scholarly journals Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing

10.3791/53592 ◽  
2016 ◽  
Author(s):  
Irene F. Villegas ◽  
Genevieve Palardy
Keyword(s):  
Welded Joints ◽  
Mechanical Characterization ◽  
Ultrasonic Welding ◽  
Thermoplastic Composite ◽  
Shear Testing ◽  
Lap Shear

scholarly journals ROBOTIC SEQUENTIAL ULTRASONIC WELDING OF THERMOPLASTIC COMPOSITES: PROCESS DEVELOPMENT AND TESTING

2021 ◽  
Author(s):  
ABHAS CHOUDHARY, ◽  
IRENE FERNANDEZ
Keyword(s):  
Welded Joints ◽  
Industrial Robot ◽  
Welding Process ◽  
Ultrasonic Welding ◽  
Thermoplastic Composite ◽  
Thermoplastic Composites ◽  
Robot Arm ◽  
Spot Welds ◽  
Robotic Platform ◽  
Lap Shear

Multi-spot sequential ultrasonic welding is a promising joining technique for fibre-reinforced thermoplastic composites structures (TPC). In existing research on the multi-spot sequential ultrasonic welding process, welds are produced through the use of a static table-top welding machine, at a coupon level. However, in order to apply this joining technology to large structures, the welding process needs to be up-scaled through the use of a robotic platform. At the Smart Advanced Manufacturing (SAM|XL) automation field lab and TU Delft Aerospace Engineering, a robotic sequential ultrasonic welding system has been developed. The system consists of a welding end-effector (EEF) equipped with various sensors that enable online process monitoring and control, which can be mounted on an industrial robot arm to perform sequential multi-spot welds. The goal of this study was to assess the welding performance of the ultrasonic welding EEF, which was mounted on an industrial KUKA KR210 R2700 Extra 10-axis robot arm, by comparing it to the performance of welds produced through the static table-top machine. In this study, single and multi-spot welds were produced on thermoplastic composite coupons, based on welding conditions which were defined in a preliminary study. The robot and EEF deflections observed during the welding process were analysed to assess the deviation of the robotic process from the static one. The feedback obtained from the welding equipment in terms of consumed power and tool displacement in both processes was also compared. The weld quality was assessed though single lap shear testing of the welded joints as well as fractography of the failure surface. The results of this study indicate that the developed robotic welding process is quite robust and is capable of producing high-quality sequential welded joints despite significant system deflections observed during the welding process. Slightly lower welded area and weld strength was obtained which can be attributed to the system deflections. Finally, the results indicate that the use of a stiffer robotic platform as well as a stiffer EEF construction will result in better system rigidity and weld spot positioning accuracy, and through this the welding process shows promise for large-scale industrial applications.

Physical and mechanical characterization of dissimilar laser welded joints of AISI 316/Cu/SMA using fiber laser technology

2020 ◽  
Vol 32 (3) ◽  
pp. 032018 ◽  
Author(s):  
Suman Chatterjee ◽  
Siba Sankar Mahapatra ◽  
Kanwer Singh Arora ◽  
Ajit Behera
Keyword(s):  
Fiber Laser ◽  
Welded Joints ◽  
Mechanical Characterization ◽  
Laser Technology ◽  
Aisi 316

Microstructural and mechanical characterization of flash-welded joints is HSLA steels

2010 ◽  
Author(s):  
Henrique Varella Ribeiro ◽  
Bruno Cassio Bertoco Versuto ◽  
Carlos Antonio Reis Pereira Baptista
Keyword(s):  
Welded Joints ◽  
Mechanical Characterization ◽  
Hsla Steels

Experimental and Analytical Strength Characterization of an Ultrasonic Welded Lap Shear Joint

2001 ◽  
Author(s):  
Samuel Ibekwe ◽  
Patrick F. Mensah ◽  
Ghanashyam Joshi ◽  
Guoqiang Li ◽  
Michael Stubblefield
Keyword(s):  
Experimental Study ◽  
Composite Materials ◽  
Statistical Difference ◽  
Ultrasonic Welding ◽  
Lap Shear ◽  
Shear Joint ◽  
Strength Characterization

Abstract An experimental study on ultrasonic welding of thermoplastic, which is a prelude to study how the technology can be adapted to join composite materials, was conducted. Three sets of specimen were studied to investigate the influence of energy guide on the bonded specimen. No major statistical difference between the ‘energy guides’ of the tested thermoplastic Celuka™ coupons were noted. Failure of the welded specimen was by shear at the interface. A 75% drop in strength for the bonded material was observed.

