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Korycki A, Garnier C, Bonmatin M, Laurent E, Chabert F. Assembling of Carbon Fibre/PEEK Composites: Comparison of Ultrasonic, Induction, and Transmission Laser Welding. MATERIALS (BASEL, SWITZERLAND) 2022; 15:6365. [PMID: 36143674 PMCID: PMC9503134 DOI: 10.3390/ma15186365] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 08/10/2022] [Revised: 09/05/2022] [Accepted: 09/07/2022] [Indexed: 06/16/2023]
Abstract
In the present work, an ultrasonic, an induction, and a through transmission laser welding were compared to join carbon fibre reinforced polyetheretherketone (CF/PEEK) composites. The advantages and drawbacks of each process are discussed, as well as the material properties required to fit each process. CF/PEEK plates were consolidated at 395 °C with an unidirectional sequence and cross-stacking ply orientation. In some configurations, a polyetherimide (PEI) layer or substrate was used. The thermal, mechanical, and optical properties of the materials were measured to highlight the specific properties required for each process. The drying conditions were defined as 150 °C during at least 8 h for PEI and 24 h for CF/PEEK to avoid defects due to water. The optical transmission factor of PEI is above 40% which makes it suitable for through transmission laser welding. The thermal conductivity of CF/PEEK is at most 55 W·(m·K)-1, which allows it to weld by induction without a metallic susceptor. Ultrasonic welding is the most versatile process as it does not necessitate any specific properties. Then, the mechanical resistance of the welds was measured by single lap shear. For CF/PEEK on CF/PEEK, the maximum lap shear strength (LSS) of 28.6 MPa was reached for a joint obtained by ultrasonic welding, while an induction one brought 17.6 MPa. The maximum LSS of 15.2 MPa was obtained for PEI on CF/PEEK assemblies by laser welding. Finally, interfacial resistances were correlated to the fracture modes through observations of the fractured surfaces. CF/PEEK on CF/PEEK joints resulted in mixed cohesive/adhesive failure at the interface and within the inner layers of both substrates. This study presents a guideline to select the suitable welding process when assembling composites for the aerospace industry.
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Affiliation(s)
- Adrian Korycki
- Laboratoire Génie de Production, ENIT-INPT, University of Toulouse, 47 Avenue d’Azereix, 65016 Tarbes, France
| | - Christian Garnier
- Laboratoire Génie de Production, ENIT-INPT, University of Toulouse, 47 Avenue d’Azereix, 65016 Tarbes, France
| | - Margot Bonmatin
- Laboratoire Génie de Production, ENIT-INPT, University of Toulouse, 47 Avenue d’Azereix, 65016 Tarbes, France
- Institut Clement Ader (ICA), University of Toulouse, CNRS, IMT Mines Albi, INSA, ISAE-SUPAERO, UPS, Campus Jarlard, 81013 Albi, France
| | - Elisabeth Laurent
- CNES, Sous-Direction Assurance Qualité, Service Technologies, Matériaux et Procédés, 18 Avenue Edouard Belin, 31401 Toulouse, France
| | - France Chabert
- Laboratoire Génie de Production, ENIT-INPT, University of Toulouse, 47 Avenue d’Azereix, 65016 Tarbes, France
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The Factors That Affect the Expansion of the Tape for It to Avoid Side Effects in the Production of Composites in Online LATP Technology. JOURNAL OF COMPOSITES SCIENCE 2021. [DOI: 10.3390/jcs5100284] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/16/2022]
Abstract
During LATP (laser automated tape placement), the compaction roller contacts the prepreg and affects the pressure distribution directly. Moreover, the design parameters of the roller are optimized with the aim of improving pressure uniformity. This paper examines the impact of the contact line and surface that depends on the compaction force, the design of the roller, the angle of inclination and the angle of inclination of the strip. These factors significantly affect the expansion of the tape, and it is important to determine it to avoid side effects in the production of composites (formation of gaps or overlaps). Their presence increases the percentage of pores of the final material and thus reduces the mechanical properties. The results show that the pressure uniformity can be improved significantly by design optimization of the roller, which indicates that higher bond quality between layers is achieved. The lower the speed and higher the compact force in this technology give better intimate contact with a lower percentage of voids and good mechanical characteristics.
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