Abstract
Using thermoplastics as the matrix in carbon fiber-reinforced polymers (CFRP) offers the possibility to make use of welded joints, which results in weight savings compared to conventional joining methods using mechanical fasteners. In this paper, the resulting temperature distribution in the material due to resistance welding is investigated by transient finite element (FE) simulations. To examine the effects on the component structure, a numerical modeling approach is created, which allows determining the residual stresses caused by the welding process. It is shown that the area of the structure, especially near the joining zone, is highly affected by the process, especially in terms of residual stresses. In particular, the stresses perpendicular to the fiber direction show failure relevant values up to a maximum of 221 MPa, which might lead to the formation of microcracks in the matrix. In turn, that is assumed to be critical in terms of the fatigue of welded composite structures. Thus, the suggested modeling approach provides residual stresses that can be used to determine their effects on the strength, structural stability, and fatigue of such composite structures. In a subsequent step, these findings could play an important role in the design process of thermoplastic composite structures.
Highlights
The use of thermoplastic matrix materials in fiber-reinforced polymers is increasingly becoming the focus of applied aerospace research
Compared to conventional joining techniques using mechanical fasteners [2,3], significant weight advantages can be achieved through welding, which in turn represents a concrete action with respect to eco-lightweight design and, as a result of lower fuel consumption, leads to lower CO2 emissions
The performed welding process simulation leads to time-temperature data for the considered component so that the temperature of every single element at a certain time during heating and cooling can be assessed
Summary
The use of thermoplastic matrix materials in fiber-reinforced polymers is increasingly becoming the focus of applied aerospace research. The recyclability of thermoplastic materials is another significant factor [1] Both aspects are to be considered concerning the possible production and resource efficiency that can be achieved and in turn represent key aspects with regard to environmentally friendly aviation. Another benefit of thermoplastic materials is their weldability. Compared to conventional joining techniques using mechanical fasteners [2,3], significant weight advantages can be achieved through welding, which in turn represents a concrete action with respect to eco-lightweight design and, as a result of lower fuel consumption, leads to lower CO2 emissions. For the induction welding of thermoplastics, the electromagnetic field of an external inductor heats the heating element
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