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<p>To overcome the challenge of quality control in ultrasonic welding of continuous carbon fiber reinforced PA66 (CF/PA66) without energy directors, the effects of surface treatment, horn diameter, and welding time on joining quality were investigated. Weld area and mechanical properties of the joint were employed as the core evaluation metrics, complemented by multi-scale analysis of the failure morphology to establish the correlation between process parameters, weld formation quality, and joint performance. A finite element model was developed to simulate the temperature evolution during ultrasonic welding and to elucidate the underlying welding mechanism. The results demonstrate that surface treatment significantly influences weld spot formation and energy input requirements. A smaller surface roughness is beneficial for concentrating welding energy and forming circular weld spots in the center of the overlap area. Horn diameter governs resin extrusion and matrix integrity, and reducing the diameter from 18&#xa0;mm to 9.5&#xa0;mm effectively suppresses excessive melt expulsion while limiting thermal damage to the polymer. For the same horn diameter, surface grinding enhanced the mechanical performance of the joints, with finer surface finishes yielding more pronounced improvements. Weld spots initiation occurs at the center of the overlap area, followed by radial expansion and subsequent longitudinal propagation to the periphery. This study provides theoretical and empirical foundations for optimizing ultrasonic welding of CF/PA66 assemblies without energy directors. </p>

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Effect of surface treatment on ultrasonic welding quality of continuous carbon fiber reinforced PA66 without energy directors

  • 期刊论文

  • 发表日期：

    2026年7月27日

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  • Yang Liu,
  • Yunzhi Zhang,
  • Hao Guo,
  • Weimin Zhuang

摘要

To overcome the challenge of quality control in ultrasonic welding of continuous carbon fiber reinforced PA66 (CF/PA66) without energy directors, the effects of surface treatment, horn diameter, and welding time on joining quality were investigated. Weld area and mechanical properties of the joint were employed as the core evaluation metrics, complemented by multi-scale analysis of the failure morphology to establish the correlation between process parameters, weld formation quality, and joint performance. A finite element model was developed to simulate the temperature evolution during ultrasonic welding and to elucidate the underlying welding mechanism. The results demonstrate that surface treatment significantly influences weld spot formation and energy input requirements. A smaller surface roughness is beneficial for concentrating welding energy and forming circular weld spots in the center of the overlap area. Horn diameter governs resin extrusion and matrix integrity, and reducing the diameter from 18 mm to 9.5 mm effectively suppresses excessive melt expulsion while limiting thermal damage to the polymer. For the same horn diameter, surface grinding enhanced the mechanical performance of the joints, with finer surface finishes yielding more pronounced improvements. Weld spots initiation occurs at the center of the overlap area, followed by radial expansion and subsequent longitudinal propagation to the periphery. This study provides theoretical and empirical foundations for optimizing ultrasonic welding of CF/PA66 assemblies without energy directors.