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<p>In the paper, the effect of additively manufactured energy directors (EDs) from polyetherimide (PEI) and polyetheretherketone (PEEK) on the structures and properties of both similar and dissimilar lap-joints of the PEI- and PEEK-based laminates fabricated by ultrasonic welding (USW) is reported. In addition to the used polymers, the EDs differed by their 3D printing infill densities. For the USW lap-joints of the PEI/CF laminates with the PEI EDs, the one at an ED infill density of 15% possessed the highest lap shear strength (LSS) value of 18&#xa0;MPa. The USW lap-joints of the similar and dissimilar PEI- and PEEK-based laminates had the maximum LSS values above 22&#xa0;MPa with the PEEK ED, and the cohesive failure type was observed. The use of the mesh like additively manufactured PEEK ED with 30% glass fibers contributed to achieving the maximum LSS value of ~ 22&#xa0;MPa for USW joint of the similar PEI-based laminates. Although it is believed that the use of EDs with low melting points is preferable for joining laminates, the obtained results showed opposite pattern. The less fusible PEEK ED provided the higher LSS values due to its semi-crystalline structure and effective mixing with the adherends.</p>

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Ultrasonic Welding of Similar and Dissimilar Polyetherimide- and Polyetheretherketone-Based Laminated Composites Using Additively Manufactured Energy Directors

  • 期刊论文

  • 发表日期：

    2025年2月5日

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  • V. O. Alexenko,
  • D. G. Buslovich,
  • D. Tian,
  • Y. V. Dontsov,
  • A. A. Bogdanov,
  • M. V. Burkov,
  • S. V. Panin

摘要

In the paper, the effect of additively manufactured energy directors (EDs) from polyetherimide (PEI) and polyetheretherketone (PEEK) on the structures and properties of both similar and dissimilar lap-joints of the PEI- and PEEK-based laminates fabricated by ultrasonic welding (USW) is reported. In addition to the used polymers, the EDs differed by their 3D printing infill densities. For the USW lap-joints of the PEI/CF laminates with the PEI EDs, the one at an ED infill density of 15% possessed the highest lap shear strength (LSS) value of 18 MPa. The USW lap-joints of the similar and dissimilar PEI- and PEEK-based laminates had the maximum LSS values above 22 MPa with the PEEK ED, and the cohesive failure type was observed. The use of the mesh like additively manufactured PEEK ED with 30% glass fibers contributed to achieving the maximum LSS value of ~ 22 MPa for USW joint of the similar PEI-based laminates. Although it is believed that the use of EDs with low melting points is preferable for joining laminates, the obtained results showed opposite pattern. The less fusible PEEK ED provided the higher LSS values due to its semi-crystalline structure and effective mixing with the adherends.