The authors would like to acknowledge the support of Ten Cate Advanced Materials in the form of free material supply to the work described in this paper.

1. 시편은 초음파 용접을 위해 절단 및 준비 <ol><li> 샘플 (예를 들면, 다이아몬드 톱 또는 워터 제트 절단)의 가장자리 박리 방지 가공 기술을 사용하여 더 큰 열가소성 복합 적층 체에서 25.4 mm X 101.6 mm 측정 직사각형 시료를 잘라. 주의 : 샘플 크기는 ASTM D 1002의 기준에 기초한다. <ol><li> 용접 이음의 강도가 표면에 섬유 방향에 의존하기 때문에 같은 방향으로 모든 샘플을 절단하는데주의를 기울여야 10 용접한다. </li></ol></li><li> 경우에 제조자의 권고에 따라 오븐에서 건조 샘플을 절단 한 후, 열가소성 수지가 수분을 흡수하는 경향이있다 (예를 들면, 여섯 층 탄소 섬유를 135 ℃에서 6 시간이 CF / PEI, 샘플, 폴리 에테르이 강화). </li><li> 약 2 (크기 (복합의 행렬과 동일한 수지)​​ 깔끔한 열가소성 필름으로 만들어진 평면 에너지 이사를 잘라적어도 0.25 mm의 두께를 6mm X 26mm). 필요한 경우, 제조업체의 권장 사항은 다음 에너지 이사를 건조 (예를 들어, PEI 에너지 이사 135 ℃에서 1 시간). </li><li> 용접하기 전에 표본을 박리 코너에 대해 하나 하나를 검사하고 필요한 경우 폐기하십시오. 탈지제 및면 헝겊을 사용하여 청소합니다. 동일한 절차에 따라 평면 에너지 이사를 청소합니다. </li></ol> 단일 랩 전단 쿠폰 2. 초음파 용접 주 : 일정한 진폭으로 용접 초음파 용접기 수 제어 마이크로 프로세서는이 단계에서 사용된다. 이러한 소모 전력 및 컴퓨터 데이터 수집 소프트웨어 sonotrode 대 시간의 변위 용접기 출력 프로세스 데이터. 설계를 정확하게 배치하고 초음파 용접시 단일 랩 전단 샘플 클램프 제조 맞춤형 지그이 단계에서 사용된다 (도 1 참조). 그림 1. 초음파 용접기이 연구에 사용 된 맞춤형 용접 설치 1. sonotrode, 2 : 슬라이딩 플랫폼, (3) : (2 부착) 상부 시료에 대한 클램프, 4 : 낮은 시료에 대한 클램프 (참조에서 재판 엘스 비어의 허가 4.) <a href="https://www.jove.com/files/ftp_upload/53592/53592fig1large.jpg" target="_blank">이 그림의 더 큰 버전을 보려면 여기를 클릭하십시오.</a> <ol><li> 각 용접 실험 전에 로그 북 시트를 작성합니다. <ol><li> RT와 습도, 용접 설치 기준, sonotrode 유형, 샘플 수와 재료, 폭, 상단과 하단 샘플의 두께 및 에너지 이사의 두께 : 다음 매개 변수를 기록해 둡니다. </li></ol></li><li> 초음파 용접기와 컴퓨터를 켭니다. 데이터 수집 소프트웨어를 시작하고 새 세션을 엽니 다. </li><li> 아니 이미의 경우, sonot 변경그 바닥 표면은 완전히 용접 영역을 덮도록 40mm의 직경을 갖는 원통형 sonotrode 탔다. 참고 sonotrode 다른 형상이 사용될 수 있지만, 그 바닥면은 용접 영역보다 작은이어야한다. </li><li> 위치 및 용접 지그에 시험편 및 에너지 디렉터를 흥분시키는 (도 1 참조). <ol><li> 이 지역은 용접하는 것보다 약간 더 큰 지역 (12.7 mm X 25.4 mm)를 덮도록 접착 테이프로 바닥 시편에 평면 에너지 디렉터를 연결합니다. </li><li> 지그로 바닥 샘플을 놓고 상단 나사를 체결하여 고정. </li><li> 그 과정에서 위치에 유지되도록 설정의베이스에 에너지 디렉터의 다른 쪽 끝을 테이프입니다. </li><li> 클램프에 위 샘플을 놓고 맞 춥니 상단 나사를 조입니다. </li><li> 슬라이딩 플랫폼에 가기 샘플에 대한 클램프를 놓고 두 나사를 조입니다. </li><li> 더 진행하기 전에, m 한 번에 4 개의 나사를 조광석. </li></ol></li><li> 단계 2.5.8 2.5.1에​​ 기술 된 바와 같이, 높은 용접 강도를 얻기 sonotrode의 변위에 기초하여 상기 진동 단계의 최적 지속 시간을 결정한다. 주 : 진동 위상의 최적 지속 시간은 용접 력 및 진폭의 원하는 각 조합에 대해 결정된다. <ol><li> 변위 제어 모드를 차동 초음파 용접기를 설정합니다. </li><li> 입력은 (예를 들어, 300 μm의 N 및 86.2)를 초음파 용접기에 힘 진폭 용접. 