Continuous Welding of Thermoplastic Composites - A398
| Continuous Welding of Thermoplastic Composites | |
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| Perspectives article | |
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| Document Type | Article |
| Document Identifier | 398 |
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Webinar Date
Presenter
Dr. Romain G. Martin
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Introduction[edit | edit source]
Thermoplastic composites are increasingly adopted across a wide range of applications due to their high impact resistance and fracture toughness, rapid processing cycles, and potential for recyclability. A key advantage of these materials is their ability to be joined through thermoplastic welding, offering an efficient alternative to adhesive bonding or mechanical fastening. Welding is a fast, clean joining method that can be implemented in either static or continuous processes.
This AIM event will introduce the principles of continuous welding of thermoplastic composites, including the fundamental physical mechanisms required to achieve high mechanical performance and an overview of the most commonly used welding techniques. The session will explore the benefits and challenges associated with transitioning from static to continuous welding, with particular emphasis on implications for equipment design and process parameters.
Recent research examples from both industry and academia will be presented, highlighting the growing interest in continuous welding and its potential for future composite applications. In addition, the webinar will address key technical challenges currently under investigation and emerging trends in this field.
Presenter[edit | edit source]
Romain G. Martin, PhD
R&D Project Manager
Hutchinson
Webinar[edit | edit source]
Webinar slides[edit | edit source]
Webinar slides available by clicking on the icon below
Additional information for select chapters[edit | edit source]
| Chapter | Chapter Title | Links to related information in the Knowledge in Practice Centre |
|---|---|---|
| 1 | Welcome & introductions | N/A |
| 2 | Knowledge in Practice Centre | |
| 3 | Outline | |
| 4 | What is thermoplastic welding | |
| 5 | Static vs Continuous welding | |
| 6 | Ultrasonic welding | N/A |
| 7 | Resistance welding | |
| 8 | Induction welding | |
| 9 | Other welding techniques | |
| 10 | Conclusion | N/A |
| 11 | Q&A | N/A |
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| About | Help |
Welcome
Welcome to the CKN Knowledge in Practice Centre (KPC). The KPC is a resource for learning and applying scientific knowledge to the practice of composites manufacturing. As you navigate around the KPC, refer back to the information on this right-hand pane as a resource for understanding the intricacies of composites processing and why the KPC is laid out in the way that it is. The following video explains the KPC approach:
Understanding Composites Processing
The Knowledge in Practice Centre (KPC) is centered around a structured method of thinking about composite material manufacturing. From the top down, the heirarchy consists of:
- The factory
- Factory cells and/or the factory layout
- Process steps (embodied in the factory process flow) consisting of:
The way that the material, shape, tooling & consumables and equipment (abbreviated as MSTE) interact with each other during a process step is critical to the outcome of the manufacturing step, and ultimately critical to the quality of the finished part. The interactions between MSTE during a process step can be numerous and complex, but the Knowledge in Practice Centre aims to make you aware of these interactions, understand how one parameter affects another, and understand how to analyze the problem using a systems based approach. Using this approach, the factory can then be developed with a complete understanding and control of all interactions.
Interrelationship of Function, Shape, Material & Process
Design for manufacturing is critical to ensuring the producibility of a part. Trouble arises when it is considered too late or not at all in the design process. Conversely, process design (controlling the interactions between shape, material, tooling & consumables and equipment to achieve a desired outcome) must always consider the shape and material of the part. Ashby has developed and popularized the approach linking design (function) to the choice of material and shape, which influence the process selected and vice versa, as shown below:
Within the Knowledge in Practice Centre the same methodology is applied but the process is more fully defined by also explicitly calling out the equipment and tooling & consumables. Note that in common usage, a process which consists of many steps can be arbitrarily defined by just one step, e.g. "spray-up". Though convenient, this can be misleading.
Workflows
The KPC's Practice and Case Study volumes consist of three types of workflows:
- Development - Analyzing the interactions between MSTE in the process steps to make decisions on processing parameters and understanding how the process steps and factory cells fit within the factory.
- Troubleshooting - Guiding you to possible causes of processing issues affecting either cost, rate or quality and directing you to the most appropriate development workflow to improve the process
- Optimization - An expansion on the development workflows where a larger number of options are considered to achieve the best mixture of cost, rate & quality for your application.
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