Advancing the manufacturing and repair of aerospace structures through continuous, energy-efficient ultrasonic welding of continuous composite tapes (CFRTP).
The aerospace industry is rapidly shifting towards thermoplastic composites due to their recyclability, high toughness, and potential for rapid processing out-of-autoclave.
The C-USW Project focuses on developing a robust, continuous ultrasonic welding process specifically tailored for Carbon Fiber Reinforced Thermoplastics (CFRTP). By localized frictional heating, our process fuses composite tapes dynamically, eliminating the need for heavy rivets or cure-time-heavy adhesives.
Traditional joining methods limit the potential of CFRTPs. Ultrasonic welding unlocks new levels of efficiency and structural integrity.
Energy is applied locally and instantaneously at the interface, requiring fractions of the power compared to resistance or induction welding.
Continuous feed rates can reach up to meters-per-minute. Rapid heating and cooling cycles happen within milliseconds under pressure.
Creates a pure autogenous joint. No rivets, no bolts, and no chemical adhesives that add weight or complicate the recycling process.
Based in our previous results, we will optimize the welding parameters in a spot-welding process. We will use our in-house made ultrasonic welding equipment and we will work with commercially available CFRTP tape.
We will weld two slit tapes together by using our in house-made USW equipment.
We will produce small thin laminates made by welding strips of CFRTP tapes, and we will compare this procedure to a standard composite process (hot-press).
Finally, we will produce complex samples by welding on top of already made laminates, in a process like overmoulding/overprinting.