주 :이 초음파 용접기를 들어 86.2 ㎛의 피크 - 투 - 피크 진폭에 상당한다. 기기 설정에서,이 값의 절반, 43.1 μm의로서 표현된다. </li><li> 입력 (예를 들면, 0.25 mm)의 에너지 디렉터의 초기 두께와 동일한 값으로 진동 위상의 끝에 sonotrode 변위 또는 여행. </li><li> 입력 응고 력 시간 초음파 용접기로 (예를 들어, 1000N 4000 밀리 초). </li><li> 준비가되면, 방음 헤드폰에 넣고 초음파 용접 공정을 시작합니다. </li><li> 용접 거리, 최대 전력, 진동 시간과 에너지 : 공정 종료 후, 다음과 같은 출력 파라미터을 기록해. 용접 설정에서 쿠폰을 제거하고 모두 페인트 마커로 끝나는에서의 식별 번호를 작성합니다. </li><li> 스프레드 시트에 용접 데이터 (전력 sonotrode 변위)를 내보내기 프로세스의 진동 단계 동안 시간 곡선 대 힘 및 변위를 플롯. 주 : 변위 곡선 진동 위상의 시작에서 그 위치에 대하여 sonotrode의 하향 변위를 플롯한다. </li><li> (이 경우, 0.10 mm에서) 그림 2에서와 같이 전원 고원 (4 단계)의 중간에 변위를 확인합니다. 주 :이 특정 변위 값 진동 위상 뜻의 지속 시간을 제어하는​​ 최적의 여행같은 용접 힘과 진폭에 대한 모든 후속 용접에 사용 될 수있다. </li></ol></li></ol><img alt="그림 2" src="/files/ftp_upload/53592/53592fig2.jpg" /> 도 2의 전원 (검정)과 최적의 이동량을 나타내는 초음파 용접 프로세스 변위 (회색) 곡선. 초음파 용착의 진동의 위상은 5 단계로 나눌 수있다. 최적의 이동량이 단계 4. 연구 케이스 내에 위치 : 탄소 섬유는 폴리 에테르이 미드 -PEI 기판, 0.25 mm 두께의 평면 PEI 에너지 이사, (300) N 용접 힘, 86.2 μm의 진동 진폭, 0.25 mm 여행을 강화했다. (엘스 비어의 허가 기준 4에서 재판.) <a href="https://www.jove.com/files/ftp_upload/53592/53592fig2large.jpg" target="_blank">이 그림의 더 큰 버전을 보려면 여기를 클릭하십시오.</a> <ol start="6"><li> 주어진 용접 힘과 진폭 combinatio에 대한 최적의 이동량에서 용접 쿠폰엔. <ol><li> 반복 각 용접을 위해 2.5.6 2.1 단계를 반복합니다. 단계 2.5.3에서 해당 용접 힘과 진폭 조합 단계 2.5.8에서 결정된 최적의 여행을 사용합니다. 주 : 모든 LSS 시험은 1.3 mm / 분의 크로스 헤드 속도로 만능 시험기에서 ASTM D 1002에 따라 수행된다. </li></ol></li></ol> 용접 쿠폰 3. 단일 랩 전단 강도 (LSS) 테스트 <ol><li> 측정하고 각각의 용접 쿠폰의 중복의 폭을 기록해 둡니다. </li><li> 만능 시험기를 켜고 컴퓨터에 LSS에 대한 테스트 절차를 엽니 다. </li><li> 테스트 인터페이스에서 샘플 수와 겹치는 크기를 입력한다. 0 힘 (예를 들면, 60mm) 초기 위치로 손잡이 대 그립 분리를 설정한다. </li><li> 도 3에 도시 된 바와 같이, 시험 장치의 그립에 샘플을 놓고. </li></ol><img alt="그림 3" srC = &quot;/ 파일 / ftp_upload / 53592 / 53592fig3.jpg&quot;/&gt; Zwick의 / Roell 사 250 KN 만능 시험기 (축척되지 않은)에 클램프의 그림 3. 도식보기. 상부와 하부 그립 사이의 오프셋 (offset) 변위는 랩 전단 중 굽힘 최소화하기 위해 중앙 용접 라인 부하 방향을 정렬 할 수 있습니다 강도 시험. <a href="https://www.jove.com/files/ftp_upload/53592/53592fig3large.jpg" target="_blank">이 그림의 더 큰 버전을 보려면 여기를 클릭하십시오.</a> <ol start="5"><li> &quot;시작&quot;버튼을 클릭하여 컴퓨터에서 테스트 절차를 시작합니다. </li><li> 샘플 휴식 후, 그립에서 제거 및 테이프와 함께 두 부분을 고정합니다. </li><li> 반복 3.3 다른 모든 샘플에 대한 3.6 단계를. </li><li> 검사가 완료되면, 각각의 용접 력 및 진폭의 조합을 위해, 표준에 기술 된 절차에 따라, 스프레드 시트에 데이터를 보내어 LSS 평균 값을 계산한다. </li></ol>

