丙烯腈-丁二烯-苯乙烯热塑性塑料的超声波焊接,无需能量导管

Materials Pub Date : 2024-07-23 DOI:10.3390/ma17153638
Qian Zhi, Yongbing Li, Xinrong Tan, Yuhang Hu, Yunwu Ma
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摘要

热塑性塑料的超声波焊接(USW)在汽车工业中发挥着重要作用。本研究探讨了焊接时间对超声波焊接丙烯腈-丁二烯-苯乙烯(ABS)接头强度的影响以及焊缝形成机理。结果表明,峰值载荷首先增加到 3.4 kN 的最大值,然后随着焊接时间的进一步延长而下降,而焊接面积则持续增加,直至达到峰值。ABS USW 的最佳焊接变量为 1.3 秒的焊接时间和 0.13 兆帕的焊接压力。界面失效和工件破损是接头的主要失效模式。在有限元模型中应用实时角位移可以提高焊缝成形的模拟精度。模拟结果与实验结果接近,1.7 s 焊接时间下的 ABS USW 焊接过程可根据振幅和牛角位移变化分为五个阶段:焊接开始(第一阶段)、牛角回缩(第二阶段)、熔流平衡(第三阶段)、牛角压痕和挤出(第四阶段)以及焊接凝固(第五阶段)。在第四阶段,由于 ABS 的热分解,出现了明显的气孔。这项研究从根本上了解了 ABS 的 USW,为进一步应用和推广其他超声焊接热塑性复合材料提供了理论基础和技术支持。
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Ultrasonic Welding of Acrylonitrile–Butadiene–Styrene Thermoplastics without Energy Directors
Ultrasonic welding (USW) of thermoplastics plays a significant role in the automobile industry. In this study, the effect of the welding time on the joint strength of ultrasonically welded acrylonitrile–butadiene–styrene (ABS) and the weld formation mechanism were investigated. The results showed that the peak load firstly increased to a maximum value of 3.4 kN and then dropped with further extension of the welding time, whereas the weld area increased continuously until reaching a plateau. The optimal welding variables for the USW of ABS were a welding time of 1.3 s with a welding pressure of 0.13 MPa. Interfacial failure and workpiece breakage were the main failure modes of the joints. The application of real-time horn displacement into a finite element model could improve the simulation accuracy of weld formation. The simulated results were close to the experimental results, and the welding process of the USW of ABS made with a 1.7 s welding time can be divided into five phases based on the amplitude and horn displacement change: weld initiation (Phase I), horn retraction (Phase II), melt-and-flow equilibrium (Phase III), horn indentation and squeeze out (Phase IV) and weld solidification (Phase V). Obvious pores emerged during Phase IV, owing to the thermal decomposition of the ABS. This study yielded a fundamental understanding of the USW of ABS and provides a theoretical basis and technological support for further application and promotion of other ultrasonically welded thermoplastic composites.
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