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.

Genetic Algorithm Based Optimization of ECDM Process for Polymer Matrix Composite

2018 ◽  
Vol 928 ◽  
pp. 144-149 ◽  
Author(s):  
Parvesh Antil ◽  
Sarbjit Singh ◽  
Alakesh Manna
Keyword(s):  
Genetic Algorithm ◽  
Polymer Matrix ◽  
Polymer Matrix Composites ◽  
Removal Rate ◽  
Research Work ◽  
Industrial Applications ◽  
Regression Equations ◽  
Matrix Composites ◽  
Micro Drilling ◽  
Hard And Brittle Materials

The acceptability of polymer matrix composites for various industrial applications has been increased over the years due to their better mechanical properties. However, nonconductive nature and fibrous residuals produced during micro drilling of these materials has become major challenge for the research fraternity. The conventional machining of these materials causes high tool wear due to presence of abrasive particles. Recently, the electrochemical discharge machining (ECDM) process has emerged as potential contender for the machining of nonconductive hard and brittle materials. Keeping in mind all these challenges, the present research work focuses on micro drilling of PMCs using ECDM process. The experimentation was planned as per Taguchi’s methodology using L9 orthogonal array. Voltage, electrolyte concentration and duty factor were considered as process parameters whereas material removal rate and taper were observed as output quality characteristics. The regression equation and coefficients were obtained using regression analysis. Using this regression equations, further solutions were obtained by genetic algorithm.

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.

Influence of filler on erosion behavior of polymer composites: A comprehensive review

2018 ◽  
Vol 37 (15) ◽  
pp. 1011-1019 ◽  
Author(s):  
S Vigneshwaran ◽  
M Uthayakumar ◽  
V Arumugaprabu ◽  
R Deepak Joel Johnson
Keyword(s):  
Polymer Composites ◽  
Polymer Matrix ◽  
Erosion Resistance ◽  
Polymer Matrix Composites ◽  
Research Work ◽  
Recent Decade ◽  
Extensive Study ◽  
Filler Materials ◽  
Matrix Composites ◽  
Filled Composite

In recent decade, polymer matrix composites were extensively used in various engineering applications owing to their advanced properties over conventional materials and enhanced performance. This motivated the researchers to generate an extensive study and research work on polymer composites. In recent studies, the erosion properties of the polymer composite attract increasing attention among researchers. The potential enhancement in the erosion resistance property of filled composites tempted the researchers to find the feasibility of using various filler materials in polymer matrix for specific erosion resistance applications. However, only limited numbers of literature are available concerning the tribological performance of the filled composite. Hence in this study, an objective was set to review the various literature that explain the erosion characteristics of filled composites.

scholarly journals Unidirectional Carbon Fiber Reinforced Thermoplastic Tape in Automated Tape Placement Process

2021 ◽  
Author(s):  
Svetlana Risteska
Keyword(s):  
Mechanical Performance ◽  
Industrial Applications ◽  
Thermoplastic Composites ◽  
Matrix Composites ◽  
Fiber Reinforced ◽  
Consolidation Process ◽  
Heating And Cooling ◽  
Thermoplastic Matrix ◽  
New Applications ◽  
Process Ability

Thermoplastic matrix composites are finding new applications in the different industrial areas, thanks to their intrinsic advantages related to environmental compatibility and process-ability. The tape placement process is one of the few techniques that have the potential to continuously process thermoplastic composites in large industrial applications. Fiber-reinforced thermoplastic tapes are subjected to high heating and cooling rates during the tape placement process. The application of laser heating for the tape placement process requires a thorough understanding of the factors involved in the process. Qualitative experimental analysis is presented to identify the important phenomena during the tape placement of carbon (PEEK, PEKK, PAEK PPS) tapes. The present chapter focuses on the input parameters in the process of manufacturing composite parts. The mechanical performance of the final parts depend on a number of parameters. It should be void-free and well consolidated for reliable use in the structure. In the present work, it is becoming increasingly wiser to introduce the production of high-quality laminates, using laser AFP and ATL with quality consolidation during the laying process. The experimental results in this chapter help to better understand the consolidation process during LATP.