Microstructural and Mechanical Characterization of Solder Joints Fabricated by Explosively Reacting Nanolayers

2008 ◽  
Author(s):  
Michael Tong ◽  
Jenn-Ming Yang
Keyword(s):  
Initial Temperature ◽  
Mechanical Characterization ◽  
Solder Joints ◽  
Initial Pressure ◽  
Processing Parameters ◽  
Joint Shear Strength ◽  
Lap Shear ◽  
Joint Shear ◽  
Solder Interface

The unique heat-releasing characteristics of explosively reactive nanolayers (RN) are used in this study to produce Si/solder/Si joints. The microstructure of the RN in the reacted state as well as the post-joining foil/solder interface is characterized via XRD, SEM, and TEM, which have never been done. Additionally, RN solder joints are mechanically characterized by single lap shear and nanoindentation to obtain a set of optimized processing parameters, specifically initial pressure applied (Pa) and initial temperature of the system (Ti). A maximum joint shear strength of ∼ 30MPa at Pa = 15MPa and Ti = 75°C. Furthermore, nanoindentation is used to clarify the mechanical behavior of individual layers and interfaces across the joints as a result of thermal aging.

Mechanical Characterization of 2219 Aluminum Alloy Welded Joints Under Bi-Axial Loading

2019 ◽  
Vol 11 (08) ◽  
pp. 1950077 ◽  
Author(s):  
Guanglong Cao ◽  
Cheng Huang ◽  
Tong Li ◽  
Yahui Zhang ◽  
Mingfa Ren
Keyword(s):  
Aluminum Alloy ◽  
Welded Joints ◽  
Mechanical Characterization ◽  
Axial Loading ◽  
Failure Behavior ◽  
Shear Load ◽  
Tensile Shear ◽  
2219 Aluminum Alloy ◽  
Mechanical Performances

The mechanical performances of welded joints under bi-axial loading are significant to the reliability of various engineering structures. However, the protocol for the mechanical characterization of welded joints still needs to be improved to represent the mechanical performances of welded joints under complex loading conditions. In this work, an experimental design is proposed for the mechanical characterization of 2219 aluminum alloy welded joints. The target is to investigate the effects of combined tensile-shear load on the mechanical responses and failure behavior of 2219 aluminum alloy welded joints. The tensile-shear characterization was then conducted using a newly developed U-notch aluminum alloy welded joints specimen. In addition, standard tensile test and standard shear test were conducted to validate of the U-notch specimen design. This newly proposed experimental protocol is suitable to obtain mechanical properties of 2219 aluminum alloy welded joints subjected to tensile-shear load.

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.

Mechanical Characterization of Electro-Bonded Laminates

2012 ◽  
Author(s):  
Luigi Di Lillo ◽  
Wolfram Raither ◽  
Claudio Di Fratta ◽  
Andrea Bergamini ◽  
Paolo Ermanni
Keyword(s):  
Electric Fields ◽  
Mechanical Characterization ◽  
Shear Tests ◽  
Shear Center ◽  
Element Analysis ◽  
Lap Shear ◽  
Morphing Wings ◽  
Center Position ◽  
High Electric Fields

This work reports on the coupled electro-mechanical simulation and mechanical characterization of electro-bonded laminates (EBL). In light of their conceivable implementation in morphing wings as leading/trailing edge reinforcement plates or as active elements for shear center position adaptation, values of shear strength comparable to those achievable by an epoxy resin, i.e. 10–15 [MPa], are needed. Finite element analysis routines have been implemented to gain insights into the shear behavior of EBL under high electric fields. Further, they allowed for the optimization of EBL in terms of electrode shaping in order to obtain a smooth introduction of axial stresses, avoiding thereby the appearance of shear stress singularities at the edges of the structures. Experimental verification was carried out through single lap shear tests. These experiments quantified the mechanical properties of electro bonded interfaces, assessed the importance of the thickness and alignment of electrodes and the degradation of their constitutive layers due to friction.

Sign in / Sign up

Export Citation Format

Share Document