<ol>
	<li>Yousefpour, A., Hojjati, M., Immarigeon, J. P. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Fusion+bonding/welding+of+thermoplastic+composites.">Fusion bonding/welding of thermoplastic composites.</a> J Thermoplast Compos. 17, 303-341 (2004).</li><li>Villegas, I. F. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=In+situ+monitoring+of+ultrasonic+welding+of+thermoplastic+composites+through+power+and+displacement+data.">In situ monitoring of ultrasonic welding of thermoplastic composites through power and displacement data.</a> J Thermoplast Compos. 28 (1), 66-85 (2015).</li><li>Benatar, A., Gutowski, T. G. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Ultrasonic+welding+of+PEEK+Graphite+APC-2+composites.">Ultrasonic welding of PEEK Graphite APC-2 composites.</a> Polym Eng Sci. 29 (23), 1705-1721 (1989).</li><li>Villegas, I. F. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Strength+development+versus+process+data+in+ultrasonic+welding+of+thermoplastic+composites+with+flat+energy+directors+and+its+application+to+the+definition+of+optimum+processing+parameters.">Strength development versus process data in ultrasonic welding of thermoplastic composites with flat energy directors and its application to the definition of optimum processing parameters.</a> Compos Part A-Appl S. 65, 27-37 (2014).</li><li>Lu, H. M., Benatar, A., He, F. G. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Sequential+ultrasonic+welding+of+PEEK/graphite+composite+plates.">Sequential ultrasonic welding of PEEK/graphite composite plates.</a> Proceedings of the ANTEC'91 Conference. , 2523-2526 (1991).</li><li>Potente, H. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Ultrasonic+welding+-+principles+&amp;+theory.">Ultrasonic welding - principles &amp; theory.</a> Mater Design. 5, 228-234 (1984).</li><li>Stavrov, D., Bersee, H. E. N. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Resistance+welding+of+thermoplastic+composites+-+an+overview.">Resistance welding of thermoplastic composites - an overview.</a> Compos Part A-Appl S. 36, 39-54 (2005).</li><li>Villegas, I. F., Valle-Grande, B., Bersee, H. E. N., Benedictus, R. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=A+comparative+evaluation+between+flat+and+traditional+energy+directors+for+ultrasonic+welding+of+CF/PPS+thermoplastic+composites.">A comparative evaluation between flat and traditional energy directors for ultrasonic welding of CF/PPS thermoplastic composites.</a> Compos Interface. , (2015).</li><li>Levy, A., Le Corre, S., Villegas, I. F. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Modelling+the+heating+phenomena+in+ultrasonic+welding+of+thermoplastic+composites+with+flat+energy+directors.">Modelling the heating phenomena in ultrasonic welding of thermoplastic composites with flat energy directors.</a> J Mater Process Tech. , 1361-1371 (2014).</li><li>Shi, H., Villegas, I. F., Bersee, H. E. N. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Strength+and+failure+modes+in+resistance+welded+thermoplastic+composite+joints:+effect+of+fibre-matrix+adhesion+and+fibre+orientation.">Strength and failure modes in resistance welded thermoplastic composite joints: effect of fibre-matrix adhesion and fibre orientation.</a> Compos Part A-Appl S. 55, 1-10 (2013).</li><li>Villegas, I. F., Bersee, H. E. N. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Ultrasonic+welding+of+advanced+thermoplastic+composites.+An+investigation+on+energy-directing+surfaces.">Ultrasonic welding of advanced thermoplastic composites. An investigation on energy-directing surfaces.</a> Adv Polym Tech. 29 (2), 113-121 (2010).</li><li>Harras, B. K., Cole, C., Vu-Khanh, T. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Optimization+of+the+ultrasonic+welding+of+PEEK-carbon+composites.">Optimization of the ultrasonic welding of PEEK-carbon composites.</a> J Reinf Plast Comp. 15 (2), 174-182 (1996).</li></ol>

