Cargando…

Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints

Ultrasonic welding is a fast and promising joining technique for thermoplastic composite parts. Understanding how changing the part thickness affects the process is crucial to its future upscaling and industrialization. This article presents an initial insight into the effect of the adherend’s thick...

Descripción completa

Detalles Bibliográficos
Autores principales: Guevara-Sotelo, Natalia Sofia, Fernandez Villegas, Irene
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10650287/
https://www.ncbi.nlm.nih.gov/pubmed/37959564
http://dx.doi.org/10.3390/ma16216968
_version_ 1785135746482438144
author Guevara-Sotelo, Natalia Sofia
Fernandez Villegas, Irene
author_facet Guevara-Sotelo, Natalia Sofia
Fernandez Villegas, Irene
author_sort Guevara-Sotelo, Natalia Sofia
collection PubMed
description Ultrasonic welding is a fast and promising joining technique for thermoplastic composite parts. Understanding how changing the part thickness affects the process is crucial to its future upscaling and industrialization. This article presents an initial insight into the effect of the adherend’s thickness on the near-field ultrasonic welding of CF/LMPAEK thermoplastic composites. Different thicknesses of the top and bottom adherend were welded and analyzed using the output data of the welding equipment, temperature measurements, and other visual characterization techniques. Increasing the thickness of both the top and the bottom adherends showed to increase the power consumed during welding. An overshoot in the power needed at the onset of the welding process for increased thickness of the top adherend precluded welding beyond a threshold thickness of 4.72 mm. In the case of the thicker top adherends, there was also melting of the energy director and early fiber squeeze-out within the top adherend as a result of increased bulk heating. Increased bulk heating was hypothesized to be caused by increased hammering, as indicated by the amplitude readings for thicker adherends. Welding with a higher force, which is known to reduce hammering, corroborated this hypothesis as fiber squeeze-out within the top adherend was not observed. It is believed that hammering contributes to heating by causing an oscillatory impact excitation that is close to the natural frequencies of the system, which would result in amplification of the cyclic strain and subsequent increase in the viscoelastic heating in the adherend.
format Online
Article
Text
id pubmed-10650287
institution National Center for Biotechnology Information
language English
publishDate 2023
publisher MDPI
record_format MEDLINE/PubMed
spelling pubmed-106502872023-10-30 Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints Guevara-Sotelo, Natalia Sofia Fernandez Villegas, Irene Materials (Basel) Article Ultrasonic welding is a fast and promising joining technique for thermoplastic composite parts. Understanding how changing the part thickness affects the process is crucial to its future upscaling and industrialization. This article presents an initial insight into the effect of the adherend’s thickness on the near-field ultrasonic welding of CF/LMPAEK thermoplastic composites. Different thicknesses of the top and bottom adherend were welded and analyzed using the output data of the welding equipment, temperature measurements, and other visual characterization techniques. Increasing the thickness of both the top and the bottom adherends showed to increase the power consumed during welding. An overshoot in the power needed at the onset of the welding process for increased thickness of the top adherend precluded welding beyond a threshold thickness of 4.72 mm. In the case of the thicker top adherends, there was also melting of the energy director and early fiber squeeze-out within the top adherend as a result of increased bulk heating. Increased bulk heating was hypothesized to be caused by increased hammering, as indicated by the amplitude readings for thicker adherends. Welding with a higher force, which is known to reduce hammering, corroborated this hypothesis as fiber squeeze-out within the top adherend was not observed. It is believed that hammering contributes to heating by causing an oscillatory impact excitation that is close to the natural frequencies of the system, which would result in amplification of the cyclic strain and subsequent increase in the viscoelastic heating in the adherend. MDPI 2023-10-30 /pmc/articles/PMC10650287/ /pubmed/37959564 http://dx.doi.org/10.3390/ma16216968 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Guevara-Sotelo, Natalia Sofia
Fernandez Villegas, Irene
Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints
title Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints
title_full Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints
title_fullStr Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints
title_full_unstemmed Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints
title_short Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints
title_sort effect of adherend thickness on near-field ultrasonic welding of single-lap cf/lmpaek thermoplastic composite joints
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10650287/
https://www.ncbi.nlm.nih.gov/pubmed/37959564
http://dx.doi.org/10.3390/ma16216968
work_keys_str_mv AT guevarasotelonataliasofia effectofadherendthicknessonnearfieldultrasonicweldingofsinglelapcflmpaekthermoplasticcompositejoints
AT fernandezvillegasirene effectofadherendthicknessonnearfieldultrasonicweldingofsinglelapcflmpaekthermoplasticcompositejoints