Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHz
Ultrasonic reconsolidation offers significant potential to replace traditional adhesive bonding techniques used in the aerospace industries for bonding repair patches to damaged composite structures without resin additives. Temperature, a characteristic variable, is a key factor influencing the qual...
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| Format: | Article |
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Elsevier
2025-03-01
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| Series: | Composites Part C: Open Access |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S266668202500009X |
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| author | Balaji Ragupathi Lena Burger Frank Balle |
| author_facet | Balaji Ragupathi Lena Burger Frank Balle |
| author_sort | Balaji Ragupathi |
| collection | DOAJ |
| description | Ultrasonic reconsolidation offers significant potential to replace traditional adhesive bonding techniques used in the aerospace industries for bonding repair patches to damaged composite structures without resin additives. Temperature, a characteristic variable, is a key factor influencing the quality of joints in ultrasonic welding of thermoplastic composites. In this study, instead of measuring temperature during the joining process, the focus was on post-joining analysis on temperature at various hold times and holding forces. The findings revealed that an average hold time of 5 s and a holding force of 750 N produced higher-quality joints with minimal damages to fiber bundles and residual matrix. Additionally, it was recommended that repair patches should only undergo a maximum of two reconsolidation cycles. Beyond this point, the fibers and matrix begins to degrade, leading to a 35% reduction in mechanical performance after the fourth cycle. |
| format | Article |
| id | doaj-art-902d5c5a4c9f4423baafc4194785788c |
| institution | Kabale University |
| issn | 2666-6820 |
| language | English |
| publishDate | 2025-03-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Composites Part C: Open Access |
| spelling | doaj-art-902d5c5a4c9f4423baafc4194785788c2025-02-03T04:16:59ZengElsevierComposites Part C: Open Access2666-68202025-03-0116100565Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHzBalaji Ragupathi0Lena Burger1Frank Balle2Walter-and-Ingeborg-Herrmann-Chair for Power Ultrasonics and Engineering of Functional Materials (EFM), Department of Sustainable Systems Engineering (INATECH), University of Freiburg, 79110 Freiburg i. Br., Germany; Corresponding author.Walter-and-Ingeborg-Herrmann-Chair for Power Ultrasonics and Engineering of Functional Materials (EFM), Department of Sustainable Systems Engineering (INATECH), University of Freiburg, 79110 Freiburg i. Br., GermanyWalter-and-Ingeborg-Herrmann-Chair for Power Ultrasonics and Engineering of Functional Materials (EFM), Department of Sustainable Systems Engineering (INATECH), University of Freiburg, 79110 Freiburg i. Br., Germany; Freiburg Materials Research Center FMF, 79104 Freiburg i. Br., Germany; Fraunhofer-Institute for High-Speed Dynamics, Ernst Mach Institute (EMI), 79104 Freiburg i. Br., GermanyUltrasonic reconsolidation offers significant potential to replace traditional adhesive bonding techniques used in the aerospace industries for bonding repair patches to damaged composite structures without resin additives. Temperature, a characteristic variable, is a key factor influencing the quality of joints in ultrasonic welding of thermoplastic composites. In this study, instead of measuring temperature during the joining process, the focus was on post-joining analysis on temperature at various hold times and holding forces. The findings revealed that an average hold time of 5 s and a holding force of 750 N produced higher-quality joints with minimal damages to fiber bundles and residual matrix. Additionally, it was recommended that repair patches should only undergo a maximum of two reconsolidation cycles. Beyond this point, the fibers and matrix begins to degrade, leading to a 35% reduction in mechanical performance after the fourth cycle.http://www.sciencedirect.com/science/article/pii/S266668202500009XThermoplastic compositesCFRPRepairUltrasonic Reconsolidation20 kHzCircularity-Engineering |
| spellingShingle | Balaji Ragupathi Lena Burger Frank Balle Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHz Composites Part C: Open Access Thermoplastic composites CFRP Repair Ultrasonic Reconsolidation 20 kHz Circularity-Engineering |
| title | Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHz |
| title_full | Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHz |
| title_fullStr | Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHz |
| title_full_unstemmed | Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHz |
| title_short | Post-joining thermal characteristics and repair integrity of carbon fiber-reinforced thermoplastic composites during ultrasonic reconsolidation at 20 kHz |
| title_sort | post joining thermal characteristics and repair integrity of carbon fiber reinforced thermoplastic composites during ultrasonic reconsolidation at 20 khz |
| topic | Thermoplastic composites CFRP Repair Ultrasonic Reconsolidation 20 kHz Circularity-Engineering |
| url | http://www.sciencedirect.com/science/article/pii/S266668202500009X |
| work_keys_str_mv | AT balajiragupathi postjoiningthermalcharacteristicsandrepairintegrityofcarbonfiberreinforcedthermoplasticcompositesduringultrasonicreconsolidationat20khz AT lenaburger postjoiningthermalcharacteristicsandrepairintegrityofcarbonfiberreinforcedthermoplasticcompositesduringultrasonicreconsolidationat20khz AT frankballe postjoiningthermalcharacteristicsandrepairintegrityofcarbonfiberreinforcedthermoplasticcompositesduringultrasonicreconsolidationat20khz |