The authors declare that they have no competing financial interest.

앞 절에서 제시된 결과는 기계적 시험을 목적으로 열가소성 복합 단일 무릎 쿠폰의 초음파 용접이 논문에서 제안하는 간단한 방법의 적합성을 나타냅니다. 다음 단락은 결과에있어서의 세 가지 기둥을 검증하는 방법을 논의, 즉 평면 느슨한 에너지 디렉터 프로세스 피드백의 사용 용도는 최적의 진동 및 용량 제어의 사용 기간뿐만 아니라, 적용 및 제한 사항을 정의 할 기술. <p class="jove...

열가소성 복합물 (TPC)는 그들의 비용 효율적인 제조에 기여 용접 될 수있는 능력을 가지고있다. 용접은 부드럽게 또는 접합면의 열가소성 수지를 용융하고 친밀한 접촉과 용접 인터페이스를 통해 열가소성 고분자 사슬의 후속 상호 확산을 허용하도록하는 압력으로 지역 난방을 필요로한다. 분자 상호 확산이 달성되면, 감압 냉각하는 용접 조인트를 통합. 몇몇 용접 기술 한 열 그러나 메인 &quot;접착&quot;메커니즘, 즉 분자의 얽힘 소스 주로 다르다 열가소성 복합 재료에 적용 할 수 있으며, 변경되지. 초음파 용접은 (몇 초 정도)에 매우 짧은 시간 용접 쉽게 자동화를 제공하며, 열가소성 복합 기판의 보강 형 거의 독립적이다. 또한, 반응계에 2,3- 모니터링 가능성을 제공한다 </sup&gt; 회선 품질 보증에 또는 처리 창 (4)의 고속 정의에 사용될 수있다. 열가소성 복합 초음파 용접 주로 스폿 용접 공정 순차 초음파 용접을 통해 긴 이음매 그러나 성공적인 용접 문헌 5에보고되어있다. 저항 또는 유도 용접 달리, 초음파 용접 공업 지금까지 열가소성 복합 부분 사이의 구조적 관절에 적용되지 않았습니다. 그럼에도 불구하고, 상당한 노력이 현재 항공기 응용 프로그램에 대한 열가소성 복합 재료의 구조 초음파 용접의 개발을 촉진하기 위해 헌신하고있다. 초음파 용접, 접합되는 부분은 횡 점탄성 표면 및 가열을 통해 발열 결과 용접 인터페이스 정적 힘 고주파 저 진폭 기계적 진동의 조합으로 실시한다. 접합 계면에서 우선적으로 가열이 촉진되고표면에 수지 돌기의 사용을 통해 기판 (6)보다 높은 주기적 변형을 겪게하고, 따라서 높은 점탄성 가열 된 용접한다. 부품 프레스 및 압전 변환기 및 부스터로 구성된 초음파 열차에 연결 sonotrode를 통해 용접 할에 힘과 진동이 작용한다. sonotrode 접점 부를 접합되는 점과 접합 계면과의 거리에 따라 차이는 근거리 및 원거리 초음파 용착 사이에 만들어 질 수있다. 근접장 용접 (sonotrode 용접 인터페이스와 6 mm 미만)는 음파 (6)을 수행하는 물질의 능력에 크게 의존 특정 열가소성 물질 원방 용접의 적용 동안 재료의 넓은 범위에 적용 할 수있다 . 초음파 용접 프로세스는 세 가지 단계로 나누어 질 수있다. 먼저, 구동력 축적 단계, 어느 sonotro 중드 서서히 소정 트리거 하중에 도달 할 때까지 부분에 힘이 증가 용접한다. 진동이 단계에서 적용되지 않습니다. 둘째, 트리거 하중에 도달하면 시작 진동 단계. 이 단계에서는 sonotrode는 용접 공정에 필요한 열을 발생 일정 시간 동안 소정 진폭으로 진동한다. 마이크로 프로세서 제어 초음파 용접기 진동 단계의 기간, 그 중 시간 (즉, 직접 제어), 변위 또는 에너지 (간접 제어)를 제어하는 몇 가지 옵션을 제공합니다. 이 단계에서 가해지는 힘은 힘을 용접 상수 트리거 하중 동일하게 유지할 수있다 즉, 서서히 진동의인가 동안 변화 될 수있다. 셋째, 용접 부분이 허용되는 동안 응고 단계는 일정 시간 동안 소정의 응고 력 하에서 냉각. 진동이 마지막 단계에서 적용되지 않습니다. 용접 FORCE, 진동의 진폭, 진동수 및 진동 위상 기간 (직접 또는 간접적으로 에너지 또는 변위를 통해 제어)의 발열을 제어하는​​ 용접 파라미터이다. 주파수는 각 초음파 용접기 고정하는 동안 힘, 크기 및 지속 시간은 사용자 정의 매개 변수입니다. 응고 력 및 고화 시간도 파라미터 용접 파라미터의 나머지 용접부의 최종 품질과 함께, 가열 공정에 개입하지만, 통합에 영향을하지 않는다. 이 논문은 D 1002 규격 (미국 재료 시험 학회) ASTM 다음 후속 기계, 하나의 랩 전단 (LSS) 테스트를위한 하나의 랩 구성에 개인 TPC 쿠폰의 근접장 초음파 용접을위한 새로운 간단한 방법을 제안한다. 용접 쿠폰의 기계 시험 특성을 가장 통신 중 하나 관절 명백 랩 전단 강도를 결정하는 허용단, 열가소성 복합 용접부 (7)의 강도를 정량화하는 데 사용된다. 이 논문에 기재된 접합 방법은 세 가지 기둥에 기초한다. 우선, 이른바 플랫 에너지 디렉터는 용접 공정 중에 접합 계면에서 우선적 8,9 발열 사용된다. 둘째, 초음파 용접기에 의해 제공되는 프로세스 데이터가 빠르게 특정 힘 / 진폭 조합 2,4-위한 진동 위상의 최적 지속 시간을 정의하는 데 사용된다. 셋째, 진동 위상 기간 간접적 용접부 (4)의 일정한 품질을 보장하기 위해 sonotrode의 변위를 통해 제어된다. 이 용접 방법은 열가소성 복합 재료에 대한 최신의 용접 절차에 관해서는 다음과 같은 주요 참신하고 장점을 제공한다 : (a) 단순화 된 샘플 대신 기존의 성형 에너지 이사 3의 느슨한 평면 에너지 이사의 사용에 의해 사용 준비, (b)는 빠르고 C일반적인 시행 착오 접근 방식에 반대 인 시츄 프로세스 모니터링에 기초하여 공정 변수 OST 효율적인 정의. 본 문서에 기재된 방법은 매우 간단한 용접 특정 형상을 얻기에 맞는하지만 실제 부품 용접 절차를 정의하는 기반이 될 수있다. 단일 랩 쿠폰의 오버랩의 네 모서리에 흐름 제한 반대 경우의 주된 차이는, 에너지 디렉터의 제한된 흐름의 결과.

