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Updated: Jul 30, 2025
Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing
Published on: February 11, 2016
Optimizing the Process of Spot Welding of Polycarbonate-Matrix-Based Unidirectional (UD) Thermoplastic Composite
Janos Birtha1,2, Christian Marschik2, Eva Kobler2
1Institute of Polymer Injection Moulding and Process Automation, Johannes Kepler University Linz, Altenbergerstraße 69, 4040 Linz, Austria.
Abstract:
The aim of this work was to optimize spot welding of unidirectional tapes made of polycarbonate and carbon fibers. Three studies were performed to investigate the influences of various welding conditions on the quality of the welded spot. First, we used a full factorial experimental design to analyze the influence of temperature and time on the welds' tensile stress at break. Second, we repeated the experiment with optimized settings and conditions. Finally, we adopted a central composite design (CCD) to investigate the stability of the process. Our results show that temperature had the greatest influence on weld quality. The maximum tensile stress achieved was 23 MPa. Using a relatively high temperature for a short welding time resulted in self-cleaning of the welding head and in a faster and more stable process, and gel permeation chromatography (GPC) confirmed that these conditions caused no additional degradation.
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