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<p>In recent years, fiber-reinforced thermoplastic composites (TPCs) have gained significant traction in the aerospace industry due to their excellent mechanical properties, recyclability, and ability to be rapidly joined through thermal fusion. Among various joining technologies, ultrasonic welding has emerged as one of the most promising techniques for aerospace-grade thermoplastic composites. However, conventional energy directors (EDs) in triangular or rectangular geometries, or the use of flat thermoplastic films as independent energy directors, often result in pronounced interfacial temperature non-uniformity. This uneven heat distribution can lead to localized thermal degradation and, consequently, compromised weld strength. To address this challenge, this study introduces an innovative woven mesh structure energy director for ultrasonic spot and continuous welding of carbon fiber reinforced polyetheretherketone (CF/PEEK) composites. Under the optimal welding time of 550 ms, the spot-welded joints achieved a lap shear strength of 40.3&#xa0;MPa. On this basis, a maximum joint strength of 33.9&#xa0;MPa was obtained for continuous ultrasonic welding at an optimal welding speed of 25&#xa0;mm/s, with uniform joint quality observed throughout the weld seam.</p>

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High-Quality Spot and Continuous Ultrasonic Welding of Carbon Fiber Reinforced Polyetheretherketone (CF/PEEK) Composites Using PEEK Mesh Energy Directors

  • 期刊论文

  • 发表日期：

    2026年1月13日

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  • Yanrui Li,
  • Zhijie Liu,
  • Wenqiang Liao,
  • Yuyao Li,
  • Li Deng,
  • Yi Zhang

摘要

In recent years, fiber-reinforced thermoplastic composites (TPCs) have gained significant traction in the aerospace industry due to their excellent mechanical properties, recyclability, and ability to be rapidly joined through thermal fusion. Among various joining technologies, ultrasonic welding has emerged as one of the most promising techniques for aerospace-grade thermoplastic composites. However, conventional energy directors (EDs) in triangular or rectangular geometries, or the use of flat thermoplastic films as independent energy directors, often result in pronounced interfacial temperature non-uniformity. This uneven heat distribution can lead to localized thermal degradation and, consequently, compromised weld strength. To address this challenge, this study introduces an innovative woven mesh structure energy director for ultrasonic spot and continuous welding of carbon fiber reinforced polyetheretherketone (CF/PEEK) composites. Under the optimal welding time of 550 ms, the spot-welded joints achieved a lap shear strength of 40.3 MPa. On this basis, a maximum joint strength of 33.9 MPa was obtained for continuous ultrasonic welding at an optimal welding speed of 25 mm/s, with uniform joint quality observed throughout the weld seam.