scholarly journals A Study of Films Incorporating Magnetite Nanoparticles as Susceptors for Induction Welding of Carbon Fiber Reinforced Thermoplastic

Materials ◽  
2020 ◽  
Vol 13 (2) ◽  
pp. 318 ◽  
Author(s):  
Inseok Baek ◽  
Seoksoon Lee
Keyword(s):  
Carbon Fiber ◽  
Induction Heating ◽  
Weight Ratio ◽  
Thermoplastic Composites ◽  
Maximum Temperature ◽  
Thermoplastic Resin ◽  
Metal Mesh ◽  
Manufacturing Method ◽  
Lap Shear ◽  
Heating Behavior

Induction welding is a fast, clean, noncontact process that often uses a metal-mesh susceptor to facilitate localized controlled heating; however, the metal mesh presents various problems. In this study, the induction heating behavior of a 450 μ m thick thin-film susceptor, fabricated by mixing magnetite (Fe 3 O 4 ) nanoparticles (NPs) and PA6/carbon fiber (CF) (30%) thermoplastic resin, was examined with respect to the weight ratio of Fe 3 O 4 (50, 67, 75, and 80 wt%). The useful induction heating behavior of the 75 wt% Fe 3 O 4 susceptor suggested its suitability for additional heat treatment experiments, carried out at 3.4 kW at a frequency of 100 kHz. This susceptor attained the same maximum temperature during 10 cycles of repeated induction heating and cooling. It was then used to weld two thermoplastic composites, with 60 s of induction heating followed by 120 s of simultaneous cooling and pressing. The resulting welded joints had lap shear strength values of 36.8, 34.0, and 36.4 MPa under tensile test loads of 884, 817, and 874 N, respectively. Scanning electron microscopy images confirmed a uniform weld quality. Thus, the proposed manufacturing method, involving the incorporation of Fe 3 O 4 NPs into thermoplastic resin, should help expand the range of applications for thermoplastic composites.

scholarly journals Microwave Heating Behavior in SiC Fiber-MO2 Mixtures (M = Ce, Zr)—Selective Heating of Micrometer-Sized Fibers Facilitated by ZrO2 Powder

Processes ◽  
2020 ◽  
Vol 8 (1) ◽  
pp. 47 ◽  
Author(s):  
Keiichiro Kashimura ◽  
Jun Fukushima ◽  
Tomoaki Namioka ◽  
Takashi Fujii ◽  
Hirotsugu Takizawa ◽  
...  
Keyword(s):  
High Temperature ◽  
Hot Spots ◽  
Weight Ratio ◽  
Temperature Gradients ◽  
Maximum Temperature ◽  
Selective Heating ◽  
Sic Fiber ◽  
Maximum Value ◽  
Rate Maximum ◽  
Heating Behavior

SiC fiber-MO2 (M = Ce, Zr) mixtures with various compositions were heated by applying an 80 W microwave electric field, to investigate their heating rate, maximum temperature, and dielectric constant. For the SiC fiber-CeO2 mixture, all three parameters continued to increase as the weight ratio of the SiC fiber increased; in contrast, for the SiC fiber-ZrO2 mixture, these parameters reached a maximum value at a certain composition. A thermal gradient of 500 °C was observed at a microlevel in the SiC fiber-ZrO2 mixture, and hot spots were located in regions with a certain composition. This result not only contributes to designing a novel good microwave absorber but also presents new aspects with regard to high-temperature microwave processing, including the mechanism behind the high-temperature gradients on the order of micrometers as well as engineering applications that utilize these high-temperature gradients.

A study on the induction heating of carbon fiber reinforced thermoplastic composites

2002 ◽  
Vol 11 (1) ◽  
pp. 71-80 ◽  
Author(s):  
Heejune Kim ◽  
Shridhar Yarlagadda ◽  
John W. Gillespie ◽  
Nicholas B. Shevchenko ◽  
Bruce K. Fink
Keyword(s):  
Carbon Fiber ◽  
Induction Heating ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced

Preparation of carbon fiber-reinforced polyimide composites via in situ induction heating

2016 ◽  
Vol 29 (9) ◽  
pp. 1027-1036 ◽  
Author(s):  
Chang Wei Liu ◽  
Chun Yan Qu ◽  
Lei Han ◽  
De Zhi Wang ◽  
Wan Bao Xiao ◽  
...  
Keyword(s):  
High Temperature ◽  
Carbon Fiber ◽  
Induction Heating ◽  
High Performance ◽  
Thermoplastic Composites ◽  
Heating Process ◽  
Current Field ◽  
Heating Method ◽  
Polyimide Composites

