Hybrid welding of carbon-fiber reinforced epoxy based composites

Francesca Lionetto*, M. De Nicolas Morillas, Silvio Pappadà, Giuseppe Buccoliero, Irene Fernandez Villegas, Alfonso Maffezzoli

*Corresponding author for this work

Research output: Contribution to journalArticleScientificpeer-review

72 Citations (Scopus)
74 Downloads (Pure)


The approach for joining thermosetting matrix composites (TSCs) proposed in this study is based on the use of a low melting co-cured thermoplastic film, added as a last ply in the stacking sequence of the composite laminate. During curing, the thermoplastic film partially penetrates in the first layer of the thermosetting composite, leading to macro-mechanical interlocking as the main connection mechanism between the thermoplastic film and the underlying composite. After curing, the thermosetting composite joints with the thermoplastic modified surface can be assembled by welding. Welding of the TSC-TSC joints is performed by ultrasonic and induction welding. The weld strength is investigated by morphological characterization of cross sections and failure surfaces and by mechanical testing. The effect of the thermoplastic film thickness on the welding process and on its outcome is also analyzed. Both induction and ultrasonic welding mostly result in good-quality welded joints. The welding process used as well as the initial thickness of the thermoplastic film are found to have a significant effect on the final thickness of the weld line and on the location of failure. Thicker thermoplastic films are found to ease the welding processes.

Original languageEnglish
Pages (from-to)32-40
Number of pages9
JournalComposites Part A: Applied Science and Manufacturing
Publication statusPublished - 1 Jan 2018


  • A. Polymer-matrix composites (PMCs)
  • B. Adhesion
  • D. Microstructural analysis
  • E. Assembly


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