Zero-flow: A novel approach to continuous ultrasonic welding of CF/PPS thermoplastic composite plates

F. Senders, M. van Beurden, Genevieve Palardy, Irene Fernandez Villegas

Research output: Contribution to journalArticleScientificpeer-review

16 Citations (Scopus)
37 Downloads (Pure)

Abstract

Continuous ultrasonic welding of plastic films, fabrics, and even thermoplastic composite prepreg tape is a common industrial practice. However, continuous ultrasonic welding of stiff thermoplastic composite plates is challenging due to squeeze flow of resin at the welding interface, and significant local deformation of the welding stack, that are generally needed to achieve strong welds. This paper presents a novel approach to continuous ultrasonic welding of thermoplastic composite plates based on zero-flow welding. The proposed technique can create strong welds before any squeeze flow takes place at the interface. It is enabled by the use of very thin flat energy directors, owing to simultaneous melting of both energy director and adherends’ matrix. The results prove the feasibility and indicate the potential for high-strength welds between thermoplastic composite plates at very high speed.
Original languageEnglish
Pages (from-to)83-92
JournalAdvanced Manufacturing: Polymer & Composites Science
Volume2
Issue number3-4
DOIs
Publication statusPublished - 2016

Keywords

  • Composites
  • Thermoplastic resin
  • Structural joining
  • Fusion bonding
  • Ultrasonic heating
  • Continuous welding

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