Advances in fusion bonding techniques for joining thermoplastic matrix composites: a review
Source abstract
Abstract
Abstract Joining composite materials is an issue because traditional joining technologies are not directly transferable to composite structures. Fusion bonding and the use of thermoplastic films as hot melt adhesives offer an alternative to mechanical fastening and thermosetting adhesive bonding. Fusion bonding technology which originated from the thermoplastic polymer industry has gain a new interest with the introduction of thermoplastic matrix composites (TPC) which are currently regarded as candidates for primary structures. The improvement of thermoplastic polymer matrices, with the introduction of recent chemistries such as PEEK, PEI and PEKEKK. exhibiting increased mechanical performance, service temperature and solvent resistance (for the semi-crystalline systems) also supported the growth of interest for fusion bonding. This review looks at the state of the art of fusion bonding technology and focuses particularly on the three most promising fusion bonding techniques: ultrasonic welding, induction welding and resistance welding. Physical mechanisms involved in the fusion bonding process for modelling purposes are discussed including heat transfer, consolidation and crystallinity aspects. Finally, the application of fusion bonding to joining dissimilar materials, namely thermosetting composites (TSC)/TPC and metal/TPC joints, is reviewed.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Mechanical Behavior of Composites · Electronic Packaging and Soldering Technologies · Epoxy Resin Curing Processes
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (100+)
Show source-provided references
1. Matthews · 1987
2. An experimental study of resistance welding of carbon fibre fabric reinforced polyetherimide (CF Fabric/PEI) composite material10.1023/A:1008879402267 ↗
3. Welding processes for plastics
4. Adhesive bonding of polymer composites10.1002/pen.760291904 ↗
5. Mechanical fastening of polymer composites10.1002/pen.760291905 ↗
6. Strong A. Brent: high performance and engineering thermoplastic composites. Technomic Pub., 1993.
7. Joining of composite materials
8. Todd SM. Joining thermoplastic composites. Proceedings of the 22nd International SAMPE Technical Conference, vol. 22, 1990. p. 383–92.
9. Treatment of composite surfaces for adhesive bonding10.1016/0143-7496(93)90036-9 ↗
10. Joining methods for graphite/PEEK thermoplastic composites
11. Welding: the way ahead for thermoplastics?
12. Adhesion and durability of metal–polymer bonds10.1007/BF00550796 ↗
13. Effect of sodium hydroxide anodization on the durability of poly(etherketonetherketoneketone) adhesive bonding of titanium10.1016/S0143-7496(96)00027-9 ↗
14. Surface treatments for adhesive bonding of carbon fibre–poly(etherether ketone) composites10.1007/BF00719701 ↗
15. Tietenberg TH. Environmental economics and policy. 2nd ed. Addison-Wesley Educational Pub. Inc., 1998.
16. Structural bonding for thermoplastics and composites
17. Lee · 1991
18. Advancements in welding technology for composite-to-metallic joints
19. Wise RJ, Watson MN. A New approach for joining plastics and composites to metals. Proceedings of the 50th Annual Technical Conference, ANTEC'92, 1992. p. 2113–16.
20. Design of adhesively bonded joints
21. Joining methods for plastics and plastic composites: an overview10.1002/pen.760291903 ↗
22. Wu S-IY, Schuler AM, Keane DV. Adhesive bonding of thermoplastic composites. 1. The effect of surface treatment on adhesive bonding. Proceedings of the 19th SAMPE Technical Conference, Oct 1987. p. 277–90.
23. Fusion welding techniques for plastics
24. Don RC, Bastien L, Jakobsen TB, Gillespie JW Jr. Fusion bonding of thermoplastic composite by resistance heating. 21st International SAMPE Technical Conference, 1989. p. 935–46.
25. Fusion bonding of thermoplastic composites by resistance heating
26. Designing plastic parts for ultrasonic assembly
27. Cogswell FN, Meakin PJ, Smiley AJ, Harvey MT, Brooth C. Thermoplastic interlayer bonding for aromatic polymer composites. 34th International SAMPE Symposium, 1989. p. 2315–25.
28. Dual bonding of thermoplastic composite structures10.1002/pen.760310709 ↗
29. Progress in joining advanced materials
30. Welding techniques for plastics and composites
31. Methods for fusion bonding thermoplastic composites
32. Joining thermoplastic composites
33. Rudolf R, Neitzel M, Strohfuss W. Interaction of variables in vibration welding of continuous fiber reinforced thermoplastics. Proceedings of the 29th International SAMPE Technical Conference. vol. 29, 1997. p. 462–74.
