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www.elsevier.com/locate/compositesa
a,b,*
a
Netherlands Institute for Metals Research, Mekelweg 2, 2628CD Delft, The Netherlands
Design and Production of Composite Structures, Faculty of Aerospace Engineering, Delft University of Technology, Kluyverweg 3,
2629HS Delft, The Netherlands
Received 6 July 2005; received in revised form 20 October 2005; accepted 20 October 2005
Abstract
This paper presents a comprehensive overview of the process of induction welding of thermoplastic composites. The main objective is
to provide a deeper insight into the nature of the induction welding process and to summarise the investigative eort that was put into it
by a large group of researchers. The main focus is put on the types of heat generation mechanisms during the induction heating process
and the parameters that govern the welding process (frequency, power, pressure, residence time), as well as on the secondary phenomena
that can inuence the quality of the weld. An overview of the experimental procedure is also presented, with an emphasis on the experimental set-up. Finally, a brief overview of the modelling of the heat generation mechanisms and the induction welding process is
presented.
2005 Elsevier Ltd. All rights reserved.
Keywords: A. Thermoplastic resin; B. Mechanical properties; E. Joining
1. Introduction
As a result of their growing potential for high performance applications, continuous bre-reinforced thermoplastic composites (CFRTPCs) are becoming of greater
interest for the industry. Recently developed matrix materials used for manufacturing thermoplastic composites
(TPCs) yield materials with basic mechanical properties
(strength, stiness) much the same, if not better than the
thermosets (TS) [1]. Additionally, TPCs also show a number of advantages when compared to the TS, among which
improved toughness, better environmental resistance (high
temperature, moisture, aggressive uids), shorter processing times, non-ammability and innite shelf life [2,3].
One of their most important advantage lies in the possibility for a low-cost, rapid production [4]. However, due to
the limited deformation allowed for the reinforcing bres,
currently produced thermoplastic components have rather
*
their glass transition temperature Tg (for amorphous polymers) or the crystalline melting point Tm (for semi-crystalline polymers) and regain their mechanical properties after
cooling down. Known also as welding, it can be generally
described as joining of two parts by fusing their contact
interfaces, followed by cooling (consolidating) under pressure that enables the bond to be made. It overcomes all
problems connected to the traditional techniques mentioned above. Fusion bonding is widely considered to be
the ideal bonding technique for TPCs.
The heat needed for melting the joint interface can be
applied by various means, e.g. hot plates, hot gas, friction,
ultrasonic and radio signal, microwaves, Joule eect in a
resistor, laser and induction, to mention some of them.
From this variety of means, three are considered to have
greatest potential for future development: ultrasonic, resistance and induction welding. A large number of research
studies were performed on these three techniques. That
resulted in the publication of several mainly collective overviews of the three welding techniques [510] that oered
full descriptions of the processes and their advantages.
This paper presents a comprehensive overview of the
process of induction welding of TPCs. The main objective
is to provide a deeper insight into the nature of the induction welding process and the investigative eort that was
put into it by a large group of researchers. After a general
description of the induction welding process, an overview
of the experimental procedure is presented, with an emphasis on the experimental set-up. The main focus is set on
types of heating that occur during the induction heating
process and the parameters that govern the welding process
(frequency, power, pressure, residence time), as well as on
the secondary phenomena that can inuence the quality
of the weld. Finally, the modelling of the heat generation
mechanisms and the induction welding process is briey
discussed.
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2. Induction welding
Induction welding is a unique process in that it requires
no contact between the induction coil or the heat susceptor and can be designed such that no heat is produced
outside of the desired weld area. The process of heating
by induction is not a new technology and since 1916
has most frequently been used for heating metals [11].
Only within the last two decades has this type of heating
come into the scope for heating composites and is proving
itself to be a very eective method for the high-speed processing of welding bre-reinforced thermoplastic composites [12]. In addition, the process is extremely versatile
with similar and dissimilar thermoplastics that can be
welded, as well as thermoplastic to non-thermoplastic
materials [13,14].
The principle behind the process itself is simple. When
an alternating voltage is placed across a conductive coil,
an alternating current is produced. Subsequently this alternating current induces a time variable magnetic eld which
has the same frequency as the alternating current causing
it. When a magnetically susceptible and electrically conductive material is placed in the vicinity of the coil and its alternating magnetic eld, eddy currents are induced, with a
frequency matched to that of the magnetic eld. A condition imposed on the material is that closed-loop circuits
must be present for eddy currents to be induced. In the case
of bre-reinforced thermoplastics, closed-loop circuits in
the form of a conductive network is produced through
weaves or cross plies, for example. The eddy currents are
met with the resistance of the material and energy is lost
in the form of heat. There are four mechanisms that result
in heat production and will be further discussed in Section
3. Pressure can then be applied during or after heating to
complete the welding process. A schematic diagram is
shown in Fig. 1.