Induction heating, a direct and contactless heating method, is generally more rapid and energetically more efficient than other heating methods used. In this work, we report the high-temperature imidization of carbon fiber/polyimide (PI) composites using an in situ induction heating method. Furthermore, we compare the advantages of the method to a conventional thermal procedure. The formed composites feature almost identical imidization rates, glass transition temperatures, and thermal oxidative stabilities cured at the same heating temperatures using a different heating process. Upon doping with ferriferous oxide, the ability of the magnetic nanoparticles in an alternating current field was studied to further drive the heating process and increase the rising and cooling time. The in situ induction heating process proves to be a powerful method for the high-temperature polymerization of high-performance thermoplastic composites, particularly for a PI matrix.

scholarly journals Comprehensive Review of the Properties and Modifications of Carbon Fiber-Reinforced Thermoplastic Composites

Polymers ◽  
2021 ◽  
Vol 13 (15) ◽  
pp. 2474
Author(s):  
Basheer A. Alshammari ◽  
Mohammed S. Alsuhybani ◽  
Alaa M. Almushaikeh ◽  
Bander M. Alotaibi ◽  
Asma M. Alenad ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Weight Ratio ◽  
Industrial Applications ◽  
Fiber Reinforced Polymers ◽  
Thermoplastic Composites ◽  
High Wear Resistance ◽  
Fiber Reinforced ◽  
Thermoplastic Polymers ◽  
Comprehensive Review ◽  
Carbon Fiber Reinforced

Carbon fiber-reinforced polymers are considered a promising composite for many industrial applications including in the automation, renewable energy, and aerospace industries. They exhibit exceptional properties such as a high strength-to-weight ratio and high wear resistance and stiffness, which give them an advantage over other conventional materials such as metals. Various polymers can be used as matrices such as thermosetting, thermoplastic, and elastomers polymers. This comprehensive review focuses on carbon fiber-reinforced thermoplastic polymers due to the advantages of thermoplastic compared to thermosetting and elastomer polymers. These advantages include recyclability, ease of processability, flexibility, and shorter production time. The related properties such as strength, modulus, thermal conductivity, and stability, as well as electrical conductivity, are discussed in depth. Additionally, the modification techniques of the surface of carbon fiber, including the chemical and physical methods, are thoroughly explored. Overall, this review represents and summarizes the future prospective and research developments carried out on carbon fiber-reinforced thermoplastic polymers.

scholarly journals Ultrasonic Welding of Novel Carbon/Elium® Thermoplastic Composites with Flat and Integrated Energy Directors: Lap Shear Characterisation and Fractographic Investigation

Materials ◽  
2020 ◽  
Vol 13 (7) ◽  
pp. 1634 ◽  
Author(s):  
Somen K. Bhudolia ◽  
Goram Gohel ◽  
Jayaram Kantipudi ◽  
Kah Fai Leong ◽  
Robert J. Barsotti
Keyword(s):  
Polymer Matrix Composites ◽  
Research Work ◽  
Ultrasonic Welding ◽  
Industrial Applications ◽  
Thermoplastic Composites ◽  
Matrix Composites ◽  
Thermoplastic Resin ◽  
Lap Shear ◽  
Weld Time ◽  
Transfer Moulding

The current research work presents a first attempt to investigate the welding attributes of Elium® thermoplastic resin and the fusion bonding using ultrafast ultrasonic welding technique. The integrated energy director (ED) polymer-matrix composites (PMCs) panel manufacturing was carried out using the Resin Transfer Moulding (RTM) technique and the scheme is deduced to manufacture a bubble-free panel. Integrated ED configurations and flat specimens with Elium® film of different thickness at the interface were investigated for ultrasonic welding optimization. Optimised weld time for integrated ED and flat Elium® panels with film (0.5 mm thick) configuration was found to be 1 s and 5.5 s, respectively. The ED integrated configuration showed the best welding results with a lap shear strength of 18.68 MPa. The morphological assessment has shown significant plastic deformation of Elium® resin and the shear cusps formation, which enhances the welding strength. This research has the potential to open up an excellent and automated way of joining Elium® composite parts in automotive, wind turbines, sports, and many other industrial applications.

scholarly journals Multi-Objective Optimization of Resistance Welding Process of GF/PP Composites

