Improving the quality of resistance welded thermoplastic composite joints by applying ultrasonic

Resistance welding, a favored method for joining thermoplastic composites, often faces the challenge of nonuniform bonding which leads to weak bonding at the overlap edge and compromises joint integrity. This study proposes a novel modification to traditional resistance welding by incorporating ultrasonic during the final stage of the process. We employed various durations of resistance welding and ultrasonic to join the GF/PPS composites, which yielded significant improvements in bonding strength and welding efficiency. Applying ultrasonic introduced a self-adaptive temperature compensation mechanism, enhancing the temperature at the overlap edge while diminishing the temperature difference between the center and edge of the overlap. This method also improved fusion bonding by encouraging resin flow along the unfused interface at the overlap edge, thereby expanding the bonding area. Notably, the introduction of ultrasonic revealed a new bonding mechanism involving the interaction between molten PPS and unmelted PPS, which was thoroughly examined. The results revealed a 19% increase in lap shear strength and a 40% reduction in welding time for joints with ultrasonic compared to those without ultrasonic.