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MultiMaterial assembly « thermal process »
Richard Tomasi
richard.tomasi@cetim.fr / 06.42.10.43.24
3
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” thermoplastic composites
Theory about hot bonding metal / thermoplastics composites
Process and machine used
Tests & results
Development & future works
4
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
In order to weld composites parts, the matrix should be THERMOPLASTIC
This is a 5 steps process :
Welding thermoplastic composites
Step Parameter to monitor
1 Fusion Time / Temperature
2 Contact between surfaces Time / Pressure
3 Interpenetration / diffusion Time / Temperature / Pressure
4 Cicatrization Time / Temperature / Pressure
5 Solidification Time / Temperature
Step 2 Step 3 Step 4
5
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
3 important parameter for welding :
Temperature : 10 – 20°C above T°f
Time : Enough for fusion, interpenetration but no more to avoid oxydation
Pressure : Enough for the contact between parts but no more to sqeeze the matrix
Which process to weld thermoplastic composites ?
Welding thermoplastic composites
6
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
7
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Induction welding is an electromagnetic process that heat materials which can
conduct electricity.
Eddy Current from induction generator can heat conductive parts by Joule effect. If there is no
conductive parts, a susceptor is required.
Carbon fibers : No need of susceptor because CF can heat himself…
Glass fibers & others : Need metallic mesh, powder… between parts to weld.
Welding thermoplastic composites Induction welding
Main parameters for induction welding :
Distance between inductor – susceptor (mm)
Pressure (N)
Power from generator (kW)
Welding time (s)
Susceptor characteristic (geometry,
material…)
Inductor geometry
8
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Induction system :
Welding thermoplastic composites Induction welding
PAGF50 + Copper
mesh
Pyrometer to monitor external
temperature
9
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Ultrasonic welding is a mechanical process. The mechanical vibrations at 20kHz to
40kHz heat the interface between.
The heat fuse the matrix and polymer can melt. The vibrations should be focused to the interface…
Focused vibration : Need energy director at the interface…
Diffused vibration : Poor weld but no need of energy director.
Welding thermoplastic composites Ultrasonic welding
Main parameters for induction welding :
Sonotrode geometry
Pressure (N)
US Frequency (kHz)
Welding time (s)
US range (µm)
10
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Ultrasonic system :
Welding thermoplastic composites Ultrasonic welding
Induction generator
CEIA 25-SA/80Sonimat
SONIMAT ESW
GP 20kHz
11
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
12
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Material tested
PA66 / GF 50 – PA66 / GF 50
PA6 / GF50 – PA6 / GF 50
Surface preparation before welding
Only degreasing
Degreasing + PA66 or PA6 film between parts
Pressure for welding:
20N to 50N (induction)
800N (US)
Welding thermoplastic composites Configuration tested
Welding time:
5s to 20s (induction)
0,5s to 2s (US)
Welding process :
Induction welding
Ultrasonic welding
13
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA66 / GF 50 – results
FASTLITE ASSEMBLAGE Project :
Single Lap Shear S=12,5 x 38mm
14
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA66 / GF 50 – results
FASTLITE ASSEMBLAGE Project :
Single Lap Shear S=12,5 x 38mm
15
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA66 / GF 50 results
FASTLITE ASSEMBLAGE Project :
Induction welding
Surface preparation : Degreasing + PA66 film
Pressure : 50N
Failure : 100% cohesive
SLS result : 22,1MPa
Ultrasonic welding
Surface preparation : Degreasing + PA66 film
Pressure : 800N
Failure : 100% cohesive
SLS result : 32,6MPa
16
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA66 / GF 50 results
US welds seems to be stronger : 27MPa Vs 18MPa
US vibrations promote contact between parts. Induction is a “static” process
The PA66 film between parts improve the strength from 10 to 20%
The matrix is not sucked from the part. We observed less voids
US welding is quicker than induction welding : 1 – 2s Vs 10 – 15s
Induction welding PA66 GF50 / PA66 GF50
Surface preparation Pressure Single Lap Shear
results Std dev.
Degreasing + PA66 film 20N 50N
13,5MPa 18,3MPa
2,6 4,2
Ultrasonic welding PA66 GF50 / PA66 GF50
Degreasing + PA66 film 800N 27,0MPa 4,9
FASTLITE ASSEMBLAGE Project :
17
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA6 / GF 50 results
DEMOS Project :
Single Lap Shear S=12,5 x 25mm
18
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA6 / GF 50 results
DEMOS Project :
Single Lap Shear S=12,5 x 25mm
19
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA6 / GF 50 results
DEMOS Project :
20
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Welding thermoplastic composites PA6 / GF 50 results
US welds seems to be stronger : 22MPa Vs 18MPa
US vibrations promote contact between parts. Induction is a “static” process
The PA66 film between parts improve the strength from 10 to 20%
The matrix is not sucked from the part. We observed less voids
US welding is qucker than induction welding : 1 – 2s Vs 15s
Induction welding PA6 GF50 / PA6 GF50
Surface preparation Pressure Single Lap Shear
results Std dev.