Development of Aerospace Composite Structures Through Vacuum-Enhanced Resin Transfer Moulding Technology (VERTMTy)

2018 ◽  
pp. 99-111
Author(s):  
Raghu Raja Pandiyan Kuppusamy
Keyword(s):  
Composite Materials ◽  
Composite Structures ◽  
Polymer Matrix Composites ◽  
Wide Spectrum ◽  
Low Cost ◽  
Matrix Composites ◽  
Resin Transfer Moulding ◽  
Advanced Composite ◽  
Advanced Composite Materials ◽  
Transfer Moulding

Quality products with low cost manufacturing routes are the major objectives for the product development in any application. The current statement is evident for polymer-matrix composites, particularly in high end applications such as aerospace and mass transit structures. These applications require advanced composite materials tailored to meet the property demands posted by dynamic load conditions, and hence, the use of wide spectrum of constituents and architectures are vital to cater the needs. Consequently, the development of novel composite materials with the permutations of ingredients leads to the innovative processing techniques. To address the gap in the manufacturing with economical processing routes of thick sectioned advanced composite parts showing superior properties at different wall sections, an innovative composite manufacturing technology coupling resin transfer moulding (RTM) processing and vacuum applications, namely vacuum enhanced resin transfer moulding technology (VERTMTy), is conceptualized, proposed, and developed.

scholarly journals Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

Materials ◽  
2020 ◽  
Vol 13 (6) ◽  
pp. 1284 ◽  
Author(s):  
Somen K. Bhudolia ◽  
Goram Gohel ◽  
Kah Fai Leong ◽  
Aminul Islam
Keyword(s):  
Composite Structures ◽  
Dissimilar Materials ◽  
Processing Parameters ◽  
Ultrasonic Welding ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Pressure Amplitude ◽  
Advantages And Disadvantages ◽  
Cost Efficient ◽  
Weld Time

The ultrasonic welding (UW) technique is an ultra-fast joining process, and it is used to join thermoplastic composite structures, and provides an excellent bonding strength. It is more cost-efficient as opposed to the conventional adhesive, mechanical and other joining methods. This review paper presents the detailed progress made by the scientific and research community to date in the direction of the UW of thermoplastic composites. The focus of this paper is to review the recent development of the ultrasonic welding technique for thermoplastic composites to thermoplastic composites, and to dissimilar materials. Different ultrasonic welding modes and their processing parameters, namely, weld time, weld pressure, amplitude, type of energy directors (EDs) affecting the welding quality and the advantages and disadvantages of UW over other bonding techniques, are summarized. The current state of the ultrasonic welding of thermoplastic composites and their future perspectives are also deliberated.

Ultrasonic Welding of Glass Fiber Reinforced Polypropylene

2012 ◽  
Vol 557-559 ◽  
pp. 1313-1316
Author(s):  
Jian Guang Zhang ◽  
Krishan.K. Chawla ◽  
Uday.K. Vaidya
Keyword(s):  
Glass Fiber ◽  
Ultrasonic Welding ◽  
Maximum Strength ◽  
Weld Strength ◽  
Fiber Reinforced ◽  
Shear Testing ◽  
Polypropylene Composites ◽  
Lap Shear ◽  
Glass Fiber Reinforced ◽  
Weld Time

Glass fiber reinforced polypropylene composites were joined by ultrasonic welding, employing various weld conditions. Single-lap shear testing was used to evaluate the effect of weld time and weld pressure on the weld performance. The weld strength increased with increasing weld time and weld pressure until a plateau or maximum strength was reached. The required weld time to obtain a complete weld became shorter when the weld pressure was increased. As lower weld pressure was applied, a complete weld could not be obtained unless relatively longer weld times were employed. A welding map, showing conditions of weld time and weld pressure to get a good weld, was obtained.

scholarly journals Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1117 ◽  
Author(s):  
Somen K. Bhudolia ◽  
Goram Gohel ◽  
Kah Fai Leong ◽  
Robert J. Barsotti
Keyword(s):  
Composite Structures ◽  
Cost Effective ◽  
Ultrasonic Welding ◽  
Welding Parameters ◽  
Thermoplastic Resin ◽  
Adhesively Bonded ◽  
Molding Process ◽  
Lap Shear ◽  
Joint Quality ◽  
Adhesively Bonded Joint