<table border="0" cellpadding="0" cellspacing="0" width="1179">
	<tbody>
		<tr height="21">
			<td height="21" style="height:21px;width:311px;">Material/Reagent</td>
			<td style="width:308px;"></td>
			<td style="width:199px;"></td>
			<td style="width:363px;"></td>
		</tr>
		<tr height="42">
			<td height="42" style="height:42px;width:311px;">Cetex&#174; carbon fiber / polyetherimide (CF/PEI) 5 harness satin prepreg</td>
			<td style="width:308px;">TenCate Advanced Composites (www.tencate.com)</td>
			<td style="width:199px;">Contact vendor</td>
			<td style="width:363px;">Material used in this study for the specimens.</td>
		</tr>
		<tr height="42">
			<td height="42" style="height:42px;width:311px;">PFQD solvent degreaser</td>
			<td style="width:308px;">PT Technologies Europe (now Socomore - www.socomore.com)</td>
			<td style="width:199px;">Contact vendor</td>
			<td style="width:363px;">Solvent degreaser for cleaning the specimens and energy directors.</td>
		</tr>
		<tr height="42">
			<td height="42" style="height:42px;width:311px;">Cotton cloths</td>
			<td style="width:308px;">-</td>
			<td style="width:199px;">-</td>
			<td style="width:363px;">For general cleaning purposes. No specific vendor was used.</td>
		</tr>
		<tr height="40">
			<td height="40" style="height:40px;width:311px;">0.25 mm PEI film</td>
			<td style="width:308px;">TenCate Advanced Composites (www.tencate.com)</td>
			<td style="width:199px;">Contact vendor</td>
			<td style="width:363px;">Thin film used as energy director.</td>
		</tr>
		<tr height="63">
			<td height="63" style="height:63px;width:311px;">Adhesive tape</td>
			<td style="width:308px;">Airtech Advanced Materials Group (www.airtechintl.com)</td>
			<td style="width:199px;">1&#34; x 72 yds MFG # 327402 Contact vendor for catalog number</td>
			<td style="width:363px;">Used to attach energy director to bottom sample for ultrasonic welding.</td>
		</tr>
		<tr height="21">
			<td height="21" style="height:21px;width:311px;">Name</td>
			<td style="width:308px;">Company</td>
			<td style="width:199px;">Catalog Number</td>
			<td>Comments</td>
		</tr>
		<tr height="21">
			<td height="21" style="height:21px;width:311px;">Equipment</td>
			<td style="width:308px;"></td>
			<td style="width:199px;"></td>
			<td></td>
		</tr>
		<tr height="42">
			<td height="42" style="height:42px;width:311px;">V&#246;tsch oven</td>
			<td style="width:308px;">V&#246;tsch Industrietechnik (www.voetsch-ovens.com)</td>
			<td style="width:199px;">VTU 60/60 - Contact vendor for specific catalog number</td>
			<td style="width:363px;">Oven used to dry PEI film (energy directors) and PEI specimens before welding.</td>
		</tr>
		<tr height="84">
			<td height="84" style="height:84px;width:311px;">Rinco Dynamic 3000 ultrasonic welder</td>
			<td style="width:308px;">Aeson BV (www.aeson.nl/en/)</td>
			<td style="width:199px;">Contact vendor</td>
			<td style="width:363px;">20 kHz ultrasonic welding machine used for the welding experiments. Several sonotrode sizes available. Contact vendor for details. ACUCapture software included.</td>
		</tr>
		<tr height="42">
			<td height="42" style="height:42px;width:311px;">Zwick/Roell universal testing machine</td>
			<td style="width:308px;">Zwick (www.zwick.com)</td>
			<td style="width:199px;">Z250 - Contact vendor for specific catalog number</td>
			<td style="width:363px;">Universal testing machine with maximum load of 250 kN used for single lap shear strength measurements.</td>
		</tr>
	</tbody>
</table>

ultrasonic welding of thermoplastic composite coupons for mechanical characterization of welded joints through single lap shear testing

This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ultrasonic welding process described in this paper is based on three main pillars. Firstly, flat energy directors are used for preferential heat generation at the joining interface during the welding process. A flat energy director is a neat thermoplastic resin film that is placed between the parts to be joined prior to the welding process and heats up preferentially owing to its lower compressive stiffness relative to the composite substrates. Consequently, flat energy directors provide a simple solution that does not require molding of resin protrusions on the surfaces of the composite substrates, as opposed to ultrasonic welding of unreinforced plastics. Secondly, the process data provided by the ultrasonic welder is used to rapidly define the optimum welding parameters for any thermoplastic composite material combination. Thirdly, displacement control is used in the welding process to ensure consistent quality of the welded joints. According to this method, thermoplastic-composite flat coupons are individually welded in a single lap configuration. Mechanical testing of the welded coupons allows determining the apparent lap shear strength of the joints, which is one of the properties most commonly used to quantify the strength of thermoplastic composite welded joints.

탄소 섬유 강화 폴리 에테르이 미드 (CF / PEI) 샘플이 논문에 기술 된 방법에 따라 용접 하였다. 샘플 (0/90) 3S 적층 순서와 1.92 mm 공칭 두께, 새틴 패브릭 CF / PEI 다섯 하네스 만든 복합 적층에서 얻었다. 섬유의 방향이 주 명백 최장 측과 평행이되도​​록 샘플이 라미네이트로부터 절단 하였다. 0.25 mm 두께로 평면 PEI 에너지 디렉터가 사용되었다. 제조자에 의해 나타...

Watch this Scientific Journal Video about Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing at JoVE.com

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing

A straightforward procedure for ultrasonic welding of thermoplastic composite coupons for basic mechanical testing is described. Key characteristics of this ultrasonic welding process are the use of flat energy directors for simplified process preparation and the use of process data for the fast definition of optimum processing conditions.

단일 랩 전단 시험을 통해 용접 조인트의 기계적 특성에 대한 열가소성 복합 쿠폰의 초음파 용접

This paper presents a novel straightforward method for ultrasonic welding of thermoplastic-composite coupons in optimum processing conditions. The ...

ultrasonic-welding-thermoplastic-composite-coupons-for-mechanical

Research

Education

JoVE Core

JoVE Journal

Civil Engineering

Engineering

Unit 1

Strength of Concrete

SCIENTISTS IN ACTION

11.5K 조회수.  Delft University of Technology. A straightforward procedure for ultrasonic welding of thermoplastic composite coupons for basic mechanical testing is described. Key characteristics of this ultrasonic welding process are the use of flat energy directors for simplified process preparation and the use of process data for the fast definition of optimum processing conditions.

