Title: Sensitivity Analysis of Induction Welding Process Variables

Authors: Kerrick Dando, PhD, Mark Wadsworth, Matt Bickhard, Michel van Tooren, PhD, and Jaspreet Pandher

DOI: 10.33599/nasampe/c.19.0842

Abstract: Carbon fiber reinforced thermoplastic composites have experienced increasing application in the aerospace industry due to their superior toughness properties and high-rate formability. Thermoplastic composites also have the ability to be reprocessed providing a potentially cost-effective method of assembly. Most notably, the use of thermoplastic welding technologies could potentially eliminate the need for most fasteners and substantially reduce the cost of manufacturing aerostructures. Fusing composite parts without introducing foreign materials into the bond line is a potential advantage of induction welding and is being investigated by Spirit AeroSystems, Inc.

This work details an experimental investigation of continuous induction welding of thermoplastic composites comprised of unidirectional tape. The focus of this investigation was to understand the effects of key weld parameters such as clamping pressure, work head speed, and applied coil current on weld quality. Mechanical characterization in the form of single lap shear tests was used to evaluate the results. Induction welding equipment at University of South Carolina’s McNAIR Aerospace Center was used for fabrication of test coupons. It was found that while significant variation in weld strength was measured across sample sets, clear trends in the process variables’ effects on weld quality were observed. Both coil speed and applied coil current show the greatest impacts on weld strength; strength increases with increasing current at high work head speeds.

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Conference: CAMX 2019

Publication Date: 2019/09/23

SKU: TP19-0842

Pages: 11

Price: $22.00