Joining large and complex polymer–matrix composite structures is becoming increasingly important in industries such as automobiles, aerospace, sports, wind turbines, and others. Ultrasonic welding is an ultra-fast joining process and also provides excellent joint quality as a cost-effective alternative to other joining processes. This research aims at investigating the welding characteristics of novel methyl methacrylate Elium®, a liquid thermoplastic resin. Elium® is the first of its kind of thermoplastic resin, which is curable at room temperature and is suitable for mass production processes. The welding characteristics of Elium® composites were investigated by optimizing the welding parameters with specially designed integrated energy directors (ED) and manufactured using the Resin transfer molding process. The results showed a 23% higher lap shear strength for ultrasonically welded composite joints when compared to the adhesively bonded joints. The optimized welding time for the ultrasonic welded joint was found to be 1.5 s whereas it was 10 min for the adhesively bonded joint. Fractographic analysis showed the significant plastic deformation and shear cusps formation on the fractured surface, which are typical characteristics for strong interfacial bonding.

Practical Aspects of Micromechanics Based Simulation of Polymer Matrix Composites

2015 ◽  
Vol 812 ◽  
pp. 425-433
Author(s):  
Zoltan Major ◽  
Martin Reiter ◽  
Michael Jerabek
Keyword(s):  
Polymer Matrix ◽  
Polymer Matrix Composites ◽  
Practical Importance ◽  
Mean Field ◽  
Industrial Applications ◽  
Matrix Composites ◽  
Material Development ◽  
Practical Engineering ◽  
Homogenization Methods ◽  
Micro Structures

As particle filled and fiber reinforced polymer matrix composites are frequently used in many demanding industrial applications, the proper prediction of the deformation behavior of these materials is of high practical importance for a reliable product design. To predict the thermo-mechanical behavior, micromechanics based simulations were performed using both the mean field homogenization methods (MFH) and full-scale finite element (FS-FE simulations on a material specific representative volume. The applicability and limitations of both methods are introduced based on five different practical examples. Both thermoplastic polymers and elastomers were used as matrix materials with combination of fillers made from different materials having different aspect ratio and revealing a wide variation of alignments and arrangements. While conventionally the behavior of composites revealing processing induced microstructure is predicted for practical engineering applications, novel artificial micro-structures revealing special functionalities might also be designed and their behavior predicted for supporting material development efforts.

scholarly journals Mechanical and thermal characterization of tungsten particulate reinforced epoxy polymer composites

2021 ◽  
Author(s):  
Jenson Joseph. E ◽  
◽  
Kiran A.K ◽  
Panneerselvam K ◽  
◽  
...  
Keyword(s):  
Flexural Strength ◽  
Polymer Matrix ◽  
Polymer Matrix Composites ◽  
Thermal Characterization ◽  
Industrial Applications ◽  
Tungsten Particle ◽  
Mechanical And Thermal Properties ◽  
Matrix Composites ◽  
Scanning Calorimetry ◽  
Wide Range

Polymer matrix composites find a wide range of industrial applications due to its unique properties like lightweight, improved strength and the properties could also be tailored to suit specific applications. In this present work, a new class of polymer matrix composites with epoxy resin as matrix and tungsten metal particles as fillers were developed. The influence of the addition of tungsten fillers on mechanical and thermal properties of the composites has been investigated. The composites are fabricated by hand lay-up method and the specimens containing tungsten particle content by 1%, 3%, 5%, 7% and 9% by weight were developed. The developed specimens were subjected to mechanical and thermal investigations. Mechanical behavior was analyzed by conducting a flexural test and hardness as per ASTM standards. Thermal behavior was analyzed by conducting Thermogravimetric analysis (TGA) and Differential Scanning Calorimetry (DSC) of the developed composites. The results show that the addition of 7 wt. % filler has a higher value of flexural strength and hardness. Further addition of particulate fillers deteriorates the flexural strength and hardness due to agglomeration of filler content in the epoxy. Analysis by TGA and DSC shows that the thermal stability of composites is improved by increasing the addition of tungsten content in the epox.

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