비디오: Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing

Experiments on Ultrasonic Lubrication Using a Piezoelectrically-assisted Tribometer and Optical Profilometer

Friction and wear are detrimental to engineered systems. Ultrasonic lubrication is achieved when the interface between two sliding surfaces is vibrated at a frequency above the acoustic range (20 kHz). As a solid-state technology, ultrasonic lubrication can be used where conventional lubricants are unfeasible or undesirable. Further, ultrasonic lubrication allows for electrical modulation of the effective friction coefficient between two sliding surfaces. This property enables adaptive systems that modify their frictional state and associated dynamic response as the operating conditions change. Surface wear can also be reduced through ultrasonic lubrication. We developed a protocol to investigate the dependence of friction force reduction and wear reduction on the linear sliding velocity between ultrasonically lubricated surfaces. A pin-on-disc tribometer was built which differs from commercial units in that a piezoelectric stack is used to vibrate the pin at 22 kHz normal to the rotating disc surface. Friction and wear metrics including effective friction force, volume loss, and surface roughness are measured without and with ultrasonic vibrations at a constant pressure of 1 to 4 MPa and three different sliding velocities: 20.3, 40.6, and 87 mm/sec. An optical profilometer is utilized to characterize the wear surfaces. The effective friction force is reduced by 62% at 20.3 mm/sec. Consistently with existing theories for ultrasonic lubrication, the percent reduction in friction force diminishes with increasing speed, down to 29% friction force reduction at 87 mm/sec. Wear reduction remains essentially constant (49%) at the three speeds considered.

We present a protocol for using a piezoelectrically-assisted tribometer and optical profilometer to investigate the dependence of ultrasonic wear and friction reduction on linear velocity, contact pressure, and surface properties.

초음파 윤활에 대한 실험은 압전 이용한 마찰 계 및 광학 프로파일로 사용

Friction and wear are detrimental to engineered systems. Ultrasonic lubrication is achieved when the interface between two sliding surfaces is vibrated at ...

연구

공학

Testing of Nanoparticle Release from a Composite Containing Nanomaterial Using a Chamber System

With the rapid development of nanotechnology as one of the most important technologies in the 21st century, interest in the safety of consumer products containing nanomaterials is also increasing. Evaluating the nanomaterial release from products containing nanomaterials is a crucial step in assessing the safety of these products, and has resulted in several international efforts to develop consistent and reliable technologies for standardizing the evaluation of nanomaterial release. In this study, the release of nanomaterials from products containing nanomaterials is evaluated using a chamber system that includes a condensation particle counter, optical particle counter, and sampling ports to collect filter samples for electron microscopy analysis. The proposed chamber system is tested using an abrasor and disc-type nanocomposite material specimens to determine whether the nanomaterial release is repeatable and consistent within an acceptable range. The test results indicate that the total number of particles in each test is within 20% from the average after several trials. The release trends are similar and they show very good repeatability. Therefore, the proposed chamber system can be effectively used for nanomaterial release testing of products containing nanomaterials.

Nanoparticle release is tested using a chamber system that includes a condensation particle counter, an optical particle counter and sampling ports to collect filter samples for microscopy analysis. The proposed chamber system can be effectively used for nanomaterial release testing with a repeatable and consistent data range.

재판부 시스템을 사용하여 나노 재료를 포함하는 복합에서 나노 입자 릴리스의 테스트

With the rapid development of nanotechnology as one of the most important technologies in the 21st century, interest in the safety of consumer products ...

Challenges in Rheological Characterization of Highly Concentrated Suspensions &#8212; A Case Study for Screen-printing Silver Pastes

A comprehensive rheological characterization of highly concentrated suspensions or pastes is mandatory for a targeted product development meeting the manifold requirements during processing and application of such complex fluids. In this investigation, measuring protocols for a conclusive assessment of different process relevant rheological parameters have been evaluated. This includes the determination of yield stress, viscosity, wall slip velocity, structural recovery after large deformation and elongation at break as well as tensile force during filament stretching.
The importance of concomitant video recordings during parallel-plate rotational rheometry for a significant determination of rheological quantities is demonstrated. The deformation profile and flow field at the sample edge can be determined using appropriate markers. Thus, measurement parameter settings and plate roughness values can be identified for which yield stress and viscosity measurements are possible. Slip velocity can be measured directly and measuring conditions at which plug flow, shear banding or sample spillover occur can be identified clearly. 
Video recordings further confirm that the change in shear moduli observed during three stage oscillatory shear tests with small deformation amplitude in stage I and III but large oscillation amplitude in stage II can be directly attributed to structural break down and recovery. For the pastes investigated here, the degree of irreversible, shear-induced structural change increases with increasing deformation amplitude in stage II until a saturation is reached at deformations corresponding to the crossover of G' and G'', but the irreversible damage is independent of the duration of large amplitude shear. 
A capillary breakup elongational rheometer and a tensile tester have been used to characterize deformation and breakup behavior of highly filled pastes in uniaxial elongation. Significant differences were observed in all experiments described above for two commercial screen-printing silver pastes used for front side metallization of Si-solar cells.

Challenges in Rheological Characterization of Highly Concentrated Suspensions &amp;#8212; A Case Study for Screen-printing Silver Pastes

A protocol for a robust and application relevant rheological characterization of highly concentrated suspensions is presented. Silver pastes used for screen-printing application in solar cell production are employed as model systems.

고농도 현탁액의 유변학 적 특성에 도전 - 스크린 인쇄 실버 페이스트에 대한 사례 연구

A comprehensive rheological characterization of highly concentrated suspensions or pastes is mandatory for a targeted product development meeting the ...

A Novel Biaxial Testing Apparatus for the Determination of Forming Limit under Hot Stamping Conditions

The hot stamping and cold die quenching process is increasingly used to form complex shaped structural components of sheet metals. Conventional experimental approaches, such as out-of-plane and in-plane tests, are not applicable to the determination of forming limits when heating and rapid cooling processes are introduced prior to forming for tests conducted under hot stamping conditions. A novel in-plane biaxial testing system was designed and used for the determination of forming limits of sheet metals at various strain paths, temperatures, and strain rates after heating and cooling processes in a resistance heating uniaxial testing machine. The core part of the biaxial testing system is a biaxial apparatus, which transfers a uniaxial force provided by the uniaxial testing machine to a biaxial force. One type of cruciform specimen was designed and verified for the formability test of aluminum alloy 6082 using the proposed biaxial testing system. The digital image correlation (DIC) system with a high-speed camera was used for taking strain measurements of a specimen during a deformation. The aim of proposing this biaxial testing system is to enable the forming limits of an alloy to be determined at various temperatures and strain rates under hot stamping conditions.

