Thermoplastic Composites and Their Promising Applications in Joining and Repair Composites Structures: A Review

Thermoset fiber reinforced composites, widely used in current structural applications, have complex repair procedures and generates significant amounts of scrap due to its recycling difficulties, which does not comply with the most recent environmental restrictions. These disadvantages may be overcome by using a thermoplastic matrix phase, which is very suitable to be joined and repaired by local melting, making the composite material fully recyclable. This work presents a literature review on the joining methods applicable to thermoplastic based composites and their potential applications to be used as repair procedures in structural elements. The effectiveness of selected adhesive and fusion bonding techniques for several thermoplastic composite systems is evaluated by a comparative study based on the joints’ strength and toughness results available in the literature. This work focuses on the three most promising fusion bonding techniques: Resistance welding, induction welding, and ultrasonic welding. The advantages and drawbacks for each one of these processes are discussed, as well as their suitability for several specific structural applications. In addition, several discordant aspects for each welding technique are identified and the corresponding recommendations are discussed. A compilation of analytical models for the mechanisms of heat generation and transient heat transfer modelling is also presented for each fusion bonding process in order to promote their application in numerical modelling.