Manufacturing of thermoplastic composite sandwich panels using induction welding under vacuum

Abstract

A new method to manufacture thermoplastic composite sandwich panels is presented, making use of the induction welding process in which a magnetic susceptor generates the heat at the core/facesheet interface. This technique proposes a fast way to assemble thermoplastic sandwich structures without risking the deconsolidation of the composites skin. The welding pressure is obtained by applying vacuum over the sandwich panel. This vacuum induction welding method (Vac-IW) allows joining thermoplastic composite facesheets to a thermoplastic polymer core in a clean and non-contact manner. The feasibility of the method is demonstrated by preparing sandwich samples made of glass fibre reinforced polyetheretherketone (PEEK) skins and a 3D-printed polyetherimide (PEI) honeycomb core. A susceptor made of PEI and µm-sized nickel (Ni) particles is used to generate heat by magnetic hysteresis losses. The strength of the sandwich samples assembled by the Vac-IW method is evaluated by flatwise tensile (FWT) tests.