This protocol proposes a novel biaxial testing system used on a resistance heating uniaxial tensile test machine in order to determine the forming limit diagram (FLD) of sheet metals under hot stamping conditions.

The hot stamping and cold die quenching process is increasingly used to form complex shaped structural components of sheet metals. Conventional ...

Experimental Implementation of a New Composite Fabrication Method: Exposing Bare Fibers on the Composite Surface by the Soft Layer Method

The bipolar plate is a key component in proton exchange membrane fuel cells (PEMFCs) and vanadium redox flow batteries (VRFBs). It is a multi-functional component that should have high electrical conductivity, high mechanical properties, and high productivity.
In this regard, a carbon fiber/epoxy resin composite can be an ideal material to replace the conventional graphite bipolar plate, which often leads to the catastrophic failure of the entire system because of its inherent brittleness. Though the carbon/epoxy composite has high mechanical properties and is easy to manufacture, the electrical conductivity in the through-thickness direction is poor because of the resin-rich layer that forms on its surface. Therefore, an expanded graphite coating was adopted to solve the electrical conductivity issue. However, the expanded graphite coating not only increases the manufacturing costs but also has poor mechanical properties.
In this study, a method to expose fibers on the composite surface is demonstrated. There are currently many methods that can expose fibers by surface treatment after the fabrication of the composite. This new method, however, does not require surface treatment because the fibers are exposed during the manufacture of the composite. By exposing bare carbon fibers on the surface, the electrical conductivity and mechanical strength of the composite are increased drastically.

A protocol to expose bare fibers on the composite surface by eliminating resin rich area is presented. The fibers are exposed during fabrication of the composites, not by the post surface treatment. The exposed carbon composites exhibit high electrical conductivity in the through-thickness direction and high mechanical property.

새로운 복합 제조 방법의 실험적 구현: 소프트 레이어 방법으로 복합 표면에 벌 거 벗은 섬유 노출

The bipolar plate is a key component in proton exchange membrane fuel cells (PEMFCs) and vanadium redox flow batteries (VRFBs). It is a multi-functional ...

Ultrasonic Fatigue Testing in the Tension-Compression Mode

Ultrasonic fatigue testing is one of a few methods which allow investigating fatigue properties in the ultra-high cycle region. The method is based on exposing the specimen to longitudinal vibrations on its resonance frequency close to 20 kHz. With use of this method, it is possible to significantly decrease the time required for the test, when compared to conventional testing devices usually working at frequencies under 200 Hz. It is also used to simulate loading of material during operation in high speed conditions, such as those experienced by components of jet engines or car turbo pumps. It is necessary to operate only in the high and ultra-high cycle region, due to the possibility of extremely high deformation rates, which can have a significant influence on the test results. Specimen shape and dimensions have to be carefully selected and calculated to fulfill the resonance condition of the ultrasonic system; thus, it is not possible to test the full components or specimens of arbitrary shape. Before each test, it is necessary to harmonize the specimen with the frequency of the ultrasonic system to compensate for deviations of the real shape from the ideal one. It is not possible to run a test until a total fracture of the specimen, since the test is automatically terminated after initiation and propagation of the crack to a certain length, when the stiffness of the system changes enough to shift the system out of the resonance frequency. This manuscript describes the process of evaluation of materials' fatigue properties at high-frequency ultrasonic fatigue loading with use of mechanical resonance at a frequency close to 20 kHz. The protocol includes a detailed description of all steps required for a correct test, including specimen design, stress calculation, harmonizing with the resonance frequency, performing the test, and final static fracture.

A protocol for ultrasonic fatigue testing in the high and ultra-high cycle region in axial tension-compression loading mode.

Ultrasonic fatigue testing is one of a few methods which allow investigating fatigue properties in the ultra-high cycle region. The method is based on ...

Magnet Assisted Composite Manufacturing: A Flexible New Technique for Achieving High Consolidation Pressure in Vacuum Bag/Lay-Up Processes

This work demonstrates a protocol to improve the quality of composite laminates fabricated by wet lay-up vacuum bag processes using the recently developed magnet assisted composite manufacturing (MACM) technique. In this technique, permanent magnets are utilized to apply a sufficiently high consolidation pressure during the curing stage. To enhance the intensity of the magnetic field, and thus, to increase the magnetic compaction pressure, the magnets are placed on a magnetic top plate. First, the entire procedure of preparing the composite lay-up on a magnetic bottom steel plate using the conventional wet lay-up vacuum bag process is described. Second, placement of a set of Neodymium-Iron-Boron permanent magnets, arranged in alternating polarity, on the vacuum bag is illustrated. Next, the experimental procedures to measure the magnetic compaction pressure and volume fractions of the composite constituents are presented. Finally, methods used to characterize microstructure and mechanical properties of composite laminates are discussed in detail. The results prove the effectiveness of the MACM method in improving the quality of wet lay-up vacuum bag laminates. This method does not require large capital investment for tooling or equipment and can also be used to consolidate geometrically complex composite parts by placing the magnets on a matching top mold positioned on the vacuum bag.