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V
V
Z Rp Rs jX Ip X Is X Ig
The formula shows that the output current, and consequently power, depends on several factors, such as coil
workpiece geometry, material properties and frequency.
To be more specic, the region of optimal eciency is
not only dened by the power source, but also by the workpiece. Therefore for each dierent application dierent
machine settings are used. Each of these parameters is a
non-linear function and in turn depend on other factors.
2.1.4. Welding xture
The nal part of the induction welding apparatus is the
test environment itself and more specically, the apparatus
where the workpiece is held. To avoid heating of the test
equipment, it is important to avoid the use of magnetically
susceptible materials within the vicinity of the magnetic
eld [15]. In cases where this is not possible, sucient cooling is necessary. It is also possible to create distance
between the xtures and the coil such that the magnetic
eld has little to no inuence. For example, a concrete slab
has been used to provide this distance between the surface
on which the workpiece is placed and the coil [26]. In these
cases where the use of metal xtures are unavoidable, the
concrete is also a sucient an insulator that acts to insulate
between the workpiece and metallic xtures underneath to
avoid the metal heating up the workpiece. In this way,
uneven heating through the thickness is avoided. However,
the surrounding area inuenced by the magnetic coil is relatively small and can be localised as will be described in
Section 3.
In order to aid in the consolidation process, pressure
needs to be applied. A number of methods have been
established to provide continuous and discontinuous pressure and two examples are shown in Fig. 4. In order for
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Fig. 5. Induction heating mechanisms [45]. (a) Fibre heating, (b) dielectric hysteresis and (c) contact resistance.
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where contact resistance is higher. Weaves and knitted fabric will show bre heating dominance due to a larger area
of contact between the bres and thus a lower contact resistance. Moreover, the processing parameters can shift the
heating mechanism from junction heating to joule loss
[40]. As the workpiece heats, the viscosity of the matrix
lowers and, upon the application of sucient pressure,
squeeze-out of the matrix occurs. This results in higher
bre contact and bre-dominated heating results [40].
3.1.5. Hysteresis loss
The nal heating process that can occur is due to hysteresis losses within magnetic materials [11,12]. When a magnetic material is exposed to the alternating magnetic eld,
the magnetic dipoles of the material change to realign with
the eld. Hysteresis indicates that energy is needed to turn
around the small internal magnets of the material to align
with the alternating magnetic eld, as shown in Fig. 6. As
the magnetic dipoles rotate, they vibrate and energy is lost
in the form of heat due to friction. Of the composite bres
that are currently used, none are magnetic and therefore
hysteresis loss is not applicable. However, if a metallic susceptor is introduced into the workpiece, hysteresis loss
becomes a source of heating.
This heating process only occurs up to the point of the
Curie temperature of the magnetic material; the point at
which the material becomes non-ferromagnetic. At this
point, the material can no longer generate heat and sustains
its Curie temperature even when a higher magnetic eld
strength is applied [46]. In this way, good temperature
control of the weld can be maintained [46].
3.2. Heating elements
In cases where the adherends are not magnetically susceptible, or controlled and localised heating is necessary,
heating elements are used as inserts in the weld. Two main
types of heating elements are available for the process of
induction welding which are common to all types of electromagnetic welding, and come in the form of a powder or
mesh. Similarly with the bre case, the prerequisites are that
they are susceptible to the eects of an electromagnetic eld,
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Table 1
Comparison of lap shear strength values
Reference
LSS (MPa)
Laminate type
Weld conguration
27
31
3848
30
25
36
44
33
46
1722
4148
27
18
20
10
Carbon/PEEK
Carbon/PEEK
Carbon/PEEK
Carbon/PPS
Carbon/PPS
Carbon/PEEK
Carbon/PEEK
Carbon/PEEK
Carbon/PEEK
Carbon/PEEK
Carbon/PEEK
Carbon/PEKK
Carbon/PPS
Glass/PPS
Glass/PPS
No insert
No insert
No insert
No insert
No insert
PEEK lm insert
PEEK lm insert
PEI/PEEK lm
Woven carbon bre insert
Metal mesh
Metal mesh and PEEK insert
PEKK lm insert
Expanded metal foil
Nickel/PSU lm insert
Expanded metal foil
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The power input is one of the most important parameters of the process because the amount of heat generated
in a specic region of the material is proportional to the
power generated in that same region. The source and the
2pf lr H IA
5
R
where H(I) is the magnetic eld intensity, which is dependent on the current of the equipment, and A the cross-sectional area of the conductive loop in the workpiece. The
amount of heat generated in the workpiece is also proportional to the frequency squared. This means that when the
magnetic eld intensity drops in distance from the coil to
the workpiece, the drop in generated power can be compensated by a rise in frequency. Fig. 11 displays the dependence of heating time with input power and coil/workpiece
separation.
