Work

Exploring ultrasonic and resistance welding for thermoplastic composite structures: Process development and application potential

Year: 2024

Type: article

Abstract: Thermoplastic composites outperform in aerospace applications compared to thermoset composites due to their weldability, a key advantage. This feature streamlines manufacturing, allowing for precise assembly of complex shapes, reducing costs, and accelerating production. Additionally, it simplifies maintenance, enabling easy repair or replacement of damaged parts, thereby extending vehicle lifespan and minimizing downtime. With exceptional strength-to-weight ratio and resistance to corrosion and fatigue, weldable thermoplastic composites ensure reliable performance in the demanding aerospace environment. Overall, their weldability enhances efficiency, versatility, and safety in aerospace applications. This paper first presents an overview of various welding processes and discusses the special challenges of assembly processes in the aviation industry. This work then focuses from the authors’ perspective with regard to industrializability on the two most promising processes, resistance and ultrasonic welding.

Source: Composites Part B Engineering

DOI: 10.1016/j.compositesb.2024.111927

Authors: Lars Larsen, Manuel Endrass, Stefan Jarka, Simon Bauer, Maximilian Janek

Language: English

Topic: Advanced Welding Techniques Analysis

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: hybrid

Estimated APC paid: $5,060

Funder: Deutsches Zentrum für Luft- und Raumfahrt