Towards robust sequential ultrasonic spot welding of thermoplastic composites

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

Zhao, T. (TU Delft Structural Integrity & Composites)
Broek, C.A. (TU Delft Education AE)
Palardy, G. (TU Delft Structural Integrity & Composites)
Villegas, I.F. (TU Delft Structural Integrity & Composites)
Benedictus, R. (TU Delft Aerospace Structures & Materials; TU Delft Structural Integrity & Composites)

Aerospace Structures & Materials

2018-06-01

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.

Fractography
Joints/joining
Mechanical properties
Thermoplastic resin

http://resolver.tudelft.nl/uuid:5c580a1c-986b-475f-9e90-5013684cab1d

https://doi.org/10.1016/j.compositesa.2018.03.024

2020-03-23

1359-835X

Composites Part A: Applied Science and Manufacturing, 109, 355-367

Institutional Repository

journal article

© 2018 T. Zhao, C.A. Broek, G. Palardy, I.F. Villegas, R. Benedictus