Towards robust sequential ultrasonic spot welding of thermoplastic composites: Welding process control strategy for consistent weld quality

Tian Zhao, Charlotte Broek, Genevieve Palardy, Irene Fernandez Villegas, Rinze Benedictus

Research output: Contribution to journalArticleScientificpeer-review

13 Citations (Scopus)
14 Downloads (Pure)

Abstract

The research in this paper is an essential part of a bigger effort on developing robust sequential ultrasonic welding of multi-spot welded joints in thermoplastic composites. It mainly focused on assessing the impact of the changes in boundary conditions on the welding process and whether it could be circumvented by using an appropriate process control strategy. A two-step approach was followed by investigating: (1) the effect of boundary conditions on displacement- and energy-controlled single-spot welded joints and (2) displacement- and energy-controlled sequential ultrasonic welding of double-spot welded joints. The results showed that previous spots indeed affect the energy required to obtain an optimum new welded spot, which challenges the use of energy-controlled welding for this application. Contrarily, displacement-controlled welding was shown to provide consistent-quality welds with a constant set of welding parameters and it was hence identified as the most promising welding strategy for sequential ultrasonic welding of thermoplastic composites.

Original languageEnglish
Pages (from-to)355-367
Number of pages13
JournalComposites Part A: Applied Science and Manufacturing
Volume109
DOIs
Publication statusPublished - 1 Jun 2018

Keywords

  • Fractography
  • Joints/joining
  • Mechanical properties
  • Thermoplastic resin

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