CN112936876A - Ultrasonic welding method for interface inclusion reinforced thermoplastic composite material - Google Patents
Ultrasonic welding method for interface inclusion reinforced thermoplastic composite material Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 379
- 229920001169 thermoplastic Polymers 0.000 title claims abstract description 150
- 239000002131 composite material Substances 0.000 title claims abstract description 149
- 239000004416 thermosoftening plastic Substances 0.000 title claims abstract description 147
- 238000000034 method Methods 0.000 title claims abstract description 44
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 202
- 239000000835 fiber Substances 0.000 claims abstract description 174
- 239000002041 carbon nanotube Substances 0.000 claims abstract description 101
- 229910021393 carbon nanotube Inorganic materials 0.000 claims abstract description 101
- 229910021389 graphene Inorganic materials 0.000 claims abstract description 101
- 239000002184 metal Substances 0.000 claims abstract description 88
- 229910003465 moissanite Inorganic materials 0.000 claims abstract description 82
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- 229910010271 silicon carbide Inorganic materials 0.000 claims abstract description 82
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- 238000001816 cooling Methods 0.000 claims abstract description 17
- 238000006073 displacement reaction Methods 0.000 claims abstract description 17
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- 239000011347 resin Substances 0.000 claims description 114
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- 238000001125 extrusion Methods 0.000 claims description 18
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- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 15
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- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 description 13
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- 229920000049 Carbon (fiber) Polymers 0.000 description 6
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/08—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using ultrasonic vibrations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/80—General aspects of machine operations or constructions and parts thereof
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- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
The invention discloses an ultrasonic welding method for an interface inclusion reinforced thermoplastic composite material, which is characterized in that an interface inclusion area is prepared by nailing carbon nano tubes, graphene, SiC particles or a high-strength metal mesh on a to-be-welded area of a first fiber reinforced thermoplastic composite material plate; overlapping a region to be welded of the second fiber reinforced thermoplastic composite plate on an interface inclusion region of the first fiber reinforced thermoplastic composite plate, and fixing the second fiber reinforced thermoplastic composite plate on an anvil block; and applying welding pressure and sinusoidal displacement load perpendicular to the interface of the workpiece right above the to-be-welded area of the second fiber reinforced thermoplastic composite material plate by using an ultrasonic welding head, and pressurizing, cooling and unloading the welding joint by using the ultrasonic welding head after welding is finished to finish welding. The invention greatly improves the tensile/peel strength of the welded joint.
Description
Technical Field
The invention belongs to the technical field of thermoplastic composite material ultrasonic connection, and particularly relates to an ultrasonic welding method for a thermoplastic composite material with an enhanced interface inclusion.
Background
Ultrasonic spot welded joints have stiffness and shear strength almost comparable to or higher than mechanically fastened joints, but ultrasonic welding has rarely been used to join carbon fiber reinforced thermoplastic structures in the engineering field due to the problem of lower tensile/peel strength of ultrasonically welded thermoplastic composite articles.
The interface strength of the welded joint directly determines the strength of the fiber reinforced thermoplastic composite material ultrasonic welded joint, the fiber surface is excessively smooth, chemically inert and low in surface energy, the peel strength between the fibers and the resin at the welded interface is low, and the strength of the resin matrix is low, so that early failure is easy to occur due to shear failure of the resin matrix and peel failure of the fibers and the resin matrix at the welded joint interface when a load is borne.
In order to exert the outstanding advantages of rapidness, high efficiency, attractive joint appearance and the like of the ultrasonic welding thermoplastic composite material, the welding interface must be enhanced from the aspects of improving the strength of the resin matrix at the welding interface and the anti-peeling strength between the fiber and the resin matrix, so that the connection strength of the welding joint is improved, and the high-strength ultrasonic welding joint which meets the actual industrial production is manufactured.
The carbon nano tubes, the graphene or the SiC particles are mixed in the resin matrix, so that the strength of the resin matrix can be obviously improved, and meanwhile, the carbon nano tubes, the graphene or the SiC particles in the fiber reinforced resin matrix composite can be attached to the surface of the carbon fibers to form a barb microstructure, so that the peeling strength between the fibers and the resin matrix in the composite is improved. Therefore, carbon nano tubes, graphene or SiC particles can be mixed in the welding interface and mixed between the resin matrix and the fibers of the welding interface under the action of ultrasonic vibration, so that the strength of the resin matrix and the anti-peeling strength between the fibers and the resin matrix at the welding interface are improved, and the tensile strength/peeling strength of the welding joint is greatly improved.
Or the high-strength metal mesh nail can be directly placed in the welding interface in a mixed mode, the high-strength metal mesh nail is directly embedded into the fibers of the welding joint to form a pinning effect under the action of ultrasonic vibration, so that the load of the welding joint is effectively transmitted among the fibers through the high-strength metal mesh nail, and the tensile strength/peel strength of the welding joint can also be greatly improved.
Disclosure of Invention
The technical problem to be solved by the present invention is to provide an ultrasonic welding method for thermoplastic composite materials with enhanced interface inclusions, which aims to overcome the defects in the prior art, so as to effectively transfer the load of the welded joint between fibers through high-strength metal mesh nails, and also greatly improve the tensile strength/peel strength of the welded joint.
The invention adopts the following technical scheme:
an ultrasonic welding method for a thermoplastic composite material reinforced by interface inclusions comprises the following steps:
s1, preparing an interface inclusion area on a to-be-welded area of the first fiber reinforced thermoplastic composite plate by adopting carbon nano tubes, graphene, SiC particles or high-strength metal mesh nails;
s2, overlapping the region to be welded of the second fiber-reinforced thermoplastic composite sheet on the interfacial inclusion region of the first fiber-reinforced thermoplastic composite sheet prepared in step S1, and fixing on an anvil;
and S3, applying welding pressure and sinusoidal displacement load perpendicular to the interface of the workpiece above the to-be-welded area of the second fiber reinforced thermoplastic composite plate prepared in the step S2 by using an ultrasonic welding head, maintaining pressure of the welding head by using the ultrasonic welding head after welding, cooling and unloading, and finishing welding.
Specifically, step S1 specifically includes:
s101, adding carbon nanotubes or graphene into an ethanol solution, performing ultrasonic stirring to prepare a carbon nanotube/graphene suspension, uniformly coating the carbon nanotube/graphene suspension on a region to be welded of a first fiber reinforced thermoplastic composite plate, and drying;
s102, uniformly coating the carbon nano tube or graphene suspension liquid prepared in the step S101 on a region to be welded of the first fiber reinforced thermoplastic composite plate, and drying to obtain a carbon nano tube or graphene interface inclusion region.
Further, in step S101, the concentration of the carbon nanotube/graphene suspension is 5 to 30 mg/mL.
