Process and performance evaluation of ultrasonic, induction and resistance welding of advanced thermoplastic composites

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DOIResolve DOI: http://doi.org/10.1177/0892705712456031
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TypeArticle
Journal titleJournal of Thermoplastic Composite Materials
ISSN0892-7057
Volume26
Issue8
Pages10071024; # of pages: 18
SubjectComparative analysis; Comparative evaluations; Dynamic mechanical; Fatigue performance; Induction welding; Polyphenylene sulphide; Static mechanical properties; Thermoplastic composite; Carbon fibers; Composite materials; Mechanical properties; Reinforcement; Resistance welding; Stainless steel; Thermoplastics; Ultrasonic welding; Welding
AbstractThe possibility of assembling through welding is one of the major features of thermoplastic composites and it positively contributes to their cost-effectiveness in manufacturing. This article presents a comparative evaluation of ultrasonic, induction and resistance welding of individual carbon fibre-reinforced polyphenylene sulphide (PPS) thermoplastic composite samples that comprises an analysis of the static and dynamic mechanical behaviour of the joints as well as of the main process variables. The induction welding process as used in this research benefitted from the conductive nature of the reinforcing fibres. Hence, no susceptor was placed at the welding interface. Resistance welding used a fine-woven stainless-steel mesh as the heating element and low welding pressures and times were applied to prevent current leakage. Triangular energy directors moulded on a separate tape of PPS resin were used to concentrate ultrasonic heat at the welding interface. The static single-lap shear strength of the joints was found similar for induction and ultrasonic welding. A 15% drop in the static mechanical properties of the resistance welded joints was attributed to incomplete welded overlaps following current leakage prevention. However, the fatigue performance relative to the static one was similar for the three sorts of joints. A comparative analysis of process variables such as welding time, required power and energy was also carried out. © The Author(s) 2012.
Publication date
LanguageEnglish
AffiliationNational Research Council Canada (NRC-CNRC)
Peer reviewedYes
NPARC number21270669
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Record identifier3de4cc36-d796-4061-9947-d77b091564c3
Record created2014-02-17
Record modified2016-05-09
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