Abstract
This paper presents an experimental investigation of fusion bonding of continuous glass fibre-reinforced polypropylene composites by resistance welding. The heating element consists of a single ply of carbon fibre ( cf)/polypropylene ( pp) prepreg. An experimental apparatus was developed to carry out experiments which yield information on the processing parameters, such as current intensity, input energy and power level which can govern, more or less, the efficiency of the welding process. The quality of the welded surface was examined by tensile (lap shear) and double cantilever beam testing. The morphology and microstructure of the welded surfaces were studied by scanning electron microscopy and differential scanning calorimetry. Experimental results indicated that sufficient joining was obtained at power levels from 40 to 140 kW m −2. The lap shear strength and mode I interlaminar fracture toughness (propagation value) of welded specimens was equivalent to that of compression moulded specimens. The fracture surfaces of welded specimens showed mostly cohesive failure or intralaminar failure in the glass fibre ( gf)/ pp composites. An optimal processing window was finally determined for the resistance welding of gf/ pp composite.
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