From a processing point of view, the starting point of
the energy needed to heat an ideally insulated conductive
workpiece of mass mw, can be the required temperature
rise, DT:
E P w t mw cDT
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4.3. Pressure
Appropriate pressure application is important for high
quality consolidation because it allows for good intimate
contact. However, Rudolf et al. [26] found that there is a
practical limit to the pressure that can be applied. The continuous welding of carbon bre-reinforced thermoplastics
was investigated and found that a higher pressure resulted
in a lower quality of weld. This was attributed to increased
squeeze-out of matrix at the weld and a compromise must
be met between adequate intimate contact and polymer
squeeze-out. Poor pressure application can result in the
following faults.
4.3.1. Voids
The appearance of voids have a close relationship with
the deconsolidation of the matrix material and there are
a number of reasons that are the cause. The release of elastic energy as bre bundles deform under pressure and heat,
expansion of entrapped gas bubbles, collapsing of air pockets, inserts and thermal stresses due to the removal of pressure before cooling to below the required temperature, all
contribute to the production of voids [57]. For the entrapment of air bubbles, the surface roughness is an important
parameter. To prevent voids it is important to strive for a
high surface smoothness and apply a high weld pressure to
suppress the occurrence of voids [27]. The high pressure
constraint can cause a contradiction with the low pressure
to avoid folds and ashes, described later. A further consequence of the creation of voids is delamination. Most of the
time delamination is a result of extreme deconsolidation. In
this case relatively large air pockets appear in the matrix
material that will separate one layer from the other in the
laminate and thus destroy the interaction between the
layers.
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4.3.2. Cracks
Rudolf et al. [26] reported cracks due to the high degree
of crystallization of the semi-nished product, which
resulted in strong shrinkage of the matrix material. These
cracks occurred due to thermal stresses due to the thermal
expansion mismatch between the matrix and bres. Crack
prevention is possible through the control of pressure
through the cooling phase. The matrix is thus prevented
from expanding and shrinking. The pressure can then be
removed when a uniform temperature prole is reached
and the temperature is well below the melt or glass transition temperature.
4.3.3. Folds and ashes
These faults are due to misalignment and poor application of pressure. When the pressure is unequally divided
over the weld zone it can force matrix material out the weld
at the sides, causing ashes, or it can result in the folding of
the laminate at the edge of the pressure device. The folding
can cause bres to buckle. To prevent these ashes it is
important not to apply a very high welding pressure. Very
high pressure forces the matrix out of the welding zone [26].
To prevent the folds it is important to have a very smooth
under surface, because when applying pressure an unequal
plate can force a fold into the laminate.
4.4. Residence time
The residence time is the time of exposure of the workpiece to the induction eld and has an inuence on the
movement of polymer molecules across the weld interface.
In general, allowing for a longer residence time results in a
higher quality of weld because more polymer chains are
given time to move across the weld interface [29,46]. If
welding parameters frequency, power and pressure are considered to be constant, three welding regimes can be established relating to the residence time and resulting
temperature; non-wetting, uniform fusion and degradation
and are shown in Fig. 12. Insucient weld times, and therefore low temperatures, result in insucient wetting and
weld strength is low. A period of uniform fusion follows,
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Fig. 14. Schematic of the bre heating and junction heating at each conductive loop of the cross-plied laminate [60].
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6. Conclusion
Induction heating has already proven to be a worthwhile
technology for metals. The past two decades have seen the
emergence of induction heating as a suitable and eective
technology for heating of thermoplastic composites. The
simplicity of the physical process and the extensive research
into numerical modelling of the heating process has
allowed for the development of the induction welding process. A number of studies that have been performed clearly
showed the potential of induction welding for application
in thermoplastic composite structures. Produced lap shear
strengths were comparable, if not better, than oven-cured,
bolted or resistance welded joints.
In spite the considerable research eort, the induction
process has not seen signicant shift in application in
industry from current bonding and welding methods.
Apart from the inherent inertness of the industry when
introducing new technologies is concerned, there are several issues, most notably the edge eect and the local heating eect, that prevent embracing induction welding on a
large scale. Addressing these and other important issues
remains as an incentive for further development of the
induction welding method.
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