Title: Through Transmission Laser Welding of PPS and PEI Continuous Fiber Reinforced Thermoplastic Composites

Authors: Jeff L. Ellis, Miranda Marcus, Matt A. Nitsch

DOI: 10.33599/nasampe/c.22.0017

Abstract: Continuous fiber reinforced thermoplastic composites (CFRTPC) are increasingly being used in aerospace, automotive, and oil & gas due to their low cost, recyclability, complex shape adaptability, high strength, and low weight. Joining CFRTPC by metal fasteners is not desirable due to the added weight, stress concentration, and corrosion, so other joining processes are needed to realize the full benefits of CFRTPCs.

Through transmission laser welding was investigated as a lightweight joining approach for new structures or repairs. Unlike the other welding processes which have been investigated for joining CFRTPC that may damage the fibers, like ultrasonic or vibration, laser welding does not mechanically disrupt the internal fibers. This gentle welding approach allows for greater retained strength at the weld seam. Welding of reinforced Nylon, polyphenylene sulfide (PPS), and polyetherimide (PEI) was proven using a Leister Technologies Novolas WS-AT laser. The weld strength was found to be high given the small area welded. Laser welding of CFTPC has been thoroughly explored and will be presented on in detail including its strengths, challenges, and limitations.

The adoption of this novel through transmission contour laser welding of the CFRTPC parts for system assembly has several important benefits. Systems will be lighter making them easier to transport and allow for longer use time on the same energy. The increased mechanical properties will make the system more robust and allow for less risk of system malfunction or break down. The lack of material diversity at interfaces, will allow for longer service life with less preventative maintenance because corrosion of these materials is not an issue, as it is with metal fasteners. The benefits of the assembled system outweigh the added complexity during assembly and make laser welding a winning manufacturing option.

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Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000017

Pages: 9

Price: $18.00