Title: Heat Generation Analysis during the Ultrasonic Welding Process in Thermoplastic Composite Joints

Authors: Felipe B Savella, Genevieve Palardy

DOI: 10.33599/nasampe/s.24.0034

Abstract: The investigation of joining methods for thermoplastic composite (TPC) structures holds significant importance, primarily for achieving reliable processes leading to structural strength. One such method involves ultrasonic welding, a process that applies high-frequency vibrations to components to be welded, resulting in rapid heat generation and fusion of both materials. However, there are knowledge gaps surrounding the various phases of this process, such as the effect of welding parameters and contact at the weld interface, which could generate different behaviors and results. This study focuses on the creation of single lap shear joints by welding glass fiber/polypropylene (GF/PP) adherends and multiphysics simulations to predict the heating process. Experiments were conducted to measure the temperature profile at different time steps using thermocouples and to observe corresponding fracture surfaces. Results were compared to simulations to validate and enhance the model created in COMSOL Multiphysics, and to analyze the effect of welding parameters and material properties on heat generation. More accurate simulations will improve prediction of the welding process behavior for diverse systems, with different materials, parameters, and joint designs, which can be applied in large-scale, continuous ultrasonic welding.

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Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000034

Pages: 14

Price: $28.00