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Updated: Jan 3, 2026

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing
Published on: February 11, 2016
Improved consistency of bond-line thickness when conducting single lap-shear joint tests
Joe Flanagan1, Lorcan Byrne2, Joseph Mohan2
1School of Mechanical & Materials Engineering, University College Dublin, Belfield, Dublin 4, Ireland.
Abstract:
This article details a method for improving the consistency of bond-line thickness during lap-shear sample preparation. This includes the schematic for a lap-shear sample test rig and consideration for controlled variation of the bond-line thickness for up to ten pairs of samples at a time. Concerns regarding the curing of the samples when held on a large heat reservoir are addressed through direct measurement of the bond-rig temperature in combination with the cure chamber temperature. Additionally, the application of a release coating to the bond-rig has been demonstrated to improve ease of sample removal for the bond-rig, minimizing potential damage to the lap-shear sample set before testing. The release coating provides a clean surface for subsequent sets of samples, ensuring an even surface and reducing cleaning and degradation of the machined geometries of the rig. Overall, the proposed bond-rig provides: •Increased bond-line uniformity•Up to ten samples prepared in a batch•Option to apply a release coating to improve usability and minimize cleaning.
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