Specifically, step S1 specifically includes:
s201, enabling a to-be-welded area of a first fiber reinforced thermoplastic composite plate to face upwards, placing the first fiber reinforced thermoplastic composite plate under an ultrasonic welding head, and fixing the first fiber reinforced thermoplastic composite plate on an anvil block;
s202, uniformly laying 10-40 mg of SiC particles in the region to be welded of the first fiber reinforced thermoplastic composite plate in the S201 to obtain an interface inclusion region of the SiC particles.
Specifically, step S1 specifically includes:
s301, uniformly mixing carbon nano tubes, graphene or SiC particles into a molten thermoplastic resin matrix, preparing a carbon nano tube/graphene/SiC particle inclusion type thermoplastic resin matrix film with the thickness of 0.2-0.35 mm by an injection molding extrusion mode, and cutting the carbon nano tube/graphene/SiC particle inclusion type thermoplastic resin matrix film into a sheet slightly larger than a welding area to prepare an inclusion type resin sheet;
s302, enabling a to-be-welded area of the first fiber reinforced thermoplastic composite plate to face upwards, placing the first fiber reinforced thermoplastic composite plate under an ultrasonic welding head, and fixing the first fiber reinforced thermoplastic composite plate on an anvil block;
s303, horizontally placing the resin inclusion sheet prepared in the step S301 on a region to be welded of the first fiber reinforced thermoplastic composite plate, and fixing the edge of the resin inclusion sheet to obtain an interface inclusion region of the carbon nano tube, the graphene or the SiC particle resin film.
Further, in step S301, the mass fraction of the carbon nanotube/graphene inclusion type thermoplastic resin matrix film with a thickness of 0.2 to 0.35m is 1 to 5%, the mass fraction of the inclusion type thermoplastic resin matrix film of SiC particles with a thickness of 0.2 to 0.35mm is 5 to 10%, and the side length of the film is 30 mm.
Specifically, step S1 specifically includes:
s401, carving metal mesh holes and metal mesh nail holes on a high-strength metal plate by using a carving machine to obtain a metal mesh plate, and installing and fixing metal nails on the metal mesh plate to obtain high-strength metal mesh nails or directly printing the high-strength metal mesh nails by using a 3D printing technology;
s402, enabling a to-be-welded area of the first fiber reinforced thermoplastic composite plate to face upwards, placing the first fiber reinforced thermoplastic composite plate under an ultrasonic welding head, and fixing the first fiber reinforced thermoplastic composite plate on an anvil block;
and S403, flatly placing the high-strength metal mesh nail prepared in the S401 on a region to be welded of the first fiber reinforced thermoplastic composite plate to obtain an interface inclusion region of the high-strength metal mesh nail.
Specifically, in step S3, the welding pressure is 500-1000N; the vibration amplitude of the sinusoidal displacement load is 25-100 mu m.
Specifically, in the step S3, the welding time is 0.8-1.5S, and the welded joint is unloaded after pressure maintaining and cooling for 5-10S.
Compared with the prior art, the invention has at least the following beneficial effects:
according to the ultrasonic welding method for the thermoplastic composite material with the enhanced interface inclusion, the resin matrix at the welding interface is melted, extruded and flowed under the transverse extrusion vibration of the ultrasonic welding head in the welding process, so that the carbon nano tubes, graphene or SiC particles included in the interface are mixed into the resin matrix and fibers at the welding interface and attached to the surfaces of the fibers to form a barb microstructure, the load applied by a welding joint can be more effectively transferred to the fibers from the resin, the strength of the resin matrix at the welding interface and the anti-peeling strength between the fibers and the resin matrix are improved, and the tensile/peeling strength of the welding joint is greatly improved; the high-strength metal mesh nail in the interface inclusion area is gradually nailed into fibers in the welding interface softening resin to form a pinning effect under the transverse extrusion vibration of the ultrasonic welding head in the welding process, so that the load of the welding joint is effectively transferred among the fibers through the high-strength metal mesh nail, and the tensile strength/peel strength of the welding joint can be greatly improved.
Further, the carbon nano tubes or the graphene are added into an ethanol solution for ultrasonic stirring, so that the carbon nano tubes or the graphene are fully dispersed in the alcohol to avoid agglomeration, the carbon nano tubes or the graphene turbid liquid is prepared, the prepared carbon nano tubes or the graphene turbid liquid is uniformly coated on a to-be-welded area of the first fiber reinforced thermoplastic composite plate, and drying treatment is performed, so that a certain amount of carbon nano tubes or graphene are uniformly distributed in an interface inclusion area, the carbon nano tubes or the graphene can be uniformly distributed in a resin matrix and fibers in a welding interface under transverse extrusion vibration of an ultrasonic welding head in the welding process, the strength of the resin matrix at the welding interface and the anti-stripping strength between the fibers and the resin matrix are improved, and the tensile strength/stripping strength of a welding joint is greatly improved.
Further, the concentration of the prepared 5mL carbon nano tube/graphene suspension is 5-30 mg/mL, the suspension is uniformly coated on the area to be welded of the first fiber reinforced thermoplastic composite material plate, drying treatment is carried out, therefore, a certain amount of carbon nano tubes or graphene are uniformly distributed on the interface inclusion area, so that the content of the carbon nano tubes or graphene in the resin matrix and the fibers uniformly distributed in the welding interface under the transverse extrusion vibration of the ultrasonic welding head in the welding process is not too small to improve the strength of the resin matrix and the peeling strength between the fibers and the resin matrix at the welding interface, and is not too large to reduce the strength of the resin matrix and the peeling strength between the fibers and the resin matrix at the welding interface, thereby not realizing the function of improving the tensile strength/peeling strength of the welding joint.
Furthermore, 10-40 mg of SiC particles are uniformly laid in the interface inclusion region, so that the melting extrusion flow of the resin matrix at the welding interface is realized under the transverse extrusion vibration of the ultrasonic welding head in the welding process, the SiC particles mixed with the interface are mixed into the resin matrix and the fibers at the welding interface and are attached to the surfaces of the fibers to form a barb microstructure, the load applied by the welding joint can be more effectively transferred to the fibers from the resin, the strength of the resin matrix at the welding interface and the anti-peeling strength between the fibers and the resin matrix are improved, and the tensile strength/peeling strength of the welding joint is greatly improved. The amount of the SiC particles laid in the interface inclusion region is 10-40 mg, so that the content of the SiC particles in the resin matrix and the fibers distributed in the welding interface after welding is not too small to improve the strength of the resin matrix at the welding interface and the peeling strength between the fibers and the resin matrix, and is not too large to reduce the strength of the resin matrix at the welding interface and the peeling strength between the fibers and the resin matrix, and the tensile/peeling strength of the welding joint cannot be improved.
Furthermore, under the transverse extrusion vibration of the ultrasonic welding head in the welding process, carbon nano tubes, graphene or SiC particles in the resin sheets at the welding interface can be gradually mixed into the resin matrix and the fibers at the welding interface along with the melting extrusion flow of the resin matrix and are attached to the surfaces of the fibers to form a barb microstructure, so that the load applied by the welding joint can be more effectively transferred to the fibers from the resin, the strength of the resin matrix at the welding interface and the anti-stripping strength between the fibers and the resin matrix are improved, and the tensile/stripping strength of the welding joint is greatly improved.
