High-efficiency ultrasonic welding of CF/epoxy joints with enhanced strength upon tailoring the energy director structure

IF 8.1 2区材料科学 Q1 ENGINEERING, MANUFACTURING Composites Part A: Applied Science and Manufacturing Pub Date : 2025-05-01 Epub Date: 2025-02-12 DOI:10.1016/j.compositesa.2025.108799

Jiaming Liu , Dong Quan , Jiaying Pan , Xuemin Wang , Xi Yang , Guoqun Zhao

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Abstract

Encouraging advancement in the ultrasonic welding of thermoset composites (TSCs) was recently achieved by co-curing weldable thermoplastic coupling layers (CLs) onto their surfaces. However, obvious temperature inhomogeneity at the welding interface easily leads to thermally decomposition of epoxy matrix and irreparable defects in the welds. This study proposed a strategy for producing high-quality ultrasonically-welded TSC joints by utilizing novel-structured thermoplastic meshes as energy directors (EDs). Compared to prevalent film EDs, the usage of mesh EDs significantly promoted the heat generation efficiency and temperature distribution uniformity at welding interfaces. The maximum temperature of TSCs reached during welding processes decreased from 373.7 °C to 216.7 °C with reduced welding time by 32.4 %. These phenomena effectively prevented thermally decomposed epoxy matrix, and resulted in high-quality welding lines with remarkable lap-shear strength, i.e. reaching a maximum value of 31.1 MPa. Overall, this study presents a promising strategy for developing robust TSC joints by tailoring ED structures.

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通过调整导能结构，实现CF/环氧树脂接头的高效超声焊接，提高接头强度

通过在热固性复合材料表面共固化可焊热塑性偶联层（CLs），热固性复合材料（tsc）的超声波焊接取得了令人鼓舞的进展。然而，焊接界面处明显的温度不均匀性容易导致环氧基热分解，导致焊缝出现不可修复的缺陷。本研究提出了一种利用新型结构热塑性网格作为能量引导器（EDs）生产高质量超声焊接TSC接头的策略。与现有的薄膜EDs相比，网状EDs的使用显著提高了焊接界面的产热效率和温度分布均匀性。焊接过程中tsc的最高温度从373.7℃降至216.7℃，焊接时间缩短了32.4%。这些现象有效地防止了环氧树脂基体的热分解，从而获得了高质量的焊缝，焊缝的搭剪强度显著，最高可达31.1 MPa。总的来说，这项研究提出了一种有前途的策略，通过定制ED结构来开发坚固的TSC关节。

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来源期刊

Composites Part A: Applied Science and Manufacturing 工程技术-材料科学：复合

CiteScore

15.20

自引率

5.70%

发文量

492

审稿时长

30 days

期刊介绍： Composites Part A: Applied Science and Manufacturing is a comprehensive journal that publishes original research papers, review articles, case studies, short communications, and letters covering various aspects of composite materials science and technology. This includes fibrous and particulate reinforcements in polymeric, metallic, and ceramic matrices, as well as 'natural' composites like wood and biological materials. The journal addresses topics such as properties, design, and manufacture of reinforcing fibers and particles, novel architectures and concepts, multifunctional composites, advancements in fabrication and processing, manufacturing science, process modeling, experimental mechanics, microstructural characterization, interfaces, prediction and measurement of mechanical, physical, and chemical behavior, and performance in service. Additionally, articles on economic and commercial aspects, design, and case studies are welcomed. All submissions undergo rigorous peer review to ensure they contribute significantly and innovatively, maintaining high standards for content and presentation. The editorial team aims to expedite the review process for prompt publication.