Degreasing + PA6 film 50N 18,6MPa 0,1
Ultrasonic welding PA6 GF50 / PA6 GF50
Degreasing + PA6 film 500N 22,2MPa 0,8 MPa
DEMOS Project :
21
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
22
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Development & future works
In welding the mechanical strength is only due to the mechanical strength of the matrix. To
improve the strength, we are working on :
Texturing the interface (Z-pins for example)
Surface treatment such as atmospheric plasma, solgel…
To go further, we already weld the arm suspension for PSA but we will test the weld in
dynamic conditions :
Dynamic solicitation of the welded zone
Comparison between welding and bonding
23
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” metal / thermoplastic composites
Theory about Warm bonding metal / thermoplastics composites
Process and machine used
Tests & results
Development & future works
24
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Warm bonding uses only THERMOPLASTIC matrix
This is a 4 steps process :
Warm bonding metal / thermoplastic composites CETIM Patent
Step Parameter to monitor
1 Fusion Time / Temperature
2 Contact between surfaces Time / Pressure
3 Wetting Time / Temperature / Pressure
4 Solidification Time / Temperature
3 important parameter for welding :
Temperature : 10 – 20°C above T°f
Time : Enough for fusion but no more to avoid oxydation
Pressure : Enough for the contact between parts but no more to sqeeze the matrix
Which process to bond thermoplastic composites ?
Induction on metallic part
25
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” metal / thermoplastic composites
Theory about Warm bonding metal / thermoplastics composites
Process and machine used
Tests & results
Development & future works
26
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Induction is applied on metallic part that will heat.
Eddy Current from induction generator can heat the metallic parts by Joule effect then the
composite part will melt by conduction
Main parameters for induction hot
bonding :
Distance between inductor – susceptor
(mm)
Pressure (N)
Power from generator (kW)
Welding time (s)
Metallic part(geometry, material…)
Inductor geometry
Warm bonding metal / thermoplastic composites Induction process
27
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” metal / thermoplastic composites
Theory about Warm bonding metal / thermoplastics composites
Process and machine used
Tests & results
Development & future works
28
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Material tested
PA66 / GF 50 – Aluminium 5182
PPS / CF 50 – Aluminium 5182
Surface preparation before welding
Only degreasing
Degreasing + PA66 film between parts
Texturation of metallic surface + PA66 film between parts
Pressure for welding:
20N to 50N (induction)
Warm bonding metal / thermoplastic composites Configuration tested
Welding time:
10s to 60s (induction)
Welding process :
Induction welding
Ultrasonic welding : no assembly !!!
29
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Warm bonding metal / thermoplastic composites PA66 / GF 50 – Aluminium 5182 results
Assembly is done is less than 1 min
Important improvement due to the texturation : 8MPa Vs 26MPa
H7 ageing is not destroying the assembly
Single Lap Shear S=12,5 x 38mm
30
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Warm bonding metal / thermoplastic composites PA66 / GF 50 – Aluminium 5182 results
31
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Warm bonding metal / thermoplastic composites PPS / CF 50 – Aluminium 5182 results
Assembly is done is less than 30s
Pressure can improve the matrix and fiber flow in grooves
Single Lap Shear S=12,5 x 38mm
32
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Warm bonding metal / thermoplastic composites PPS / CF 50 – Aluminium 5182 results
33
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Warm bonding metal / thermoplastic composites PPS / CF 50 – Aluminium 5182 results
Single Lap Shear S=12,5 x 38mm
Metal
Composite
34
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Presentation
I. Welding thermoplastic composites
Theory about welding of thermoplastics composites
Process and machine used
Tests & results
Development & future works
II. “Warm bonding” metal / thermoplastic composites
Theory about Warm bonding metal / thermoplastics composites
Process and machine used
Tests & results
Development & future works
35
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Development & future works
The mechanical strength is improved by fiber incrustation in the grooves. To improve the
strength, we are working on :
Geometry of the texturation
Machining of the texturation
Density of the texturation
Warm bonding can replace classical bonding process :
This process is quicker (less than 1min) for 20 – 30MPa
IF we can propose NDT to verify the good fiber incrustation
Searching an industrial Partner to improve and
transfer this technology
36
jeudi 9 février 2017
« Thermal process » in multimaterial assembly
Multi-material assembly Engineer
Richard Tomasi
02 40 37 35 83
06 42 10 43 24
Richard.tomasi@cetim.fr
Many thanks for your attention
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