Furthermore, the mass fraction of the carbon nanotube/graphene inclusion type thermoplastic resin matrix film is 1-5%, and the mass fraction of the SiC particle inclusion type thermoplastic resin matrix film is 5-10%, so that the content of the carbon nanotube, the graphene or the SiC particle in the resin matrix and the fiber distributed in the welding interface after welding is not too small to improve the strength of the resin matrix at the welding interface and the peeling resistance strength between the fiber and the resin matrix, and the content of the carbon nanotube, the graphene or the SiC particle in the resin matrix and the fiber distributed in the welding interface is not too large to reduce the strength of the resin matrix at the welding interface and the peeling resistance strength between the fiber and the resin matrix, thereby not realizing the function of improving the tensile strength/peeling strength of the welding joint.
Furthermore, the high-strength metal mesh nail in the interface inclusion area is gradually nailed into fibers in the welding interface softening resin to form a pinning effect under the transverse extrusion vibration of the ultrasonic welding head in the welding process, so that the load of the welding joint is effectively transferred among the fibers through the high-strength metal mesh nail, and the tensile strength/peel strength of the welding joint can be greatly improved.
Furthermore, the welding pressure is 500-1000N, so that the two welded fiber reinforced thermoplastic composite plates can be ensured to be in close contact with an interface inclusion area in the welding process. The vibration amplitude of the sinusoidal displacement load is 25-100 mu m, and the ultrasonic welding head can be ensured to apply mechanical energy to a welding interface in a vibration mode, so that a large amount of welding heat can be generated in a short time to form a welding joint.
Further, the welding joint is maintained in pressure and cooled for 5-10 seconds and then unloaded, the welding interface can be ensured to be fully cooled and solidified under certain pressure, the defect of incomplete fusion is avoided, the strength of the welding joint is reduced, the welding time is 0.8-1.5 seconds, enough energy can be input into the welding interface to form a larger fusion area, the obtained welding joint has enough strength, the welding time cannot be too long, and the reduction of the welding strength caused by the excessive extrusion of resin and fibers of the welding interface is avoided.
In summary, the invention improves the strength of the resin matrix at the welding interface and the peeling resistance between the fiber and the resin matrix by mixing the carbon nanotube, the graphene or the SiC particle at the welding interface of the fiber reinforced thermoplastic composite material, or mixes the high-strength metal mesh nail at the welding interface of the fiber reinforced thermoplastic composite material, thereby realizing the effective transmission of the load of the welding joint between the fibers through the high-strength metal mesh nail, greatly improving the tensile strength/peeling strength of the welding joint, and providing a technical scheme for effectively promoting the ultrasonic welding to be used in the field of structural engineering for connecting carbon fiber reinforced thermoplastic plastics.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
FIG. 1 is a schematic diagram of ultrasonic welding used in an ultrasonic welding technique for fiber reinforced thermoplastic composites based on interfacial inclusion reinforcement according to the present invention;
FIG. 2 is a schematic view of the high strength metal mesh nail;
FIG. 3 is a schematic view of the high strength metal mesh nail required for the interface inclusion of the prepared metal mesh nail;
FIG. 4 is a single lap ultrasonic welded joint obtained using carbon nanotube, graphene or SiC particle interface inclusion enhancement of scheme I and carbon nanotube, graphene or SiC particle resin film interface inclusion enhancement of scheme II;
FIG. 5 is a single lap ultrasonic welded joint resulting from the enhanced inclusion at the high strength metal mesh nail interface using scheme III;
FIG. 6 shows that the method of scheme I, scheme II and scheme III is adopted to perform cross lap welding, and a cross lap ultrasonic welding joint with enhanced interface inclusions can be obtained.
Wherein: 1. an ultrasonic horn; 2. a transverse sinusoidal displacement load applied by the ultrasonic horn; 3. a second sheet of fiber reinforced thermoplastic composite material; 4. interface inclusion; 5. a first sheet of fiber reinforced thermoplastic composite material; 6. the welding pressure applied by the ultrasonic welding head; 7. an anvil block; 4-1. carbon nano tube or graphene interface inclusion region; 4-1-1. carbon nano tube, graphene or SiC particle interface inclusion reinforced welding area; 4-2. carbon nanotube, graphene interface or SiC particle resin film interface inclusion region; 4-3. high-strength metal net nail interface inclusion zone; 4-4. high-strength metal mesh nails; 4-4-1. high-strength metal mesh plate; 4-4-2. high-strength metal nails; 5-1. welding fibers in the interface; 5-2, welding carbon nano tubes, graphene or SiC particle inclusions in the interface resin matrix; 5-3, welding carbon nano tube graphene or SiC particle inclusions attached to fibers in the interface resin matrix; 5-4. welding the resin matrix in the interface.
Detailed Description
It will be understood that the terms "comprises" and/or "comprising," when used in this specification and the appended claims, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
It is also to be understood that the terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used in the specification of the present invention and the appended claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
It should be further understood that the term "and/or" as used in this specification and the appended claims refers to and includes any and all possible combinations of one or more of the associated listed items.
Various structural schematics according to the disclosed embodiments of the invention are shown in the drawings. The figures are not drawn to scale, wherein certain details are exaggerated and possibly omitted for clarity of presentation. The shapes of various regions, layers and their relative sizes and positional relationships shown in the drawings are merely exemplary, and deviations may occur in practice due to manufacturing tolerances or technical limitations, and a person skilled in the art may additionally design regions/layers having different shapes, sizes, relative positions, according to actual needs.
The invention provides an ultrasonic welding method for a thermoplastic composite material with enhanced interface inclusion, which is characterized in that carbon nano tubes, graphene or SiC particles are included in a welding interface of a fiber reinforced thermoplastic composite material, and the carbon nano tubes, the graphene or the SiC particles included in the interface are mixed in the resin matrix and fibers of the welding interface and attached to the surface of the fibers to form a barb microstructure by the fusion extrusion flow of the resin matrix at the welding interface under the transverse extrusion vibration of an ultrasonic welding head in the welding process, so that the load applied by a welding joint can be more effectively transferred from the resin to the fibers, the strength of the resin matrix at the welding interface and the anti-stripping strength between the fibers and the resin matrix are improved, and the tensile/stripping strength of the welding joint is greatly improved. Or a high-strength metal mesh nail with a larger scale is mixed in the ultrasonic welding interface of the fiber reinforced thermoplastic composite material, and the metal mesh nail is gradually nailed into fibers in the softened resin of the welding interface to form a pinning effect under the transverse extrusion vibration of the ultrasonic welding head in the welding process, so that the load of the welding joint is effectively transferred among the fibers through the high-strength metal mesh nail, and the tensile strength/peel strength of the welding joint can also be greatly improved. The problem that the tensile strength/peel strength of the thermoplastic composite material product subjected to ultrasonic welding is low at present is solved, and the technical scheme for effectively promoting ultrasonic welding to be used for connecting the carbon fiber reinforced thermoplastic plastic structure engineering field is provided.
