<p>Continuous ultrasonic welding is an efficient and precise technique for joining thermoplastic composites. However, the dynamic nature of the process poses challenges in maintaining uniform joint quality, often leading to significant variation between the start and end of the weld. To address this issue, this study aims to enhance the uniformity of weld quality. Finite element analysis is employed to simulate energy density distribution under varying welding speeds, revealing a hysteresis effect in energy transfer. Based on this observation, several welding speed control strategies are proposed. The energy density distribution characteristics of these strategies are analyzed to identify the optimal welding speed control strategies. Subsequent continuous ultrasonic welding experiments are conducted to quantitatively assess joint quality uniformity, using tensile strength as the evaluation metric. The results demonstrate that the optimized speed control strategy significantly enhances weld quality consistency, providing a reliable method for quality control in continuous ultrasonic welding of carbon-fiber reinforced thermoplastic composite.</p>

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Enhancing process stability in continuous ultrasonic welding of CFRTP: A welding speed-quality uniformity correlation study

  • Fulin Yao,
  • Zhelin Li,
  • Yue Zhao,
  • Yuan Wei,
  • Tingfeng Yan,
  • Xue Cao

摘要

Continuous ultrasonic welding is an efficient and precise technique for joining thermoplastic composites. However, the dynamic nature of the process poses challenges in maintaining uniform joint quality, often leading to significant variation between the start and end of the weld. To address this issue, this study aims to enhance the uniformity of weld quality. Finite element analysis is employed to simulate energy density distribution under varying welding speeds, revealing a hysteresis effect in energy transfer. Based on this observation, several welding speed control strategies are proposed. The energy density distribution characteristics of these strategies are analyzed to identify the optimal welding speed control strategies. Subsequent continuous ultrasonic welding experiments are conducted to quantitatively assess joint quality uniformity, using tensile strength as the evaluation metric. The results demonstrate that the optimized speed control strategy significantly enhances weld quality consistency, providing a reliable method for quality control in continuous ultrasonic welding of carbon-fiber reinforced thermoplastic composite.