A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites

Continuous ultrasonic welding is a promising technique for joining thermoplastic composites structures together. The aim of this study was to gain further insight into what causes higher through-the-thickness heating in continuous ultrasonic welding of thermoplastic composites as compared to the sta...

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Autores principales:	Bram C. P. Jongbloed, Julie J. E. Teuwen, Rinze Benedictus, Irene Fernandez Villegas
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	fusion bonding heat transfer high-frequency welding joining CF/PPS energy director Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
Acceso en línea:	https://doaj.org/article/a39154483bb64a75a42902a87cfb1b8f
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spelling	oai:doaj.org-article:a39154483bb64a75a42902a87cfb1b8f2021-11-11T18:09:13ZA Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites10.3390/ma142166201996-1944https://doaj.org/article/a39154483bb64a75a42902a87cfb1b8f2021-11-01T00:00:00Zhttps://www.mdpi.com/1996-1944/14/21/6620https://doaj.org/toc/1996-1944Continuous ultrasonic welding is a promising technique for joining thermoplastic composites structures together. The aim of this study was to gain further insight into what causes higher through-the-thickness heating in continuous ultrasonic welding of thermoplastic composites as compared to the static process. Thermocouples were used to measure temperature evolutions at the welding interface and within the adherends. To understand the mechanisms causing the observed temperature behaviours, the results were compared to temperature measurements from an equivalent static welding process and to the predictions from a simplified heat transfer model. Despite the significantly higher temperatures measured at the welding interface for the continuous process, viscoelastic bulk heat generation and not thermal conduction from the interface was identified as the main cause of higher through-the-thickness heating in the top adherend. Interestingly the top adherend seemed to absorb most of the vibrational energy in the continuous process as opposed to a more balanced energy share between the top and bottom adherend in the static process. Finally, the higher temperatures at the welding interface in continuous ultrasonic welding were attributed to pre-heating of the energy director due to the vibrations being transmitted downstream of the sonotrode, to reduced squeeze-flow of energy director due to the larger adherend size, and to heat flux originating downstream as the welding process continues.Bram C. P. JongbloedJulie J. E. TeuwenRinze BenedictusIrene Fernandez VillegasMDPI AGarticlefusion bondingheat transferhigh-frequency weldingjoiningCF/PPSenergy directorTechnologyTElectrical engineering. Electronics. Nuclear engineeringTK1-9971Engineering (General). Civil engineering (General)TA1-2040MicroscopyQH201-278.5Descriptive and experimental mechanicsQC120-168.85ENMaterials, Vol 14, Iss 6620, p 6620 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	fusion bonding heat transfer high-frequency welding joining CF/PPS energy director Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85
spellingShingle	fusion bonding heat transfer high-frequency welding joining CF/PPS energy director Technology T Electrical engineering. Electronics. Nuclear engineering TK1-9971 Engineering (General). Civil engineering (General) TA1-2040 Microscopy QH201-278.5 Descriptive and experimental mechanics QC120-168.85 Bram C. P. Jongbloed Julie J. E. Teuwen Rinze Benedictus Irene Fernandez Villegas A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites
description	Continuous ultrasonic welding is a promising technique for joining thermoplastic composites structures together. The aim of this study was to gain further insight into what causes higher through-the-thickness heating in continuous ultrasonic welding of thermoplastic composites as compared to the static process. Thermocouples were used to measure temperature evolutions at the welding interface and within the adherends. To understand the mechanisms causing the observed temperature behaviours, the results were compared to temperature measurements from an equivalent static welding process and to the predictions from a simplified heat transfer model. Despite the significantly higher temperatures measured at the welding interface for the continuous process, viscoelastic bulk heat generation and not thermal conduction from the interface was identified as the main cause of higher through-the-thickness heating in the top adherend. Interestingly the top adherend seemed to absorb most of the vibrational energy in the continuous process as opposed to a more balanced energy share between the top and bottom adherend in the static process. Finally, the higher temperatures at the welding interface in continuous ultrasonic welding were attributed to pre-heating of the energy director due to the vibrations being transmitted downstream of the sonotrode, to reduced squeeze-flow of energy director due to the larger adherend size, and to heat flux originating downstream as the welding process continues.
format	article
author	Bram C. P. Jongbloed Julie J. E. Teuwen Rinze Benedictus Irene Fernandez Villegas
author_facet	Bram C. P. Jongbloed Julie J. E. Teuwen Rinze Benedictus Irene Fernandez Villegas
author_sort	Bram C. P. Jongbloed
title	A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites
title_short	A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites
title_full	A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites
title_fullStr	A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites
title_full_unstemmed	A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites
title_sort	study on through-the-thickness heating in continuous ultrasonic welding of thermoplastic composites
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/a39154483bb64a75a42902a87cfb1b8f
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A Study on Through-the-Thickness Heating in Continuous Ultrasonic Welding of Thermoplastic Composites

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