The invention relates to an ultrasonic welding method for a thermoplastic composite material with enhanced interface inclusion, which comprises the following steps:
scheme I: carbon nanotube, graphene or SiC particle interface inclusion enhancement
S101, adding carbon nanotubes or graphene into an ethanol solution, performing ultrasonic stirring to prepare 5mL of turbid liquid, uniformly coating the prepared carbon nanotube/graphene turbid liquid on a to-be-welded area of a first fiber reinforced thermoplastic composite plate, and drying;
s102, uniformly coating the carbon nano tube or graphene suspension liquid prepared in the step S101 on a region to be welded of the first fiber reinforced thermoplastic composite material plate 5, and drying to obtain a carbon nano tube or graphene interface inclusion region 4-1;
s103, enabling the interface inclusion area 4-1 of the first fiber reinforced thermoplastic composite material plate 5 processed in the step S102 to face upwards, placing the first fiber reinforced thermoplastic composite material plate under the ultrasonic welding head 1, and fixing the first fiber reinforced thermoplastic composite material plate on an anvil 7;
if SiC particles are used, the above steps S101, S102, and S103 are replaced with:
s201, enabling a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5 to face upwards, placing the first fiber reinforced thermoplastic composite plate under an ultrasonic welding head 1, and fixing the first fiber reinforced thermoplastic composite plate on an anvil 7;
s202, uniformly laying a certain amount of SiC particles in the to-be-welded area of the first fiber reinforced thermoplastic composite plate 5 in the S101 to obtain an SiC particle interface inclusion area 4-1;
s204, overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the interface inclusion area 4-1 of the first fiber reinforced thermoplastic composite plate, and fixing the second fiber reinforced thermoplastic composite plate on an anvil 7;
s205, applying 500-1000N welding pressure 6 perpendicular to a workpiece interface and a sinusoidal displacement load 2 with the vibration amplitude of 25-100 mu m to the position right above a to-be-welded area of a second fiber reinforced thermoplastic composite plate 3 in S104 by using the ultrasonic welding head 1, wherein the welding time is 0.8-1.5S, and after welding, the ultrasonic welding head 1 maintains pressure of a welding joint and unloads the welding joint after cooling for 3-10S, so that the whole welding process is completed.
Scheme II: carbon nanotube, graphene or SiC particle resin film interface inclusion enhancement
S301, uniformly mixing carbon nano tubes, graphene or SiC particles into a molten thermoplastic resin matrix, preparing an inclusion type thermoplastic resin matrix film which is 0.2-0.35 mm thick and contains a certain mass fraction of carbon nano tubes/graphene/SiC particles in an injection molding extrusion mode, and cutting the inclusion type thermoplastic resin matrix film into sheets slightly larger than a welding area to prepare inclusion type resin sheets;
s302, enabling a to-be-welded area of the first fiber reinforced thermoplastic composite material plate 5 to face upwards, placing the first fiber reinforced thermoplastic composite material plate under the ultrasonic welding head 1, and fixing the first fiber reinforced thermoplastic composite material plate on an anvil 7;
s303, flatly placing the resin sheet with inclusions prepared in the S301 on a to-be-welded area of the first fiber reinforced thermoplastic composite material plate 5, fixing the edge of the resin sheet, and avoiding the resin sheet from deviating due to vibration in the welding process to obtain a carbon nano tube, graphene or SiC particle resin film interface inclusion area 4-2;
s304, overlapping the area to be welded of the second fiber reinforced thermoplastic composite material plate 3 on the resin film interface inclusion area 4-2 of the first fiber reinforced thermoplastic composite material plate 5, and fixing the second fiber reinforced thermoplastic composite material plate on an anvil 7;
s305, applying 500-1000N welding pressure 6 perpendicular to a workpiece interface and a sinusoidal displacement load 2 with the vibration amplitude of 25-100 mu m to the position right above a to-be-welded area of a second fiber reinforced thermoplastic composite plate 3 in S304 by using an ultrasonic welding head 1, wherein the welding time is 0.8-1.5S, and after welding, the ultrasonic welding head 1 maintains pressure of a welding joint and unloads the welding joint after cooling for 3-10S, so that the whole welding process is completed.
Scheme III: high strength metal mesh nail interface inclusion enhancement
S401, preparing a high-strength metal mesh nail: carving metal mesh holes and metal mesh nail holes on the high-strength metal plate by using a carving machine to obtain a metal mesh plate 4-4-1, installing and fixing metal nails 4-4-2 on the metal mesh plate 4-4-1 to obtain high-strength metal mesh nails 4-4 or directly printing the high-strength metal mesh nails 4-4 by using a 3D printing technology;
s402, enabling a to-be-welded area of the first fiber reinforced thermoplastic composite material plate 5 to face upwards, placing the first fiber reinforced thermoplastic composite material plate under the ultrasonic welding head 1, and fixing the first fiber reinforced thermoplastic composite material plate on an anvil 7;
s403, horizontally placing the high-strength metal mesh nail 4-4 prepared in the S1 on a region to be welded of the first fiber reinforced thermoplastic composite plate 5 to obtain a high-strength metal mesh nail interface inclusion region 4-3;
s404, overlapping the area to be welded of the second fiber reinforced thermoplastic composite material plate 3 on the high-strength metal mesh nail interface inclusion area 4-3 of the first fiber reinforced thermoplastic composite material plate, and fixing the second fiber reinforced thermoplastic composite material plate on an anvil 7;
s405, applying 500-1000N welding pressure 6 perpendicular to a workpiece interface and a sinusoidal displacement load 2 with the vibration amplitude of 25-100 mu m to the position right above the second fiber reinforced thermoplastic composite material plate 3 in the step S304 by using the ultrasonic welding head 1, wherein the welding time is 0.8-1.5S, and after welding, the ultrasonic welding head 1 maintains pressure of the welding joint and unloads the welding joint after cooling for 3-10S, so that the whole welding process is completed.
