Effects of processing parameters on electro-fusion joining of CF/PPS composites using carbon fiber heating elements

Abstract

This study aims to develop the electro-fusion joining method for continuous fiber reinforced thermoplastic (cFRTP) composites using various carbon fibers as a resistance heating element. The material used for the experiment was woven CF/PPS laminates. The effects of processing conditions such as applied voltage, time and current and also material conditions such as thickness of the inserted PPS films on the fusion behavior of cFRTP composites were investigated. The optimum condition for electro-fusion joining were obtained from experimental results such as surface condition of joint section peeled off after applying current and welding area obtained from those images. The electro-fusion mechanism was revealed by investigating the electro-fusion condition such as applied voltage, conducting time and thickness of PPS films. The welding area was increased with increasing the applied voltage and the conducting time. It was revealed that there was optimum applied voltage and conducting time in order to prevent the thermal deformation and thermal degradation of CF/PPS laminates. It was also revealed that the uniform welding area was obtained by inserting the PPS film with the optimum thickness. When the fusion joining was carried out at the current control, the conducting behavior became stable compared to the voltage control. The results of single lap tensile strength tests revealed that the LSS value was more than 28MPa. When the spread carbon fiber 0° was used as heating element, the joining layer was reinforced with carbon fiber to the load direction.

Keywords

• thermoplastic composite
• electro-fusion joining
• carbon fiber bundle
• spread carbon fiber
• polyphenylene sulfide
• single lap tensile test
• welding