Title: OPTIMIZATION OF ULTRASONIC WELDING PARAMETERS FOR CARBON FIBER REINFORCED THERMOPLASTIC COMPOSITE PLIE

Authors: Harry K. Lee, Garam Kim, Eduardo V. Barocio

DOI: 10.33599/nasampe/s.23.0158

Abstract: Ultrasonic spot welding is often used to fix fiber-reinforced thermoplastic composite plies before they are consolidated in the tool. However, the temperature development during the ultrasonic spot welding of fiber reinforced thermoplastic composites is not fully understood, and there are no guidelines for choosing an optimal welding parameter. Improper ultrasonic welding parameters can cause thermal degradation, fiber breakage, warping, or incomplete welds. In this research, different welding amplitude was utilized to weld 8 plies of carbon fiber-reinforced polyether ketone ketone (PEKK) composite plies. A thermal camera was used to measure the temperature development and distribution over time during the welding. The thermal data showed different temperature pattern and welding mechanism for different amplitudes. 20 to 50 % amplitude did not weld any plies. The temperature rose and plateaued at the temperatures that are not high enough to soften the thermoplastic. 60 % amplitude or above allowed the thermoplastic to soften or melt and welded all plies together. The transient temperature responses showed three stages during the welding, which were the build-up, welding, and steady-state stage. Increase in amplitude caused faster increase in temperature, higher peak temperatures, and higher steady-state temperatures.

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Conference: SAMPE 2023

Publication Date: 2023/04/17

SKU: TP23-0000000158

Pages: 10

Price: $20.00