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The embodiments of the invention generally described and illustrated in the figures herein may be made in various different combinations or with other materials replaced. Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
1) Preparing a second fiber-reinforced thermoplastic composite material sheet 3 and a first fiber-reinforced thermoplastic composite material sheet 5 having a length of 101.6mm, a width of 25.4mm and a thickness of 2 mm;
2) adding carbon nano tubes or graphene into an ethanol solution, and performing ultrasonic stirring to prepare 5mL of turbid liquid with the concentration of 5 mg/mL;
3) uniformly coating the turbid liquid prepared in the step 2) on a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5, and drying at the temperature of 60 ℃ for 10 minutes to obtain a carbon nano tube or graphene interface inclusion area 4-1;
4) the carbon nano tube or graphene interface inclusion region 4-1 obtained on the treated first fiber reinforced thermoplastic composite material plate 5 is upward and placed right below the ultrasonic welding head 1, and is fixed on a welding anvil block 7;
(if SiC particles are used, steps 2), 3) and 4) are replaced by: 2) the area to be welded of the first fiber reinforced thermoplastic composite material plate 5 faces upwards, is placed under the ultrasonic welding head 1 and is fixed on an anvil 7; 3) uniformly laying 10mg of SiC particles on the region to be welded of the first fiber-reinforced thermoplastic composite plate 5 in 2) to obtain an interface inclusion region 4-1 of the SiC particles
5) Overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the carbon nanotube or graphene interface inclusion area 4-1 of the first fiber reinforced thermoplastic composite plate 5, and fixing on an anvil 7, wherein the installation condition is shown as scheme I in FIG. 1;
6) applying 750N welding pressure 6 vertical to a workpiece interface directly above the workpiece by using an ultrasonic welding head 1, applying a sine displacement load 2 with the welding frequency of 20kHz and the vibration amplitude of 65 mu m, wherein the welding time is 1.2s, and unloading the welding joint by using the ultrasonic welding head 1 after the welding is finished by keeping pressure and cooling for 7.5s by using the welding pressure 6 to finish the whole welding process;
(if SiC grains are used, the welding time in the above step 6 is set to 0.8s, the welding pressure 6 is set to 500N, the pressure-holding cooling time is set to 5s, the other parameters are not changed, and the operation steps are the same as above)
7) The single lap ultrasonic welding joint of the carbon fiber reinforced PEEK with the carbon nanotube, graphene or SiC particle interface inclusion reinforcement shown in FIG. 4 is obtained, and the cross lap ultrasonic welding joint with the interface inclusion reinforcement shown in FIG. 6 can be obtained by performing the cross lap welding in the same way.
Because the addition of SiC on the welding interface can increase the interface friction and more energy can be input into the welding interface in a shorter time, when 10mg of SiC is added on the welding interface, in order to ensure that SiC particles in an interface inclusion region are mixed into a resin matrix and fibers of the welding interface in a shorter time, a medium amplitude of 65 microns is adopted, a shorter welding time of 0.8s is adopted, and the influence of the welding time on the welding is larger, so when the shorter welding time of 0.8s is adopted, a smaller welding pressure of 500N is adopted, and a smaller pressure maintaining time of 5s is adopted, and higher-strength welding can be realized.
When the carbon nano tube/graphene with a lower concentration of 5mg/mL is added to the interface, the carbon nano tube/graphene has a lubricating effect, so that the interface friction is reduced, in order to ensure that enough energy is input into the welding interface in a short time to ensure that the carbon nano tube/graphene in an interface inclusion region is mixed into a resin matrix and fibers of the welding interface, the welding time needs to be prolonged to 1.2s while the amplitude is 65 mu m, and the welding time has a large influence on the welding, so when the welding time is 1.2s, the welding pressure is 750N at a medium level, and the pressure maintaining time is 7.5s at a medium level, the welding with higher strength can be realized.
Example 2
1) Preparing a second fiber-reinforced thermoplastic composite material sheet 3 and a first fiber-reinforced thermoplastic composite material sheet 5 having a length of 101.6mm, a width of 25.4mm and a thickness of 2 mm;
2) adding carbon nano tubes or graphene into an ethanol solution, and performing ultrasonic stirring to prepare 5mL of turbid liquid with the concentration of 5 mg/mL;
3) uniformly coating the turbid liquid prepared in the step 2) on a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5, and drying at the temperature of 60 ℃ for 10 minutes to obtain a carbon nano tube or graphene interface inclusion area 4-1;
4) the carbon nano tube or graphene interface inclusion region 4-1 obtained on the treated first fiber reinforced thermoplastic composite material plate 5 is upward and placed right below the ultrasonic welding head 1, and is fixed on a welding anvil block 7;
(if SiC particles are used, steps 2), 3) and 4) are replaced by: 2) the area to be welded of the first fiber reinforced thermoplastic composite material plate 5 faces upwards, is placed under the ultrasonic welding head 1 and is fixed on an anvil 7; 3) uniformly laying 10mg of SiC particles on the region to be welded of the first fiber-reinforced thermoplastic composite plate 5 in 2) to obtain an interface inclusion region 4-1 of the SiC particles
5) Overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the carbon nanotube or graphene interface inclusion area 4-1 of the first fiber reinforced thermoplastic composite plate 5, and fixing on an anvil 7, wherein the installation condition is shown as scheme I in FIG. 1;
6) applying 1000N welding pressure 6 vertical to a workpiece interface directly above the workpiece by using an ultrasonic welding head 1, applying a sinusoidal displacement load 2 with the welding frequency of 20kHz and the vibration amplitude of 25 mu m, wherein the welding time is 1.5s, and unloading the welding joint by using the ultrasonic welding head 1 after the welding is finished by performing pressure maintaining cooling on the welding joint by using the welding pressure 6 for 10s to finish the whole welding process;
(if SiC grains are used, the welding time in the above step 6 is set to 1.2s, the welding pressure 6 is set to 750N, the dwell cooling time is set to 7.5s, the other parameters are not changed, and the operation steps are the same as above)
7) The single lap ultrasonic welding joint of the carbon fiber reinforced PEEK with the carbon nanotube, graphene or SiC particle interface inclusion reinforcement shown in FIG. 4 is obtained, and the cross lap ultrasonic welding joint with the interface inclusion reinforcement shown in FIG. 6 can be obtained by performing the cross lap welding in the same way. Embodiment 2 compared with embodiment 1, the content of the carbon nanotube, graphene or SiC particles included in the interface is equivalent but the vibration amplitude is 25 μm, which is smaller with less energy input per unit time. In order to ensure that enough energy is input into the welding interface to mix SiC particles in an interface inclusion region into a resin matrix and fibers of the welding interface, when a small amplitude of 25 mu m is adopted, the welding time needs to be prolonged to be 1.2s, and because the welding time has a large influence on welding, when the welding time is 1.2s, a medium welding pressure of 750N is adopted, and a medium pressure holding time of 7.5s is adopted, so that high-strength welding can be realized.
In order to ensure that enough energy is input into a welding interface to mix carbon nano tubes/graphene in an interface inclusion region into a resin matrix and fibers of the welding interface, when a small amplitude of 25 micrometers is adopted, the welding time needs to be prolonged to be longer for 1.5s, and because the welding time has a large influence on welding, when the longer welding time is adopted for 1.5s, the higher welding pressure is adopted for 1000N, and the longer pressure maintaining time is adopted for 10s, so that higher-strength welding can be realized.
