Optimization of thermoplastic composites resistance welding parameters based on transient heat transfer finite element modeling

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DOIResolve DOI: http://doi.org/10.1177/0892705711428657
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TypeArticle
Journal titleJournal of Thermoplastic Composite Materials
ISSN0892-7057
Volume26
Issue5
Pages699717; # of pages: 19
SubjectExperimental datum; Finite element modeling; Finite element models; Heat transfer mechanism; Joints/joining; Mechanical performance; Thermoplastic composite; Transient heat transfer; Composite materials; Finite element method; Heat transfer; Optimization; Polymer matrix composites; Resistance welding; Thermoplastics; Three dimensional computer graphics; Welds; Three dimensional
AbstractThe use of resistance welding technology to join thermoplastic composite aerospace structures is still contingent upon a better understanding of the heat transfer mechanisms occurring during welding, which govern the joint quality and mechanical performance. In this study, two-dimensional (2D) and three-dimensional (3D) transient heat transfer finite element models were developed to simulate resistance welding of thermoplastic composites. The 2D model was used to investigate the effect of the length of the exposed areas of the heating element to air (clamping distance) on the local overheating at the edges and the effects of the input power level on the thermal behavior of the welds. It is shown that controlling the clamping distance improves the thermal uniformity of the weld. The 3D model shows that heat conduction along the length of the laminates influences the thermal uniformity of the weld interface. An optimization chart is developed in order to minimize the undesirable edge effect and to define the conditions required to obtain a complete weld. The results of the 3D model are compared with experimental data. © The Author(s) 2011.
Publication date
LanguageEnglish
AffiliationNational Research Council Canada (NRC-CNRC); Aerospace (AERO-AERO)
Peer reviewedYes
NPARC number21269659
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Record identifierb9c41e04-79b2-4aae-9f2d-3a9435262ebb
Record created2013-12-13
Record modified2016-05-09
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