Acousto-ultrasonic composite transducers integration into thermoplastic composite structures via ultrasonic welding

Shankar Galiana*, M. Moradi, Peter Wierach, D. Zarouchas

*Corresponding author for this work

Research output: Chapter in Book/Conference proceedings/Edited volumeConference contributionScientificpeer-review

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Abstract

Acousto-ultrasonic composite transducers (AUCT), which are made of piezoceramic materials embedded in a reinforced polymeric matrix, are promising for the health monitoring of composite structures. However, when they are integrated into highly loaded thermoplastic composite structures, ensuring proper joining properties is a challenge. The conventional approach of attaching the AUCT using adhesive may not be sufficiently reliable in aeronautic applications for low surface energy materials such as polyaryletherketone composites, where surface treatments are needed for adhesion. Welding techniques can be used to create a joint in which the interface material interfuses with the AUCT embedment and the structure matrix, resulting in a homogeneous interface with properties comparable to the host structure matrix throughout its service life. With this in mind, the main objective of the present work is to investigate the viability of attaching AUCT to low-melting polyaryletherketone carbon fiber reinforced thermoplastic composite structures using the ultrasonic welding (UW) procedure and characterize the joint performance. The ultrasonic welded joint using an external energy director in the interface is investigated by comparing the findings to those of a reference AUCT system integrated into the structure with autoclave co-consolidation. Infrared thermography is employed to monitor the process, and a parameter study of the UW process is carried out. The AUCT survivability during the UW process is determined by measuring the capacitance, and C-scan is used to assess joint quality. The results show the challenges of attaching AUCT to thermoplastic composite structures using UW and surviving the procedure.
Original languageEnglish
Title of host publicationProceedings of the 10th ECCOMAS Thematic Conference on Smart Structures and Materials
Place of PublicationPatras, Greece
Pages956-965
Number of pages10
Volume10
DOIs
Publication statusPublished - 2023
Event10th ECCOMAS Thematic Conference on Smart Structures and Materials - Patras, Greece
Duration: 3 Jul 20235 Jul 2023
Conference number: 10

Conference

Conference10th ECCOMAS Thematic Conference on Smart Structures and Materials
Abbreviated titleECCOMAS SMART 2023
Country/TerritoryGreece
CityPatras
Period3/07/235/07/23

Keywords

  • Structural Health Monitoring
  • Piezoelectric Transducers
  • Composite materials
  • Ultrasonic Welding
  • Guided waves
  • SHM

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