Example 3
1) Preparing a second fiber-reinforced thermoplastic composite material sheet 3 and a first fiber-reinforced thermoplastic composite material sheet 5 having a length of 101.6mm, a width of 25.4mm and a thickness of 2 mm;
2) adding carbon nano tubes or graphene into an ethanol solution, and performing ultrasonic stirring to prepare 5mL of turbid liquid with the concentration of 30 mg/mL;
3) uniformly coating the turbid liquid prepared in the step 2) on a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5, and drying at the temperature of 60 ℃ for 10 minutes to obtain a carbon nano tube or graphene interface inclusion area 4-1;
4) the carbon nano tube or graphene interface inclusion region 4-1 obtained on the treated first fiber reinforced thermoplastic composite material plate 5 is upward and placed right below the ultrasonic welding head 1, and is fixed on a welding anvil block 7;
(if SiC particles are used, steps 2), 3) and 4) are replaced by: 2) the area to be welded of the first fiber reinforced thermoplastic composite material plate 5 faces upwards, is placed under the ultrasonic welding head 1 and is fixed on an anvil 7; 3) uniformly laying 40mg of SiC particles in the region to be welded of the first fiber reinforced thermoplastic composite plate 5 in the step 2) to obtain a SiC particle interface inclusion region 4-1; )
5) Overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the carbon nanotube or graphene interface inclusion area 4-1 of the first fiber reinforced thermoplastic composite plate 5, and fixing on an anvil 7, wherein the installation condition is shown as scheme I in FIG. 1;
6) applying 1000N welding pressure 6 vertical to a workpiece interface directly above the workpiece by using an ultrasonic welding head 1, applying a sine displacement load 2 with the welding frequency of 20kHz and the vibration amplitude of 65 mu m, wherein the welding time is 1.5s, and unloading the welding joint by using the ultrasonic welding head 1 after the welding is finished by performing pressure maintaining cooling on the welding joint by using the welding pressure 6 for 10s to finish the whole welding process;
(if SiC grains are used, the welding time in the above step 6 is set to 1.2s, the welding pressure 6 is set to 750N, the dwell cooling time is set to 7.5s, the other parameters are not changed, and the operation steps are the same as above)
7) The single lap ultrasonic welding joint of the carbon fiber reinforced PEEK with the carbon nanotube, graphene or SiC particle interface inclusion reinforcement shown in FIG. 4 is obtained, and the cross lap ultrasonic welding joint with the interface inclusion reinforcement shown in FIG. 6 can be obtained by performing the cross lap welding in the same way.
In comparison with embodiment 1, since the interface inclusion region is added with more 40mg of SiC particles, more welding energy is required to ensure that the SiC particles in the interface inclusion region are mixed into the resin matrix and the fibers of the welding interface, when the same medium vibration amplitude of 65 μm is used, the welding time needs to be prolonged to be 1.2s, and when the welding time is greatly influenced, when the welding time is 1.2s, the welding pressure is 750N at a medium level, and the dwell time is 7.5s, the welding with higher strength can be realized.
Compared with embodiment 1, the carbon nanotubes/graphene with a higher concentration of 30mg/mL is added in the interface inclusion region, so that more welding energy is needed to ensure that the carbon nanotubes/graphene in the interface inclusion region are mixed in the resin matrix and the fibers of the welding interface, when the same medium vibration amplitude of 65 μm is adopted, the welding time needs to be prolonged to be longer for 1.5s, and because the welding time has a larger influence on the welding, when the longer welding time is adopted for 1.5s, the higher welding pressure of 1000N is adopted, and the longer pressure maintaining time is 10s, so that the higher-strength welding can be realized.
Example 4
1) Uniformly mixing carbon nanotubes or graphene or SiC particles into a molten PEEK resin matrix, preparing a carbon nanotube/graphene inclusion type PEEK resin matrix film with the thickness of 0.2mm and the mass fraction of 1% or an inclusion type PEEK resin matrix film of SiC particles with the mass fraction of 5% in an injection molding extrusion mode, and cutting the carbon nanotube/graphene inclusion type PEEK resin matrix film into resin sheets with the side length of 30 mm;
2) preparing a second fiber-reinforced thermoplastic composite material sheet 3 and a first fiber-reinforced thermoplastic composite material sheet 5 having a length of 101.6mm, a width of 25.4mm and a thickness of 2 mm;
3) the first fiber reinforced thermoplastic composite material plate 5 is placed under an ultrasonic welding head with the area to be welded upward and fixed on an anvil 7;
4) flatly placing the sheet prepared in the step 1) on a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5 to obtain a carbon nano tube, graphene interface or SiC particle resin film interface inclusion area 4-2, and fixing the edge of the carbon nano tube, graphene interface or SiC particle resin film interface inclusion area to avoid resin sheet deviation caused by vibration in the welding process;
5) overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the inclusion area 4-2 of the carbon nanotube, graphene interface or SiC particle resin film interface of the first fiber reinforced thermoplastic composite plate 5, and fixing on an anvil block 7, wherein the installation condition is shown as scheme II in FIG. 1;
6) applying 750N welding pressure 6 vertical to a workpiece interface directly above the workpiece by using an ultrasonic welding head 1, applying a sinusoidal displacement load 2 with the welding frequency of 20kHz and the vibration amplitude of 100 mu m, wherein the welding time is 1.2s, and unloading the welding joint by using the ultrasonic welding head 1 after the welding is finished by performing pressure maintaining cooling on the welding joint by using the welding pressure 6 for 5s to finish the whole welding process;
7) the single lap ultrasonic welding joint of the carbon fiber reinforced PEEK with the carbon nanotube, graphene or SiC particle interface inclusion reinforcement shown in FIG. 4 is obtained, and the cross lap ultrasonic welding joint with the interface inclusion reinforcement shown in FIG. 6 can be obtained by performing the cross lap welding in the same way.
When a resin sheet is added to a welding interface, the resin film of the interface needs to be melted, extruded and flowed to be fused with the welding interface into a whole during welding, so that more energy needs to be input into the welding interface, the carbon nano tube/graphene in an inner interface inclusion region is mixed into a resin matrix and fibers of the welding interface in order to ensure that enough energy is input into the welding interface in a short time, the higher amplitude of the input more energy per unit time is 100 micrometers, and the energy needed for the resin sheet with the thickness of 0.2mm is less, so that the moderate welding time is 1.2s, and the welding influence on the welding is large because the welding time is moderate, so when the moderate welding time is 1.2s, the moderate welding pressure is 750N, and the moderate pressure maintaining time is 7.5s, and the high-strength welding can be realized.
