Multifunctional films for thermoplastic composite joints: Ultrasonic welding and damage detection under tension loading

Li, Wencai; Frederick, Harry; Palardy, Geneviève

doi:10.1016/j.compositesa.2020.106221

Cited by 33 publications

(33 citation statements)

References 45 publications

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“…For the GF/PP adherends and MWCNT/PP films used in this study, their melting temperature ( T m ) was measured by differential scanning calorimetry (DSC) in a previous study [ 36 ]. The adherends’ T m was 150 °C, while the T m of the MWCNT/PP films varied between 141 °C and 149 °C.…”

Section: Resultsmentioning

confidence: 99%

“…MWCNT loading ratios equal to 15 wt.%, 20 wt.%, and 25 wt.% were purchased from Cheap Tubes Inc (Brattleboro, VT, USA). Those specific ratios were selected based on preliminary Joule heating experiments, previous work demonstrating suitability for ultrasonic welding [ 36 , 37 ] and literature on high content CNT-based polymer films for sensing, self-heating and resistance welding [ 38 , 39 , 44 , 45 ].…”

Section: Materials and Experimental Methodsmentioning

confidence: 99%

“…After reaching the prescribed travel value, a consolidation force of 1000 N, for a duration of 4 s, was applied. Those welding parameters were chosen based on previous research [ 36 , 37 ]. The power and travel curves with respect to welding time were acquired for each weld.…”

Section: Materials and Experimental Methodsmentioning

confidence: 99%

“…The contact between ED and adherend was defined as “Bonded”. The temperature at the interface was set at three values: 120 °C, 140 °C or 160 °C, based on the melting temperature of GF/PP adherends and MWCNT/PP films, between 140 °C and 150 °C [ 36 ]. Due to the orthotropic behavior of the adherends (UD layup), two thermal conductivity values ( k y , k x = k z ) were estimated using the rule of mixture shown in Equation (2) and Equation (3):

where V GF is the glass fiber volume fraction, k PP is the thermal conductivity of polypropylene (in W/m·K) and k GF is the thermal conductivity of glass fibers (in W/m·K).…”

Section: Prediction Of Heat-affected Zone For Disassembly Experimentsmentioning

confidence: 99%

“…While the USW process and bond strength have been extensively studied for a wide range of TPCs, there is limited research on structural health monitoring and repair of joints. Prior research has shown the potential for multifunctional, nanocomposite films as EDs for USW [ 36 , 37 ]. Those films, rendered electrically conductive by the addition of multi-walled carbon nanotubes (MWCNTs), enabled USW and structural health monitoring at the welded interface through electrical resistance changes.…”

Section: Introductionmentioning

confidence: 99%

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Disassembly Study of Ultrasonically Welded Thermoplastic Composite Joints via Resistance Heating

Frederick

Palardy

2021

Materials

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This manuscript explores the disassembly potential of ultrasonically welded thermoplastic composite joints for reuse or recycling through resistance heating via a nanocomposite film located at the welded interface. Nanocomposite films containing multi-walled carbon nanotubes (MWCNTs) were characterized for thermo-electrical behavior to assess self-heating. It was generally observed that maximum temperature increased with MWCNT and film thickness. To demonstrate potential for disassembly, glass fiber/polypropylene adherends were welded with nanocomposite films. Shear stress during disassembly was measured for three initial adherend’s surface temperatures. It was found that the required tensile load decreased by over 90% at the highest temperatures, effectively demonstrating the potential for disassembly via electrically conductive films. Fracture surfaces suggested that disassembly was facilitated through a combination of nanocomposite and matrix melting and weakened fiber–matrix interface. Limitations, such as slow heating rates and the loss of contact at the interface, imply that the method could be more suited for recycling, instead of repair and reuse, as the heat-affected zone extended through the adherends’ thickness at the overlap during heating.

