Enhancing weld in ultrasonic spot welding of carbon fibre-reinforced polyetheretherketone with polyetherimide energy director
Year: 2025
Type: conference-paper
Abstract: . Static ultrasonic welding (USW) is a widely used technique for assembling thermoplastic composites. However, joining them remains challenging due to the lack of knowledge of the impact of process parameters (time, pressure, temperature) on welded joints. Continuous USW of large parts is a challenge for industrial applications. Spot welding is a more credible way of assembling large industrial parts. Improving the manufacturing efficiency and weld attributes such as welded area and strength are essential. To achieve this goal, the research was carried out in two steps: i) single-lap welding (SLW) was optimized and assessed in displacement single mode, ii) single-spot welding (SSW) with integrated and loose energy director (ED) was studied. The effect on the welding processes and weld attributes of the manufactured welded joints was investigated. The displacement single mode on integrated ED and a new method using multi-mode ultrasonic welding on loose ED were tested. The results of both approaches were compared to achieve robust sequential ultrasonic welding of thermoplastic composites with integrated or loose energy director. The ultrasonic welding parameters such as time, displacement and pressure with a specific amplitude of vibrations were explored to define the optimum conditions for the chosen composite material. The parts were assembled in a single lap shear (SLS) configuration to evaluate mechanical resistance and to observe the interfaces after failure. Mechanical results indicate that the SSW with a smaller sonotrode size can reach similar values as SLW. The loose ED significantly improved the welding efficiency. The weld resistance was effectively enhanced by adopting multi-mode ultrasonic welding.
Source: Materials research proceedings
Author: Adrian KORYCKI
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
OpenAlex ID: W4410028090