34. Joining materials with microwave energy
35. An introduction into welding of engineering thermoplastics using focused microwave energy10.1016/S0924-0136(97)00269-0 ↗
36. Microwave curing of composites10.1177/002199838401800405 ↗
37. Interaction of electromagnetic radiation with organic matrix composites10.1177/002199838401800404 ↗
38. Tateishi N, Zach TB, Woodhams RT, North TH. Ultrasonic bonding of roll-drawn polypropylene using tie-layers. Proceedings of the 47th Annual Technical Conference, ANTEC'89, 1989. p. 496–98.
39. Joining of high strength oriented polypropylene using electromagnetic induction bonding and ultrasonic welding10.1179/mst.1989.5.3.281 ↗
40. Ultrasonic welding of thermoplastic in the near-field10.1002/pen.760292311 ↗
41. Ultrasonic welding of thermoplastics in the far-field10.1002/pen.760292312 ↗
42. Wolcott J. Recent advances in ultrasonic welding technology. Proceedings of the 47th Annual Technical Conference, ANTEC'89, 1989. p. 502–5.
43. Hornstein J. Ultrasonic assembly of plastic parts. Proceedings of the Regional Technical Conference on Decorating in the Year 2000, 1996. p. 64–71.
44. Joining plastics the sound way
45. John MS, Park JB. Ultrasonic weldability of painted plastics. Proceedings of the 55th Annual Technical Conference, ANTEC'97, 1997. p. 1242–6.
46. Benatar, A., Welding of thermoplastic and thermoplastic composites. In: Hui D, editor. Proceedings of the Second International Conference of Composites Engineering, 1995. p. 61–2.
47. Joining and repair of a carbon fibre-reinforced thermoplastic10.1016/0010-4361(91)90199-Q ↗
48. Variable interactions in ultrasonic welding of thermoplastic composites
49. Wise RJ, Bates ADH, Ultrasonic welding of PES to aluminium alloy. Proceedings of the 54th Annual Technical Conference, ANTEC'96, 1996. p. 1203–7.
50. Ultrasonic welding of PEEK graphite APC-2 composites10.1002/pen.760292313 ↗
51. Leatherman AF. Composite plastic-metallic bonding means and method. United States Patent No. 4,029,837, 1977.
52. Buckley JD, Swaim RJ, Fox RL. One-step dual purpose joining technique. United States Patent No. 4,313,777, 1982.
53. Williams G, Green S, McAfee J, Heward CM. Induction welding of thermoplastic composites. FRC90 — Proceedings, ImechE, 1990. p. 133–6.
54. Border, J., Salas, R., Induction Heated Joining of Thermoplastic Composites without Metal Susceptors, Proceedings of the 34th International SAMPE Symposium, May 1989, pp. 2569–78.
55. Sindt MR. Fastening device for use with induction heater apparatus and system for holding together two nonmetal surfaces. United States Patent No. 3,996,402, 1976.
56. Induction heating model for graphite fibre/thermoplastic matrix composites
57. Resistive susceptor design for uniform heating during induction bonding of composites10.1177/089270579801100403 ↗
58. Electromagnetic welding: an advance in thermoplastic assembly10.1016/0261-3069(87)90059-8 ↗
59. Xiao XR, Hoa SV, Street KN. Repair of thermoplastic composite structures by fusion bonding. Proceedings of the 35th International SAMPE Symposium, 1990. p. 37–5.
60. Repair of thermoplastic resin composite by fusion bonding10.1520/STP12913S ↗
61. Bourban PE, Karamuk E, Don RC, Gillespie JW Jr. Induction heating for rehabilitation of steel structures using composites. ASCE Conference, New Material and Methods for Repair, 1994. p. 287–94.
62. Joining thermoplastic pipe
63. The joining of biaxially oriented polyethylene pipes10.1002/pen.760292303 ↗
64. Swartz HD, Swartz JL. Focused infrared melt fusion: another option for welding thermoplastic composites. SME Technical Paper, Joining Composites, 1989. p. EM89-175-1–EM89-175-16.
65. Experimental investigation of the resistance welding of thermoplastic composite materials. Part I: heating element and heat transfer10.1016/S0266-3538(00)00005-1 ↗
66. Ageorges C, Ye L, Hou M. Experimental investigation of the resistance welding of thermoplastic composite materials. Part II: consolidation quality and fracture mechanisms. Submitted for publication.
67. Resistance welding of graphite polyetheretherketone composites: an experimental investigation10.1177/089270578800100402 ↗
68. Eveno E, Gillespie Jr. JW, Vinson JR. Resistance welding of graphite polyetheretherketone composites. Proceedings of the 47th Annual Technical Conference, ANTEC'89, 1989. p. 493–5.
69. Experimental characterization of processing–performance relationship of resistance welded graphite/polyetheretherketone composite joints10.1002/pen.760320908 ↗
70. Bastien L, Don RC, Gillespie Jr. JW. Processing and Performance of Resistance Welded Thermoplastic Composites. Proceedings of the 45th Annual Conference, ANTEC'90, 1990. p. 1–9.