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Section: Resultsmentioning

confidence: 99%

Section: Materials and Experimental Methodsmentioning

confidence: 99%

Section: Materials and Experimental Methodsmentioning

confidence: 99%

where V GF is the glass fiber volume fraction, k PP is the thermal conductivity of polypropylene (in W/m·K) and k GF is the thermal conductivity of glass fibers (in W/m·K).…”

Section: Prediction Of Heat-affected Zone For Disassembly Experimentsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Disassembly Study of Ultrasonically Welded Thermoplastic Composite Joints via Resistance Heating

Frederick

Palardy

2021

Materials

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Acrylonitrile‐butadiene‐lignin thermoplastic rubber adhesive for enhanced metal‐to‐metal joining

Yu,

Kanbargi,

Gupta

et al. 2024

Polymer Composites

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With the growing requirement for lightweight structural materials in automotive, aerospace, and infrastructure applications, multi‐material joints made with adhesive have attracted intense research interest. Commercial thermoset adhesives are one‐time cures, and difficult to disassemble the bonded components for repair and recycling. Our prior work with a thermoplastic acrylonitrile‐butadiene‐lignin rubber (ABL) addresses this sustainability/recycling challenge, but the adhesive exhibits deficient joining strength compared to standard thermosets. Here, we modify the ABL matrix by loading particulate fillers to enhance its modulus and toughness. The goal is to manufacture a cure‐free thermoplastic adhesive system with a simple dispensing protocol and characteristic ductility combined with a high yield stress for improved shear strength of a bonded joint. Fumed silica (FS) and epoxidized glass spheres (EGS) were used as fillers in the ABL to promote the dispersion of lignin particles that tailored the functionalities and free energy components of the adhesive surface. With optimal loading of FS (5 wt%) and EGS (30 wt%) in the ABL adhesive matrix, the lap‐shear strength of the bonded aluminum joint was elevated by 128%, compared to the neat ABL, reaching 21 MPa, which is 90% of the performance of a commercial epoxy‐based adhesive.Highlights A partly renewable filler‐toughened thermoplastic adhesive has been developed. This thermoplastic gives nearly equivalent performance of adhesively bonded aluminum joint compared to standard thermosets. Experimental and simulation data help understand the adhesive reinforcing mechanism by the fillers.

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Optimization of Hot Gas Welding of Hybrid Thermoplastic-Thermoset Composites Using Taguchi Method

Steiner,

Kuttner,

Lochner

et al. 2024

Appl Compos Mater

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In this study, the influence of four different process parameters on hot gas welding of CF/epoxy fiber composites functionalized with a PA6 thermoplastic film is investigated. Additional experiments are carried out on specimens adorned with triangular beads of coupling material that are printed onto the plates, ensuring extra material within the joining zone. This approach offers a great advantage for compensating geometric tolerances. The parameters considered are common process parameters for regular two-step processes: Heating element temperature (THE), heating time (HT), welding force (F) and welding time (HTF). The design of experiments (DoE) is planned according to the Taguchi method. An orthogonal array is used to set up the experimental plan. Three factor levels of each welding parameter are considered. The test series are carried out with two sample variants. In the second sample variant, additional thermoplastic material is placed in the joining zone. The strength of the welded joints is investigated by tensile shear tests according to DIN EN 1465. The results show that the welding force has the greatest influence on the welding strength. Heating times of 20 s were found to be optimal. Within the first sample variant, a saturation behavior of the welding force can be observed at 500 N. Higher heating element temperatures (500 °C) and welding forces (1165 N) are advantageous using additional material. High welding temperatures result in a negative effect on the interdiffusivity of the polymer chains.

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Multifunctional films for thermoplastic composite joints: Ultrasonic welding and damage detection under tension loading

Cited by 33 publications

References 45 publications

Disassembly Study of Ultrasonically Welded Thermoplastic Composite Joints via Resistance Heating

Disassembly Study of Ultrasonically Welded Thermoplastic Composite Joints via Resistance Heating

Acrylonitrile‐butadiene‐lignin thermoplastic rubber adhesive for enhanced metal‐to‐metal joining

Optimization of Hot Gas Welding of Hybrid Thermoplastic-Thermoset Composites Using Taguchi Method

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