Weld Quality Prediction in Ultrasonic Welding of Carbon Fiber Composite Based on an Ultrasonic Wave Transmission Model

2019 ◽  
Vol 141 (8) ◽  
Author(s):  
Yang Li ◽  
Zhiwei Liu ◽  
Junqi Shen ◽  
Tae Hwa Lee ◽  
Mihaela Banu ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Ultrasonic Wave ◽  
Composite Structures ◽  
Fiber Composite ◽  
Ultrasonic Welding ◽  
Wave Transmission ◽  
Transmission Model ◽  
Quality Prediction ◽  
Weld Quality ◽  
Carbon Fiber Composite

Ultrasonic welding has been widely used in joining plastic parts since it is fast, economical, and suitable for automation. It also has great potential for joining thermoplastic composite structures in the aerospace and automotive industries. For a successful industrial application of ultrasonic composite welding, it is necessary to have effective weld quality prediction technology. This paper proposes a model for weld quality prediction by establishing a correlation between ultrasonic wave transmission and welding process signatures. The signatures, welding power, and force are directly related to the weld quality. This model is used to predict the weld quality with three contact conditions and validated by experiments. The results show that the quality model performs well when a centralized and consistent contact condition is achieved. The model provides a process physics-based solution for the online weld quality prediction in ultrasonic welding of carbon fiber composite.

Research about Jet Flow Mechanism and Flow Field Analysis for Layered Composite Materials

2013 ◽  
Vol 415 ◽  
pp. 642-646
Author(s):  
Yi Yong Yao ◽  
Rong Ya Zhou ◽  
Li Ping Zhao
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Composite Structures ◽  
Cfd Simulation ◽  
Simulation Analysis ◽  
Fiber Composite ◽  
Layered Composite ◽  
Field Analysis ◽  
Carbon Fiber Composite ◽  
Flow Field Analysis

Layered carbon fiber composite performing microstructure was a part of multi-layer porous piping dielectric structure. At first a jet mechanism was put forward and researched for layered composite materials. The Z reinforcing fibers puncture was put to the layered composite structures. By the CFD simulation analysis, the feasibility of jet puncture was verified, the interlayer strength of the connection was increased and the Z bunch to the carbon fiber was eliminated, which laid theoretical foundation by enhancing the layered carbon fiber composite perform quality.

Damage Location Sensing in Carbon Fiber Composites Using Extrusion Printed Electronics

2021 ◽  
Author(s):  
Mohamad Kannan Idris ◽  
Paria Naderi ◽  
Garrett W. Melenka ◽  
Gerd Grau
Keyword(s):  
Carbon Fiber ◽  
Composite Structures ◽  
Fiber Composite ◽  
Weight Ratio ◽  
Textile Composites ◽  
Carbon Fiber Composites ◽  
Carbon Fiber Composite ◽  
Engineering Structures ◽  
Fiber Sheet ◽  
Carbon Fiber Sheet

Abstract Structural Health Monitoring (SHM) uses sensors in advanced engineering structures to evaluate integrity and detect damage or deformation affecting structural performance, e.g., cracks, holes, or corrosion. Carbon fiber textile composites are commonly used to reinforce structures such as aircraft, vehicles, or bridges due to their high tensile strength to weight ratio, chemical resistance, and thermal and electrical conductivity. Printing electronics on textiles is a scalable manufacturing technology combining the physical properties of textile materials with the added functionality of electronic elements making them self-sensing. Extrusion printing is a contactless digital printing method to print electrical conductors and passive circuit elements. This paper proposes to combine conventional carbon fiber composite manufacturing processes with printed conductors to create self-sensing carbon fiber textile composites. Damage is sensed by measuring resistance changes in a carbon fiber sheet. Contacts are extrusion printed directly on woven carbon fiber sheets using silver flake ink. A multiplexed Kelvin Double Bridge circuit is the read-out interface. This allows small resistance changes due to damage to be measured in a 4-point configuration. The circuit is connected to the printed contacts on the carbon fiber sheet through multiplexers to detect damage in different locations. This 2D digital sensor can detect the location and size of damage holes for SHM. The resolution of the sensor is controlled by the location and spacing of the silver electrodes, which were studied experimentally and by simulation. The resolution is 26 mm in the current direction and 16 mm in the orthogonal direction. The threshold of detectable damage is 4 mm2. Simulation of the sensor as an isotropic 2D conductor shows good agreement with experimental results for the orthotropic fabric. The resultant sensing device could be integrated into many composite structures as one of its layers or simply printed on the surface to create smart structures.

Introducing graphene thin films into carbon fiber composite structures for lightning strike protection

2018 ◽  
Vol 40 (S1) ◽  
pp. E517-E525 ◽  
Author(s):  
Sachin S.A. Kumar ◽  
Md. Nizam Uddin ◽  
Muhammad M. Rahman ◽  
Ramazan Asmatulu
Keyword(s):  
Thin Films ◽  
Carbon Fiber ◽  
Composite Structures ◽  
Fiber Composite ◽  
Lightning Strike ◽  
Carbon Fiber Composite

scholarly journals Global and local area inspection methods in damage detection of carbon fiber composite structures

Measurement ◽  
2021 ◽  
pp. 110336
Author(s):  
Kaleeswaran Balasubramaniam ◽  
Piotr Fiborek ◽  
Dominika Ziaja ◽  
Michał Jurek ◽  
Mirosław Sawczak ◽  
...  
Keyword(s):  
Carbon Fiber ◽  
Damage Detection ◽  
Composite Structures ◽  
Fiber Composite ◽  
Local Area ◽  
Carbon Fiber Composite ◽  
Global And Local

Isothermal Multisection Tooling for the Automated Preforming of Carbon Fiber Composite Structures

2014 ◽  
Vol 611-612 ◽  
pp. 349-355
Author(s):  
Farbod Nosrat Nezami ◽  
Thomas Gereke ◽  
Chokri Cherif
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Weight Reduction ◽  
Composite Structures ◽  
Fiber Composite ◽  
High Volume ◽  
Carbon Fiber Composite ◽  
Reinforced Composite ◽  
Temperature Levels

In order to decrease CO2 emissions caused by individual transport, fibre-reinforced composite materials are used to reduce vehicle weight and thus fuel consumption. Low productivity of current processes complicates the introduction of fibre-reinforced materials to high volume series, where weight reduction would have a large impact. This paper presents an experimental preforming environment designed to take into account diverse process requirements of different binder systems and a new tooling concept. By setting different temperature levels on the moulds in areas where the material is drawn in under the blank holders and inside the cavity, prebonding of the fabric plies can be avoided and quality of the preforms is improved. Moreover, cycle time can be reduced as no heating or cooling of the tools is necessary.

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