Example 5
1) Uniformly mixing carbon nanotubes or graphene or SiC particles into a molten PEEK resin matrix, preparing a carbon nanotube/graphene inclusion type PEEK resin matrix film with the thickness of 0.35mm and the mass fraction of 1% or an inclusion type PEEK resin matrix film of SiC particles with the mass fraction of 5% in an injection molding extrusion mode, and cutting the carbon nanotube/graphene inclusion type PEEK resin matrix film into resin sheets with the side length of 30 mm;
2) preparing a second fiber-reinforced thermoplastic composite material sheet 3 and a first fiber-reinforced thermoplastic composite material sheet 5 having a length of 101.6mm, a width of 25.4mm and a thickness of 2 mm;
3) the first fiber reinforced thermoplastic composite material plate 5 is placed under an ultrasonic welding head with the area to be welded upward and fixed on an anvil 7;
4) flatly placing the sheet prepared in the step 1) on a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5 to obtain a carbon nano tube, graphene interface or SiC particle resin film interface inclusion area 4-2, and fixing the edge of the carbon nano tube, graphene interface or SiC particle resin film interface inclusion area to avoid resin sheet deviation caused by vibration in the welding process;
5) overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the inclusion area 4-2 of the carbon nanotube, graphene interface or SiC particle resin film interface of the first fiber reinforced thermoplastic composite plate 5, and fixing on an anvil block 7, wherein the installation condition is shown as scheme II in FIG. 1;
6) applying 1000N welding pressure 6 vertical to a workpiece interface directly above the workpiece by using an ultrasonic welding head 1, applying a sinusoidal displacement load 2 with the welding frequency of 20kHz and the vibration amplitude of 100 mu m, wherein the welding time is 1.5s, and unloading the welding joint by using the ultrasonic welding head 1 after the welding is finished by performing pressure maintaining cooling on the welding joint by using the welding pressure 6 for 10s to finish the whole welding process;
7) the single lap ultrasonic welding joint of the carbon fiber reinforced PEEK with the carbon nanotube, graphene or SiC particle interface inclusion reinforcement shown in FIG. 4 is obtained, and the cross lap ultrasonic welding joint with the interface inclusion reinforcement shown in FIG. 6 can be obtained by performing the cross lap welding in the same way.
When the thickness of the adopted resin sheet is 0.35mm, more energy needs to be input into the welding interface than when the resin sheet with the thickness of 0.2mm is adopted in the embodiment 4, so that enough energy is input into the welding interface in a shorter time, carbon nano tubes/graphene in an interface inclusion region are mixed into a resin matrix and fibers of the welding interface, a higher amplitude 100um which can input more energy per unit time is adopted, a longer welding time is 1.5s, the influence of the welding time on welding is larger, a higher welding pressure is 1000N when the longer welding time is 1.5s, and a longer pressure holding time is 10s, so that higher-strength welding can be realized.
Example 6
1) Preparing a second fiber-reinforced thermoplastic composite material sheet 3 and a first fiber-reinforced thermoplastic composite material sheet 5 having a length of 101.6mm, a width of 25.4mm and a thickness of 2 mm;
2) preparing a high-strength metal mesh nail: carving metal mesh holes and metal mesh nail holes on the high-strength metal plate by using a carving machine to obtain a metal mesh plate 4-4-1, installing and fixing metal nails 4-4-2 on the metal mesh plate 4-4-1 to obtain high-strength metal mesh nails 4-4 or directly printing the high-strength metal mesh nails 4-4 by using a 3D printing technology;
3) the second fiber reinforced thermoplastic composite material plate 3 is placed with the area to be welded upward and right below the ultrasonic welding head 1, and is fixed on an anvil 7;
4) flatly placing the high-strength metal mesh nail 4-4 prepared in the step 1) on a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5 to obtain a high-strength metal mesh nail interface inclusion area 4-3;
5) overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the high-strength metal mesh nail interface inclusion area 4-3 of the first fiber reinforced thermoplastic composite plate 5, and fixing the second fiber reinforced thermoplastic composite plate on an anvil 7, wherein the installation condition is shown as a scheme III in the figure 1;
6) applying 750N welding pressure 6 vertical to a workpiece interface directly above the workpiece by using an ultrasonic welding head 1, applying a sinusoidal displacement load 2 with the welding frequency of 20kHz and the vibration amplitude of 100 mu m, and performing pressure maintaining and cooling on the welding joint by using the ultrasonic welding head 1 for 7.5s after welding is finished, and then unloading to finish the whole welding process;
7) the single-lap ultrasonic welded joint obtained by enhancing the inclusions at the interface of the high-strength metal mesh nail in the figure 5 is obtained, and the cross-lap welded joint shown in the figure 6 can be obtained by performing the cross-lap welding in the same way.
When the interface inclusion reinforcement of the high-strength metal mesh nail is adopted, in order to ensure that the metal mesh nail can be sufficiently nailed into fibers in the softening resin of the welding interface to form a pinning effect in a short time, the high amplitude 100 mu m and the medium welding time 1.2s which can input more energy in unit time are adopted, and the welding time has large influence on welding, so when the medium welding time is 1.2s, the medium welding pressure 750N and the medium pressure maintaining time 7.5s are adopted, and the high-strength welding can be realized.
Example 7
1) Preparing a second fiber-reinforced thermoplastic composite material sheet 3 and a first fiber-reinforced thermoplastic composite material sheet 5 having a length of 101.6mm, a width of 25.4mm and a thickness of 2 mm;
2) preparing a high-strength metal mesh nail: carving metal mesh holes and metal mesh nail holes on the high-strength metal plate by using a carving machine to obtain a metal mesh plate 4-4-1, installing and fixing metal nails 4-4-2 on the metal mesh plate 4-4-1 to obtain high-strength metal mesh nails 4-4 or directly printing the high-strength metal mesh nails 4-4 by using a 3D printing technology;
3) the second fiber reinforced thermoplastic composite material plate 3 is placed with the area to be welded upward and right below the ultrasonic welding head 1, and is fixed on an anvil 7;
4) flatly placing the high-strength metal mesh nail 4-4 prepared in the step 1) on a to-be-welded area of a first fiber reinforced thermoplastic composite plate 5 to obtain a high-strength metal mesh nail interface inclusion area 4-3;
5) overlapping the area to be welded of the second fiber reinforced thermoplastic composite plate 3 on the high-strength metal mesh nail interface inclusion area 4-3 of the first fiber reinforced thermoplastic composite plate 5, and fixing the second fiber reinforced thermoplastic composite plate on an anvil 7, wherein the installation condition is shown as a scheme III in the figure 1;
6) applying 1000N welding pressure 6 vertical to a workpiece interface directly above the workpiece by using an ultrasonic welding head 1, applying a sine displacement load 2 with the welding frequency of 20kHz and the vibration amplitude of 65 mu m, and performing pressure maintaining and cooling on the welding joint by using the ultrasonic welding head 1 for 10s after welding is finished, and then unloading to finish the whole welding process;
7) the single-lap ultrasonic welded joint obtained by enhancing the inclusions at the interface of the high-strength metal mesh nail in the figure 5 is obtained, and the cross-lap welded joint shown in the figure 6 can be obtained by performing the cross-lap welding in the same way.
In comparison with example 6, when the medium amplitude of 65 μm is used, in order to ensure that sufficient energy is input to the welding interface to sufficiently pin the metal mesh nail into the fiber in the softened resin of the welding interface to form the pinning effect, it is necessary to use a longer welding time of 1.5s than the condition of the high amplitude of 100 μm used in example 6, and since the welding time has a large influence on the welding, when the long welding time of 1.5s is used, the welding pressure is used at a high value of 1000N, and the dwell time is 10s, the high strength welding can be realized.
