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research-article

Ultrasonic Welding of Carbon Fiber Reinforced Nylon 66 Composite without Energy Director

[+] Author and Article Information
Yuhao Gao

Key Lab of Materials Physics, School of Physics and Engineering, Zhengzhou University, Zhengzhou, Henan, 450052, China
914011015@qq.com

Qian Zhi

Key Lab of Materials Physics, School of Physics and Engineering, Zhengzhou University, Zhengzhou, Henan, 450052, China
393464135@qq.com

Lei Lu

Key Lab of Materials Physics, School of Physics and Engineering, Zhengzhou University, Zhengzhou, Henan, 450052, China
luleizzu@163.com

Zhongxia Liu

Key Lab of Materials Physics, School of Physics and Engineering, Zhengzhou University, Zhengzhou, Henan, 450052, China
liuzhongxia@zzu.edu.cn

Pei-Chung Wang

Manufacturing Systems Research Lab, General Motors Research and Development Center, 30500 Mound Road, Warren, MI 48090, USA
pei-chung.wang@gm.com

1Corresponding author.

ASME doi:10.1115/1.4039113 History: Received July 11, 2017; Revised December 23, 2017

Abstract

In this study, weldability of ultrasonic welding of 4mm thick fiber carbon/nylon 66 composite in lap configuration was investigated. Ultrasonic welding tests were performed, and the weld appearance, microstructure, fractography of the welded joints were examined using optical and scanning electron microscope (SEM). The transient temperatures near the faying surfaces and horn-workpiece interfaces were recorded to understand the weld growth mechanism. It was found that it is feasible to join 4mm thick lapped carbon fiber reinforced nylon 66 composite with ultrasonic welding. Under the ultrasonic vibration, the weld initiated and grew at the faying surface while the weld indentation developed at the horn-workpiece interface. The pores observed in the regions between the heat-affected-zone and fusion zone and the severe weld indentation on the surface of upper workpieces decreased the loading capacity of the UW joints and caused the welded carbon/nylon 66 composite fractured prematurely. The strengths of the ultrasonic welds were determined by the balance of positive effect of the weld area and negative effects of the weld indentation and porosity near the fusion zone. To ensure the joint strength, it is necessary to apply the proper weld schedules (i.e., welding time and horn pressure) in ultrasonic welding of 4mm thick carbon fiber reinforced nylon 66 composite, which were developed based on the joint strength criterion.

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