SAMPE Journal - January/February 2017 - 50

Feature Article

Figure 14. Comparison between simulated lap shear strength and measured lap shear strength.

absolute lap shear value of the
welded specimens in respect to the
lap shear values of the autoclave
specimens is a result of the smaller
joined area. A comparison of
the joining areas shows that the
calculated joined area corresponds
pretty well with the measured
joined area for all process speeds.
Consequently, the simulation was
verified with a good accordance and
the lap shear strength was calculated
correctly.

Conclusions

A process diagram for the
continuous
induction
welding
process for carbon fiber reinforced
thermoplastics is developed on a
3-dimentional finite element thermal
model. By changing the temperature
restrictions and heating factor the
model can slightly be adapted to new
material conditions. The verification
of the process simulation showed
good accordance between measured
and simulated lap shear strength.
Void development was predicated
correctly and can be prevented
by using appropriate parameter
settings. The used finite element
model was not able to predict matrix
squeeze-out, but this result only
in a local increase of fiber volume
content. Also minor local surface
50

melting was not predicted well. With
the help of the developed process
simulation and user interface a
quality controlled welding of 2 mm
thick, Polyamide 66 laminates with
50 vol.-% carbon fiber, satin ¼ textiles
was shown. Process speeds of 200
mm/min, 350 mm/min and 450 mm/
min were realized and the bonded
area of the welded specimens had
lap shear strength at autoclave level.

Acknowledgement

The presented work was conducted
in cooperation with 'KSL Keilmann
Sondermaschinenbau GmbH' in
the project 'AutoIndu', funded by
the German federal ministry for
economy and energy.

References

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Induction Welding of Carbon
Fiber Reinforced Thermoplastics".
Proceedings of 19th International Conf.
on Composites Materials. Montreal,
Canada, May 15, 2013. Canadian
Association for Composite Structures
and Materials, pp. 5844-5852
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2011.

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SAMPE Journal, Volume 53, No. 1, January/February 2017

http://www.polytron-gmbh.de/eigenschaften_mdm.aspx http://www.polytron-gmbh.de/eigenschaften_mdm.aspx http://www.agk.de/international/en/html/html_produkte/AS500MAS600MAS800M.htm#AS600M http://www.agk.de/international/en/html/html_produkte/AS500MAS600MAS800M.htm#AS600M http://www.agk.de/international/en/html/html_produkte/AS500MAS600MAS800M.htm#AS600M http://www.agk.de/international/en/html/html_produkte/AS500MAS600MAS800M.htm#AS600M

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