In summary, according to the ultrasonic welding method for the thermoplastic composite material with the reinforced interface mixed, the carbon nano tube, the graphene or the SiC particle is mixed at the welding interface of the fiber reinforced thermoplastic composite material, so that the strength of the resin matrix at the welding interface and the peeling resistance between the fiber and the resin matrix are improved, or the high-strength metal mesh nail is mixed at the welding interface of the fiber reinforced thermoplastic composite material, so that the load of the welding joint is effectively transmitted among the fibers through the high-strength metal mesh nail, the tensile strength/peeling strength of the welding joint is greatly improved, and a technical scheme for effectively promoting ultrasonic welding to be used for connecting the carbon fiber reinforced thermoplastic plastic structural engineering field is provided.
The above-mentioned contents are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical idea of the present invention falls within the protection scope of the claims of the present invention.
Claims (9)
1. An ultrasonic welding method for a thermoplastic composite material reinforced by interface inclusions is characterized by comprising the following steps:
s1, preparing an interface inclusion area on a to-be-welded area of the first fiber reinforced thermoplastic composite plate by adopting carbon nano tubes, graphene, SiC particles or high-strength metal mesh nails;
s2, overlapping the region to be welded of the second fiber-reinforced thermoplastic composite sheet on the interfacial inclusion region of the first fiber-reinforced thermoplastic composite sheet prepared in step S1, and fixing on an anvil;
and S3, applying welding pressure and sinusoidal displacement load perpendicular to the interface of the workpiece above the to-be-welded area of the second fiber reinforced thermoplastic composite plate prepared in the step S2 by using an ultrasonic welding head, maintaining pressure of the welding head by using the ultrasonic welding head after welding, cooling and unloading, and finishing welding.
2. The method according to claim 1, wherein step S1 is specifically:
s101, adding carbon nanotubes or graphene into an ethanol solution, performing ultrasonic stirring to prepare a carbon nanotube/graphene suspension, uniformly coating the carbon nanotube/graphene suspension on a region to be welded of a first fiber reinforced thermoplastic composite plate, and drying;
s102, uniformly coating the carbon nano tube or graphene suspension liquid prepared in the step S101 on a region to be welded of the first fiber reinforced thermoplastic composite plate, and drying to obtain a carbon nano tube or graphene interface inclusion region.
3. The method of claim 2, wherein in step S101, the concentration of the carbon nanotube/graphene suspension is 5-30 mg/mL.
4. The method according to claim 1, wherein step S1 is specifically:
s201, enabling a to-be-welded area of a first fiber reinforced thermoplastic composite plate to face upwards and be placed under an ultrasonic welding head, and then fixing the first fiber reinforced thermoplastic composite plate on an anvil block;
s202, uniformly laying 10-40 mg of SiC particles in the region to be welded of the first fiber reinforced thermoplastic composite plate in the S101 to obtain an interface inclusion region of the SiC particles.
5. The method according to claim 1, wherein step S1 is specifically:
s301, uniformly mixing carbon nano tubes, graphene or SiC particles into a molten thermoplastic resin matrix, preparing a carbon nano tube/graphene/SiC particle inclusion type thermoplastic resin matrix film with the thickness of 0.2-0.35 mm by an injection molding extrusion mode, and cutting the carbon nano tube/graphene/SiC particle inclusion type thermoplastic resin matrix film into a sheet slightly larger than a welding area to prepare an inclusion type resin sheet;
s302, enabling a to-be-welded area of the first fiber reinforced thermoplastic composite plate to face upwards, placing the first fiber reinforced thermoplastic composite plate under an ultrasonic welding head, and fixing the first fiber reinforced thermoplastic composite plate on an anvil block;
s303, horizontally placing the resin inclusion sheet prepared in the step S301 on a region to be welded of the first fiber reinforced thermoplastic composite plate, and fixing the edge of the resin inclusion sheet to obtain an interface inclusion region of the carbon nano tube, the graphene or the SiC particle resin film.
6. The method as claimed in claim 5, wherein in step S301, the mass fraction of the carbon nanotube/graphene inclusion type thermoplastic resin matrix film having a thickness of 0.2 to 0.35m is 1 to 5%, the mass fraction of the inclusion type thermoplastic resin matrix film of SiC particles having a thickness of 0.2 to 0.35mm is 5 to 10%, and the side length of the inclusion type thermoplastic resin matrix film is 30 mm.
7. The method according to claim 1, wherein step S1 is specifically:
s401, carving metal mesh holes and metal mesh nail holes on a high-strength metal plate by using a carving machine to obtain a metal mesh plate, and installing and fixing metal nails on the metal mesh plate to obtain high-strength metal mesh nails or directly printing the high-strength metal mesh nails by using a 3D printing technology;
s402, enabling a to-be-welded area of the first fiber reinforced thermoplastic composite plate to face upwards, placing the first fiber reinforced thermoplastic composite plate under an ultrasonic welding head, and fixing the first fiber reinforced thermoplastic composite plate on an anvil block;
and S403, flatly placing the high-strength metal mesh nail manufactured in the step S401 on a region to be welded of the first fiber reinforced thermoplastic composite plate to obtain an interface inclusion region of the high-strength metal mesh nail.
8. The method according to claim 1, wherein in step S3, the welding pressure is 500-1000N; the vibration amplitude of the sinusoidal displacement load is 25-100 mu m.
9. The method according to claim 1, wherein in step S3, the welding time is 0.8-1.5S, and the welded joint is unloaded after being pressure-maintained and cooled for 5-10S.
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| CN113997574A (en) * | 2021-11-01 | 2022-02-01 | 南京工程学院 | Ultrasonic welding method for fiber-reinforced thermoplastic resin composite sheet |
| CN114346616A (en) * | 2022-01-17 | 2022-04-15 | 哈焊国创(青岛)焊接工程创新中心有限公司 | Light alloy and fiber reinforced composite material heterojunction and preparation method thereof |
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| US20170355150A1 (en) * | 2016-06-14 | 2017-12-14 | GM Global Technology Operations LLC | Ultrasonic weld-bonding of thermoplastic composites |
| CN109910318A (en) * | 2019-03-20 | 2019-06-21 | 上海交通大学 | A method of using interface In-situ reaction phase strengthened metal/macromolecule bonding strength |
| CN110653479A (en) * | 2019-09-26 | 2020-01-07 | 沈阳航空航天大学 | Friction stir and ultrasonic composite welding method for light alloy and resin-based composite material |
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| CN113681906A (en) * | 2021-07-19 | 2021-11-23 | 天津工业大学 | Ultrasonic welding lap joint of thermoplastic fiber reinforced composite material and design method thereof |
| CN113997574A (en) * | 2021-11-01 | 2022-02-01 | 南京工程学院 | Ultrasonic welding method for fiber-reinforced thermoplastic resin composite sheet |
| CN114346616A (en) * | 2022-01-17 | 2022-04-15 | 哈焊国创(青岛)焊接工程创新中心有限公司 | Light alloy and fiber reinforced composite material heterojunction and preparation method thereof |
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