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<p>This article presents a comprehensive exploration of ultrasonic welding across conventional, water-submerged, and saltwater-submerged conditions. Utilizing Taguchi L25 arrays, a systematic optimization process revealed nuanced parameter adjustments tailored to each welding scenario. Shore-D hardness tests confirmed mechanical resilience under optimized settings, showcasing distinct outcomes in water and saltwater-submerged welding. SEM imaging unveiled unique microstructural characteristics, emphasizing increased porosity in the central region in saltwater-submerged conditions. The deductions drawn underscore the feasibility of ultrasonic welding for thermoplastic composites in diverse environments, challenging conventional methods. Notably, optimized weld strength or USL in water and saltwater-submerged conditions exceeded that of conventional welding, demonstrating the potential of ultrasonic welding in subaqueous applications. The increased hardness observed in all welded specimens, attributed to post-weld refusion of 3D-printed layers, was substantiated by LOM and SEM analyses. While providing valuable insights, the study calls for further research to explore into the intricate physical and chemical changes during ultrasonic welding of thermoplastic composites in varied environmental conditions. This research lays a foundation for tailoring welding parameters and advancing subaqueous joining and repair operations.</p>

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Experimental Assessment of Quasi-static Strength and Microstructural Integrity in Ultrasonically Welded CF/PA-6 Composites Subjected to Hygrothermal and Saline Immersion

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月9日

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  • Sandeep Bose,
  • Nitesh Dutt,
  • Rahul Shukla,
  • Ashwani Kumar,
  • Yogesh Kumar Singla

摘要

This article presents a comprehensive exploration of ultrasonic welding across conventional, water-submerged, and saltwater-submerged conditions. Utilizing Taguchi L25 arrays, a systematic optimization process revealed nuanced parameter adjustments tailored to each welding scenario. Shore-D hardness tests confirmed mechanical resilience under optimized settings, showcasing distinct outcomes in water and saltwater-submerged welding. SEM imaging unveiled unique microstructural characteristics, emphasizing increased porosity in the central region in saltwater-submerged conditions. The deductions drawn underscore the feasibility of ultrasonic welding for thermoplastic composites in diverse environments, challenging conventional methods. Notably, optimized weld strength or USL in water and saltwater-submerged conditions exceeded that of conventional welding, demonstrating the potential of ultrasonic welding in subaqueous applications. The increased hardness observed in all welded specimens, attributed to post-weld refusion of 3D-printed layers, was substantiated by LOM and SEM analyses. While providing valuable insights, the study calls for further research to explore into the intricate physical and chemical changes during ultrasonic welding of thermoplastic composites in varied environmental conditions. This research lays a foundation for tailoring welding parameters and advancing subaqueous joining and repair operations.