum strength properties (tensile strength) were revealed for the USW joints with the minimum polymer content in the prepreg. In this case, rising the USW time from 400 up to 800 ms radically changed the macrostructure of the fusion zone, while the strength properties did not vary significantly (shear stresses were 42–48 MPa). Computer simulation of the influence of the PEI/CF-fabric ratios in the prepregs on the deformation response of the USW joints showed that the prepreg thicknesses and, accordingly, the PEI/CF ratios did not exert a noticeable effect on the strain–stress (tensile) diagrams, while the determining factor was the adhesion level.

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Heat distribution simulation and effects of ultrasonic welding amplitude on carbon fiber/polyetherimide composite joint properties

Cited by 5 publications

References 8 publications

Effect of the Energy Director Material on the Structure and Properties of Ultrasonic Welded Lap Joints of PEI Plates with CF Fabric/PEI Prepreg

Effect of the Energy Director Material on the Structure and Properties of Ultrasonic Welded Lap Joints of PEI Plates with CF Fabric/PEI Prepreg

The Effect of the Distance between Ultrasonic Horn and Torch on the Microstructure of Ultrasonic-Assisted Gas Tungsten Arc Welded Inconel 690 Alloy Joint

Ultrasonic welding of lap joints of PEI plates with PEI/CF-fabric prepregs

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