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<p>Continuous ultrasonic welding presents an efficient and energy-saving approach for joining large thermoplastic composite structures. This study examines the heating behavior and weld growth mechanism of carbon fiber-reinforced nylon 66 (CF/PA66) composites through finite element simulations and experimental validation. The analysis reveals that the upper adherend generates approximately 20% more viscoelastic dissipation energy than the lower one, resulting in a 4–7% higher peak temperature at the top interface. The heating process is divided into three distinct stages: initial frictional heating, friction-assisted viscoelastic heating, and steady-state viscoelastic heating. These findings establish a theoretical foundation for enhancing the quality and performance of joints in continuous ultrasonic welding.&#xa0;</p>

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Study on heating process and weld growth mechanism in continuous ultrasonic welding of carbon fiber reinforced thermoplastic composite

  • 期刊论文

  • 发表日期：

    2025年5月19日

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  • Fulin Yao,
  • Zenan Chu,
  • Chao Tan,
  • Yue Zhao,
  • Yuan Wei,
  • Tingfeng Yan,
  • Zhelin Li

摘要

Continuous ultrasonic welding presents an efficient and energy-saving approach for joining large thermoplastic composite structures. This study examines the heating behavior and weld growth mechanism of carbon fiber-reinforced nylon 66 (CF/PA66) composites through finite element simulations and experimental validation. The analysis reveals that the upper adherend generates approximately 20% more viscoelastic dissipation energy than the lower one, resulting in a 4–7% higher peak temperature at the top interface. The heating process is divided into three distinct stages: initial frictional heating, friction-assisted viscoelastic heating, and steady-state viscoelastic heating. These findings establish a theoretical foundation for enhancing the quality and performance of joints in continuous ultrasonic welding.