Ring-Focused Ultrasonic Welding of CF/PEEK Composites Without Energy Director
摘要
Ultrasonic welding has a promising application prospect in the connection of thermoplastic composites. Upgrading ultrasonic welding technology is extremely important to achieve rapid connection while ensuring the reliable quality of the joint. In this paper, the carbon fiber-reinforced polyether-ether-ketone (CF/PEEK) was welded by the ring-focused ultrasonic welding process, and a comparative study was conducted with the conventional ultrasonic welding process. A simple model of ring-focused ultrasonic welding was established and the thermal generation of the welding interface was analyzed. The experimental results show that the introduced circular suspended area can effectively focus the welding energy and limit the Coulomb friction to the suspended area, generating more heat at the welding interface, promoting the diffusion of molten resin at the interface, and ultimately obtaining a larger weld area, significantly improving the weld strength. For example, at a suspended diameter of 10 mm, the optimal joint strength obtained is more than 2.1 times the strength of the conventional ultrasonic welded joint. Finally, the ring-focused ultrasonic welding proposed in this paper provides a new method for welding without energy guide ribs, enhancing joint strength and design flexibility, reducing costs, and facilitating the large-scale manufacturing of thermoplastic composites.