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Current leakage prevention in resistance welding of carbon fibre reinforced thermoplastics

机译:碳纤维增强热塑性塑料电阻焊中的电流泄漏预防

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摘要

Current leakage is a concern with resistance welding of carbon fibre reinforced thermoplastic composites. This phenomenon is particularly important when unidirectional adherends, with the carbon fibres parallel to the electrical current direction, are welded. In this investigation, a new electrically-insulated heating element consisting of a ceramic-coated (TiO\u2082) stainless steel mesh was developed to prevent current leakage. Special specimen geometry, called a skin/stringer configuration, was welded with this newly developed heating element to represent typical reinforced aerospace structures. The adherends were made of APC-2/AS4 (carbon fibre/PEEK) composites. Unidirectional specimens, which represent the most critical case, were first welded using the new heating element. The insulated heating element successfully prevented current leakage and showed great improvement in temperature homogeneity over the weld area. The impact of the new heating element on the mechanical performance of the welds was then assessed by welding quasi-isotropic specimens. The mechanical performances of quasi-isotropic specimens welded using the new insulated heating elements and conventional (non-insulated) ones were compared under short beam and three-point bending tests. No mechanical performance drawback was observed with the new heating element; however, the failure mode of the welded quasi-isotropic specimens was changed from a delamination in the skin laminate failure to a weld interface debonding failure.
机译:漏电流是碳纤维增强热塑性复合材料电阻焊接的一个问题。当碳纤维平行于电流方向的单向被粘物被焊接时,这种现象尤为重要。在这项研究中,开发了一种新型的由陶瓷涂层(TiO \ u2082)不锈钢网构成的电绝缘加热元件,以防止电流泄漏。这种新开发的加热元件与特殊的试样几何形状(称为蒙皮/纵梁构造)焊接在一起,代表了典型的航空航天增强结构。被粘物由APC-2 / AS4(碳纤维/ PEEK)复合材料制成。首先使用新的加热元件焊接代表最关键情况的单向试样。绝缘的加热元件成功地防止了电流泄漏,并且在整个焊接区域的温度均匀性方面显示出极大的改善。然后,通过焊接准各向同性试样来评估新加热元件对焊缝机械性能的影响。在短梁和三点弯曲试验下,比较了使用新型绝缘加热元件和常规(非绝缘)加热元件焊接的准各向同性试样的力学性能。新型加热元件未发现机械性能缺陷;但是,准各向同性焊接试样的破坏模式从表皮层压板的分层剥离变为焊接界面剥离失败。

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