Polymers ◽  
2021 ◽  
Vol 13 (15) ◽  
pp. 2560
Author(s):  
Guowei Zhang ◽  
Ting Lin ◽  
Ling Luo ◽  
Boming Zhang ◽  
Yuao Qu ◽  
...  
Keyword(s):  
Signal To Noise Ratio ◽  
Welding Process ◽  
Welding Current ◽  
Resistance Welding ◽  
Thermoplastic Composites ◽  
Current Time ◽  
Process Factor ◽  
Welding Equipment ◽  
Lap Shear ◽  
Adhesive Connections

Thermoplastic composites (TPCs) are promising materials for aerospace, transportation, shipbuilding, and civil use owing to their lightweight, rapid prototyping, reprocessing, and environmental recycling advantages. The connection assemblies of TPCs components are crucial to their application; compared with traditional mechanical joints and adhesive connections, fusion connections are more promising, particularly resistance welding. This study aims to investigate the effects of process control parameters, including welding current, time, and pressure, for optimization of resistance welding based on glass fiber-reinforced polypropylene (GF/PP) TPCs and a stainless-steel mesh heating element. A self-designed resistance-welding equipment suitable for the resistance welding process of GF/PP TPCs was manufactured. GF/PP laminates are fabricated using a hot press, and their mechanical properties were evaluated. The resistance distribution of the heating elements was assessed to conform with a normal distribution. Tensile shear experiments were designed and conducted using the Taguchi method to evaluate and predict process factor effects on the lap shear strength (LSS) of GF/PP based on signal-to-noise ratio (S/N) and analysis of variance. The results show that current is the main factor affecting resistance welding quality. The optimal process parameters are a current of 12.5 A, pressure of 2.5 MPa, and time of 540 s. The experimental LSS under the optimized parameters is 12.186 MPa, which has a 6.76% error compared with the result predicted based on the S/N.

scholarly journals Clinching of Thermoplastic Composites and Metals—A Comparison of Three Novel Joining Technologies

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2286
Author(s):  
Benjamin Gröger ◽  
Juliane Troschitz ◽  
Julian Vorderbrüggen ◽  
Christian Vogel ◽  
Robert Kupfer ◽  
...  
Keyword(s):  
Computed Tomography ◽  
Composite Material ◽  
Process Design ◽  
Failure Mechanisms ◽  
Thermoplastic Composites ◽  
Material Structure ◽  
Shear Tests ◽  
Load Bearing ◽  
Lap Shear ◽  
Resultant Material

Clinching continuous fibre reinforced thermoplastic composites and metals is challenging due to the low ductility of the composite material. Therefore, a number of novel clinching technologies has been developed specifically for these material combinations. A systematic overview of these advanced clinching methods is given in the present paper. With a focus on process design, three selected clinching methods suitable for different joining tasks are described in detail. The clinching processes including equipment and tools, observed process phenomena and the resultant material structure are compared. Process phenomena during joining are explained in general and compared using computed tomography and micrograph images for each process. In addition the load bearing behaviour and the corresponding failure mechanisms are investigated by means of single-lap shear tests. Finally, the new joining technologies are discussed regarding application relevant criteria.

scholarly journals Static ultrasonic welding of carbon fibre unidirectional thermoplastic materials and the influence of heat generation and heat transfer

2021 ◽  
pp. 002199832097681
Author(s):  
F Köhler ◽  
IF Villegas ◽  
C Dransfeld ◽  
A Herrmann
Keyword(s):  
Cross Sections ◽  
Weld Line ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Thermoplastic Composites ◽  
Squeeze Flow ◽  
Anisotropic Flow ◽  
Lap Shear ◽  
Anisotropic Thermal Conductivity ◽  
Edge Defects

Ultrasonic welding is a promising technology to join fibre-reinforced thermoplastic composites. While current studies are mostly limited to fabric materials the applicability to unidirectional materials, as found in aerospace structures, would offer opportunities for joining primary aircraft structures. However, due to the highly anisotropic flow of a molten unidirectional ply undesired squeeze flow phenomena can occur at the edges of the weld overlap. This paper investigates how the fibre orientation in the plies adjacent to the weld line influences the welding process and the appearance of edge defects. Ultrasonic welding experiments with different layups and energy director configurations were carried out while monitoring temperatures at different locations inside and outside the weld overlap. The joints were characterized by single lap shear tests, analysis of corresponding fracture surfaces and microscopic cross-sections. Results showed that the anisotropic flow and the anisotropic thermal conductivity of the plies adjacent to the weld line have a distinct effect on the appearance and location of edge defects. By using energy directors that cover only part of the weld overlap area a new approach was developed to mitigate edge defects caused by the highly directional properties of the unidirectional plies.

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