71. Two-dimensional thermal analysis of resistance welded thermoplastic composites10.1002/pen.760292314 ↗
72. Resistance welding of graphite–polyarylsulfone/polysulfone dual-polymer composites10.1177/089270579300600303 ↗
73. Resistance welding of continuous carbon fibre/polypropylene composites
74. Resistance welding of continuous glass fiber-reinforced polyethylene composites10.1016/0956-7143(92)90078-9 ↗
75. Lambing CLT, Don RC, Andersen SM, Holmes ST, Leach BS, Gillespie Jr. JW. Design and manufacture of an automated resistance welder for thermoplastic composites. Proceedings of the 49th Annual Technical Conference, ANTEC'91. p. 2527–31.
76. Holmes ST, Don RC, Gillespie Jr. JW, Howie I, Ortona A. Sequential resistance welding of large-scale IM7/PEEK double lap joints. CCM Report 91-55. Centre for Composite Materials, University of Delaware, 1991.
77. Tackitt KD, Gillespie Jr. JW. Through transmission ultrasonics for process monitoring of thermoplastic fusion bonding. Proceedings of the 11th Technical Conference of the American Society for Composites, 1996. p. 812–21.
78. Taylor NS, Davenport R. The resistive implant welding of thermoplastic composite materials. Proceedings of the 49th Annual Technical Conference, ANTEC‘91, 1991. p. 2038–41.
79. McKnight SH, Holmes ST, Gillespie Jr. JW, Lambing CLT, Marinelli. Resistance heated fusion bonding of carbon fibre/PEEK composites and 7075-T6 aluminium. Proceedings of the 51st Annual Technical Conference, ANTEC'93, 1993. p. 1474–9.
80. Arias M, Ziegmann G. The impulse resistance welding: a new technique for joining advanced thermoplastic composite parts. Proceedings of the 41st International SAMPE Symposium, 1996. p. 1361–71.
81. Ageorges C, Ye L. Simulation of impulse resistance welding for thermoplastic matrix composites. Submitted for publication.
82. Lambing, CLT, Andersen SM, Holmes, ST, Don RC, Leach BS, Gillespie Jr. JW. Apparatus and method for resistance welding. United State Patent No. 5,225,025, 1993.
83. Scaling issues in resistance welded thermoplastic composite joints10.1002/(SICI)1098-2329(199711)16:4<279::AID-ADV3>3.0.CO;2-S ↗
84. Influence and control of bondline thickness of fusion bonded joints of thermoplastic composites10.1016/0956-7143(91)90144-6 ↗
85. Chao M, Gillespie Jr. JW. The influence of healing and bondline thickness on the mechanical performance of fusion-bonded thermoplastic composites joints. Proceedings of the 39th International SAMPE Symposium, 1994. p. 2023–37.
86. The effect of cooling rate and annealing on residual stress development in graphite fibre reinforced PEEK laminates10.1177/002199839302700201 ↗
87. Xiao XR. A model for the deconsolidation phenomenon in induction heating of thermoplastic resin composites. In: Miravete A, editor. Proceedings of the Ninth International Conference on Composite Materials, ICCM9, 1993. p. 243–50.
88. A non-isothermal healing model for strength and toughness of fusion bonded joints of amorphous thermoplastics10.1002/pen.760312406 ↗
89. An analysis of mechanisms governing fusion bonding of thermoplastic composites10.1177/089270579801100404 ↗
90. Welding of PEEK/carbon fibre composite laminates
91. Characteristics of resistance welding of lap shear coupons. Part III: crystallinity10.1016/S1359-835X(98)00024-4 ↗
92. Processing and modelling of resistance welding of APC-2 composite10.1177/002199839202600705 ↗
93. Thermal analysis for resistance welding of large-scale thermoplastic composite joints10.1177/073168449301200609 ↗
94. Characteristics of resistance welding of lap shear coupons. Part I: heat transfer10.1016/S1359-835X(98)00022-0 ↗
95. Karamuk E, Wetzel ED, Gillespie Jr. JW. Modeling and design of induction bonding process for infrastructure rehabilitation with composite materials. Proceedings of the 53rd Annual Technical Conference, ANTEC'95, 1995. p. 1239–43.
96. A resin flow/fibre deformation model for composites
97. The consolidation of laminate composites10.1177/002199838702100207 ↗
98. Consolidation experiments for laminate composites10.1177/002199838702100705 ↗
99. Norpoth L, Butt A, Muzzy J. Quantitative analysis of APC-2 consolidation. Proceedings of the 33rd International SAMPE Symposium, 1988. p. 1331–41.
100. A theory of healing at a polymer–polymer interface10.1021/ma00241a013 ↗