Speaker
Description
Continuous induction welding is particularly suitable for joining carbon fiber-reinforced polymer composites (CFRPC) with thermoplastic matrix, as the energy required for welding is introduced without contact and leads to intrinsic volumetric heating of the adherends. However, the heating is not homogeneous in thickness direction of the laminate. Instead, it leads to a temperature maximum on the inductor faced laminate surface. The great potential of fast heating cannot be fully exploited. Therefore, a process optimization of continuous induction welding was carried out, which follows three complementary approaches.
The first approach provides for the development of an adapted laminate structure. By means of inductive heating tests, the heating behavior of textile-reinforced CFRPC laminates was investigated. Based on these findings, an adapted laminate structure was developed. Compared to a conventional CFRPC laminate, the heating in the joining zone is approx. 16 K/s faster with the adapted laminate structure.
The second approach intends to optimize the currently used compressed air cooling system to cool the inductor faced laminate surface. Spray cooling proved to be the most suitable method. Compared to compressed air cooling, it was possible to achieve a temperature difference between the joining zone and the inductor faced laminate surface, that was approximately twice as large.
The third approach aims at the simulation-based improvement of the consolidation phase. Based on a mechanical-thermal model of the consolidation roller, it can be shown, that the cooling effect of the roller has no significant influence on the temperature profile in the joining zone at a typical part thicknesses of 2 mm. Furthermore, this model can be used to determine the joining pressure required to achieve intimate contact. This increases the robustness of the process.
All approaches will be presented together with the underlying methodology and the gained results.
| Speaker Country | Germany |
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