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Updated: Nov 10, 2025

Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing
Published on: February 11, 2016
In-Plane Shear Strength of Single-Lap Co-Cured Joints of Self-Reinforced Polyethylene Composites
Felipe Vannucchi de Camargo1,2, Eduardo da Silva Fernandes3, Carla Schwengber Ten Caten3
1Post-Graduation Program in Mining, Metallurgical and Materials Engineering, Federal University of Rio Grande do Sul, Av. Osvaldo Aranha 99, Porto Alegre 90035-190, Brazil.
Abstract:
The present study introduces the analysis of single-lap co-cured joints of thermoplastic self-reinforced composites made with reprocessed low-density polyethylene (LDPE) and reinforced by ultra-high-molecular-weight polyethylene (UHMWPE) fibers, along with a micromechanical analysis of its constituents. A set of optimal processing conditions for manufacturing these joints by hot-press is proposed through a design of experiment using the response surface method to maximize their in-plane shear strength by carrying tensile tests on co-cured tapes. Optimal processing conditions were found at 1 bar, 115 °C, and 300 s, yielding joints with 6.88 MPa of shear strength. The shear failure is generally preceded by multiple debonding-induced longitudinal cracks both inside and outside the joint due to accumulated transversal stress. This composite demonstrated to be an interesting structural material to be more widely applied in industry, possessing extremely elevated specific mechanical properties, progressive damage of co-cured joints (thus avoiding unannounced catastrophic failures) and ultimate recyclability.
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