Influence of Pre-Pressing Ring on the Weld Quality of Ultrasonically Welded Short Carbon Fiber Reinforced Nylon 6 Composite

The ultrasonic welding (UW) technique is a fast-joining process; it is very suitable for the carbon fiber reinforced thermoplastic (CFRTP) composite. For improving the consistency of the welded joint quality, a new pre-pressing ring clamp (PPRC) was designed for ultrasonic welding carbon fiber reinforced nylon composites in this paper. The effects of the PPRC on the weld quality of the ultrasonic welding welded 4.0 mm thick 30% mass short carbon fiber reinforced Nylon 6 composite was investigated and compared with that of normal clamp weld joint. The weld strength, microstructure, and temperature evolution of the joint were analyzed by tensile test, scanning electron microscope, and temperature measurement. The results showed that the PPCR UW joints had larger central weld nugget size (478 mm(2) vs. 300 mm(2)), thicker stable fusion region thickness (1.10 mm vs. 0.96 mm), resulting in a higher joint strength (6.86 kN vs. 6.21 kN) compared with the normal clamp UW joints under the same welding parameters. The real-time monitor curve of the horn displacement and temperature at the faying interface showed that the PPRC increased the heat rating at the faying interface during instable melting stage. The PPRC could improve the contact condition between workpieces and the utilization efficiency of ultrasonic energy, which boosted the melting rate of materials at faying interface and consequently the formation of a sound joint with enough weld size (i.e., 433 mm(2)) in a shorter welding time (i.e., 1.3 s). Therefore, the flexibility of component assembly would be increased by the use of this sort of clamps.