| Abstract: | The ultrasonic welding process is modeled using a five part model that includes mechanics and vibration of the parts, viscoelastic heating, heat transfer, flow and wetting, and intermolecular diffusion. The model predicts that melting and flow occur in steps, which has been confirmed by experiments. The model also indicates the possibility of monitoring joint quality by measuring the dynamic mechanical impedance of the parts during welding, which has also been verified experimentally by indirectly monitoring the magnitude of the impedance. via measurements of both the power and the acceleration of the base. When the melt fronts of the energy directors meet, at the end of welding, the dynamic impedance of the composites' interface is shown to rise rapidly. This raises the possibility of developing closed loop control procedures for the ultrasonic welding of thermoplastic composites. Ultrasonic welding of polyetheretherketone (PEEK) graphite APC-2 composites produced joints with excellent strengths. |
