Thermoplastic Composite Blind Welding With Segmented Susceptor Heating
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Solution Overview
Problem
Current techniques for welding thermoplastic composite components face challenges in creating blind welds, where applying opposing forces is not possible, leading to increased component collapse and deformation.
Innovation Solution
A method involving an interface layer between thermoplastic composite components, using an external susceptor and electromagnetic field to heat the components differently, allowing for blind welding by applying force and electromagnetic field from one side, with controlled thermal energy to create a weld pool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If opposing force is applied to both sides of components to create a weld path, then welding control is improved, but the method cannot be used in blind weld scenarios where opposing force cannot be applied
Solution Approach 1:
A force application interface is introduced as an intermediary between the force application device and the first thermoplastic composite component. This interface transmits the applied force through the component to create the weld pool at the bonding surface, enabling blind welds by eliminating the need for direct opposing force on the second component.
Solution Approach 2:
The mechanical system is replaced by using electromagnetic induction heating to melt the thermoplastic material. An external susceptor with central and lateral segments responds differently to the electromagnetic field, heating the central segment to melt the material at the bonding surface while the lateral segments remain below melting temperature to prevent deformation.
2Productivity
If electromagnetic field heats the entire susceptor uniformly, then heating efficiency is improved, but component deformation and collapse increase
Solution Approach 1:
The external susceptor is designed with different segments (central and lateral) that have different electromagnetic response characteristics. The central segment is configured to heat to melting temperature for weld pool creation, while the lateral segments are configured to heat below melting temperature to provide structural support and prevent deformation.
Solution Approach 2:
The external susceptor is divided into functionally distinct segments: a central segment that responds strongly to the electromagnetic field to create the weld pool, and lateral segments that respond less strongly to maintain structural integrity. This segmentation allows different parts of the same component to serve different functions during the welding process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates blind welds by reducing component deformation and ensuring consistent bonding despite tolerances and surface irregularities, enhancing the welding process efficiency.
Implementation Method 1
applying an electromagnetic field to the central segment and the plurality of lateral segments using an inductor, wherein the central segment and the plurality of lateral segments are configured such that the electromagnetic field heats the central segment to the first melting temperature or above, and heats the lateral segments to a temperature below first melting temperature
Implementation Method 2
the electromagnetic filed is applied until a region of the first thermoplastic composite component aligned with the central segment is at or above the first melting temperature, the interface layer is at or above the third melting temperature
Implementation Method 3
applying a normal force to the outer surface of the first thermoplastic composite component without an application of an opposing second normal force to the second thermoplastic component
Data Source
Figure 1
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AI summary
A method of welding thermoplastic composite components comprising providing first and second thermoplastic composites components (20, 24) and an interface layer (26) comprising thermoplastic between the two, disposing an external susceptor (54) adjacent to the outer surface (20B) of the first component (20), applying a normal force (F) to the outer surface (20B) of the first component (20) without an application of an opposing normal force to the second component (24), and applying an electromagnetic field (42) to the external susceptor (54) so that the induction heating melts the first and second thermoplastic composite components (20, 24) and the interface layer (26). The external susceptor (54) includes a central segment (54A) and lateral segments (54B) configured to respond differently to the induction heating. A further method involves determining a first, second and third inflection point of the applied normal force during welding and then stopping the induction heating.