Work

Influence of Welding Control Mode on the Joint Performance of Ultrasonically Welded Carbon Fiber-Reinforced Polycarbonate

Year: 2026

Type: article

Abstract: Carbon fiber-reinforced thermoplastic (CFRTP) composites are now widely used in many fields. Ultrasonic welding (UW) is a key technology for joining these materials. The control mode of UW has a great effect on the quality of the welded joints. However, there is still not enough research comparing the different welding control modes. This paper investigates the effects of the time control, energy control, and displacement control modes on the ultrasonic welding quality of carbon fiber-reinforced polycarbonate (CF/PC). A flat PC film is used as the energy director (ED). The evaluation focuses on the lap-shear strength (LSS), macro- and micro-morphology, fracture surface characteristics and power-displacement curves of the welding process. Furthermore, significant differences are observed in the temperature field evolution and joint failure modes across the different control modes and process parameters. Results indicate that the displacement control mode achieves the highest joint quality and process stability, yielding a maximum LSS of 30.6 MPa. A correlation analysis reveals that the displacement-energy relationship exhibits the strongest coupling, and the Pearson correlation coefficient r is 0.896.

Source: Materials

DOI: 10.3390/ma19061138

Authors: Zhaolong Zhang, Yuanduo Yang, Lunan Wei, Sansan Ao, Yang Li

Institutions: Tianjin University, Anhui Jianzhu University

Language: English

Topic: Advanced Welding Techniques Analysis

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $3,137

Funder: National Natural Science Foundation of China