A new technique for applying consolidation pressure on the vacuum bag lay-up to fabricate composite laminates is described. The goal of this protocol is to develop a simple, cost-effective technique to improve the quality of laminates fabricated by the wet lay-up vacuum bag method.

자석 복합 제조 지원: 유연한 새로운 기술 진공 가방/Lay 업 프로세스에 높은 통합 압력을 달성 하기 위한

This work demonstrates a protocol to improve the quality of composite laminates fabricated by wet lay-up vacuum bag processes using the recently developed ...

Generating Lap Joints Via Friction Stir Spot Welding on DP780 Steel

Friction stir spot welding (FSSW), a derivative of friction stir welding (FSW), is a solid-state welding technique that was developed in 1991. An industry application was found in the automotive industry in 2003 for the aluminum alloy that was used in the rear doors of automobiles. Friction stir spot welding is mostly used in Al alloys to create lap joints. The benefits of friction stir spot welding include a nearly 80% melting temperature that lowers the thermal deformation welds without splashing compared to resistance spot welding. Friction stir spot welding includes 3 steps: plunging, stirring, and retraction. In the present study, other materials including high strength steel are also used in the friction stir welding method to create joints. DP780, whose traditional welding process involves the use of resistance spot welding, is one of several high strength steel materials used in the automotive industry. In this paper, DP780 was used for friction stir spot welding, and its microstructure and microhardness were measured. The microstructure data showed that there was a fusion zone with fine grain and a heat effect zone with island martensite. The microhardness results indicated that the center zone exhibited a greater degree of hardness compared with the base metal. All data indicated that the friction stir spot welding used in dual phase steel 780 can create a good lap joint. In the future, friction stir spot welding can be used in high-strength steel welding applied in industrial manufacturing processes.

Here, we present a friction stir spot welding (FSSW) protocol on dual phase 780 steel. A tool pin with high-speed rotation generates heat from friction to soften the material, and then, the pin plunges into 2 sheet joints to create the lap joint.

DP780 강철의 마찰 교반 점 용접을 통해 랩 조인트 생성

Friction stir spot welding (FSSW), a derivative of friction stir welding (FSW), is a solid-state welding technique that was developed in 1991. An industry ...

Cutting Procedures, Tensile Testing, and Ageing of Flexible Unidirectional Composite Laminates

Many body armor designs incorporate unidirectional (UD) laminates. UD laminates are constructed of thin (&#60;0.05 mm) layers of high-performance yarns, where the yarns in each layer are oriented parallel to each other and held in place using binder resins and thin polymer films. The armor is constructed by stacking the unidirectional layers in different orientations. To date, only very preliminary work has been performed to characterize the ageing of the binder resins used in unidirectional laminates and the effects on their performance. For example, during the development of the conditioning protocol used in the National Institute of Justice Standard-0101.06, UD laminates showed visual signs of delamination and reductions in V50, which is the velocity at which half of the projectiles are expected to perforate the armor, after ageing. A better understanding of the material property changes in UD laminates is necessary to comprehend the long-term performance of armors constructed from these materials. There are no current standards recommended for mechanically interrogating unidirectional (UD) laminate materials. This study explores methods and best practices for accurately testing the mechanical properties of these materials and proposes a new test methodology for these materials. Best practices for ageing these materials are also described.

The goal of the study was to develop protocols to prepare consistent specimens for accurate mechanical testing of high-strength aramid or ultra-high-molar-mass polyethylene-based flexible unidirectional composite laminate materials and to describe protocols for performing artificial ageing on these materials.

Many body armor designs incorporate unidirectional (UD) laminates. UD laminates are constructed of thin (&#60;0.05 mm) layers of high-performance yarns, ...

Operation of the Collaborative Composite Manufacturing (CCM) System

The automated tape placement and the automated fiber placement (AFP) machines provide a safer working environment and reduce the labor intensity of workers than the traditional manual fiber placement does. Thus, the production accuracy, repeatability and efficiency of composite manufacturing are significantly improved. However, the current AFP systems can only produce the composite components with large open surface or simple revolution parts, which cannot meet the growing interest in small complex or closed structures from industry.
In this research, by employing a 1-degree of freedom (DoF) rotational stage, a 6-RSS parallel robot, and a 6-DoF serial robot, the dexterity of the AFP system can be significantly improved for manufacturing complex composite parts. The rotational stage mounted on the parallel robot is utilized to hold the mandrel and the serial robot carries the placement head to mimic two human hands that have enough dexterity to lay the fiber to the mandrel with complex contour.
Although the CCM system increases the flexibility of composite manufacturing, it is quite time-consuming or even impossible to generate the feasible off-line path, which ensures uniform lay-up of subsequent fibers considering the constraints like singularities, collisions between the fiber placement head and mandrel, smooth fiber direction change and keeping the fiber placement head along the norm of the part&#39;s surface, etc. Moreover, due to the existing positioning error of the robots, the on-line path correction is needed. Therefore, the on-line pose correction algorithm is proposed to correct the paths of both parallel and serial robots, and to keep the relative path between the two robots unchanged through the visual feedback when the constraint or singularity problems in the off-line path planning occur. The experimental results demonstrate the designed CCM system can fulfill the movement needed for manufacturing a composite structure with Y-shape.

Operation of the Collaborative Composite Manufacturing CCM System

A collaborative composite manufacturing system is developed for robotic lay-up of composite laminates using the prepreg tape. The proposed system allows the production of composite laminates with high levels of geometrical complexity. The issues in the path planning, coordination of the robots and control are addressed in the proposed method.

협업 복합제조(CCM) 시스템 운영

The automated tape placement and the automated fiber placement (AFP) machines provide a safer working environment and reduce the labor intensity of ...