Effect of Adherend Thickness on Near-Field Ultrasonic Welding of Single-Lap CF/LMPAEK Thermoplastic Composite Joints

Ultrasonic welding is a fast and promising joining technique for thermoplastic composite parts. Understanding how changing the part thickness affects the process is crucial to its future upscaling and industrialization. This article presents an initial insight into the effect of the adherend's thickness on the near-field ultrasonic welding of CF/LMPAEK thermoplastic composites. Different thicknesses of the top and bottom adherend were welded and analyzed using the output data of the welding equipment, temperature measurements, and other visual characterization techniques. Increasing the thickness of both the top and the bottom adherends showed to increase the power consumed during welding. An overshoot in the power needed at the onset of the welding process for increased thickness of the top adherend precluded welding beyond a threshold thickness of 4.72 mm. In the case of the thicker top adherends, there was also melting of the energy director and early fiber squeeze-out within the top adherend as a result of increased bulk heating. Increased bulk heating was hypothesized to be caused by increased hammering, as indicated by the amplitude readings for thicker adherends. Welding with a higher force, which is known to reduce hammering, corroborated this hypothesis as fiber squeeze-out within the top adherend was not observed. It is believed that hammering contributes to heating by causing an oscillatory impact excitation that is close to the natural frequencies of the system, which would result in amplification of the cyclic strain and subsequent increase in the viscoelastic heating in the adherend.