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Continuous resistance welding of thermoplastic composites: Modelling of heat generation and heat transfer
Affiliation:1. Structural Integrity & Composites, Faculty of Aerospace Engineering, Delft University of Technology, Kluyverweg 1, 2629 HS Delft, The Netherlands;2. Aerospace Portfolio, National Research Council Canada, 5145 Decelles Avenue, Montréal, Québec H3T 2B2, Canada;1. Consorzio CETMA, Department of Materials and Structures Engineering, Technologies and Processes Area, Cittadella della Ricerca, SS7-Km706+300, 72100 Brindisi, Italy;2. Agusta Westland, Structures R&D Production Line Structural Engineering, Contrada S. Teresa, 72100 Brindisi, Italy;3. University of Salento, Department of Engineering for Innovation, Via per Monteroni, 73100 Lecce, Italy;1. ThermoPlastic Composites Research Center (TPRC), Enschede, The Netherlands;2. Faculty of Engineering Technology, Chair of Production Technology, University of Twente, Enschede, The Netherlands;3. Structural Integrity and Composites, Faculty of Aerospace Engineering, Delft University of Technology, Delft, The Netherlands;1. Department of Engineering for Innovation, University of Salento, Via per Monteroni, 73100 Lecce, Italy;2. Aerospace Structures and Materials Department, Delft University of Technology, Kluyverweg 1, 2629HS Delft, The Netherlands;3. Department of Materials and Structures Engineering, Technologies and Processes Area, Consorzio CETMA, SS7-Km706+300, 72100 Brindisi, Italy
Abstract:A process model composed of electrical and heat transfer models was developed to simulate continuous resistance welding of thermoplastic composites. Glass fabric reinforced polyphenylenesulfide welded in a lap-shear configuration with a stainless steel mesh as the heating element was considered for modelling and experimental validation of the numerical results. The welding temperatures predicted by the model showed good agreement with the experimental results. Welding input power and welding speed were found to be the two most important parameters influencing the welding temperature. The contact quality between the electrical connectors and the heating element was found to influence the distribution of the welding temperature transverse to the welding direction. Moreover, the size of the electrical connectors was found to influence the achievable welding speed and required power input for a certain welding temperature.
Keywords:A  Polymer-matrix composites (PMCs)  A  Thermoplastic resin  E  Joints/joining
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