Documente Academic
Documente Profesional
Documente Cultură
04033912
1
Universidade Estadual Paulista Júlio de Mesquita Filho– Guaratinguetá/SP – Brazil
2
Instituto de Aeronáutica e Espaço – São José dos Campos/SP, Brazil
3
EMBRAER– São José dos Campos/SP, Brazil
4
Universidade de São Paulo – São Carlos/SP, Brazil
Abstract: Reinforced thermoplastic structural detail parts and assemblies are being developed to be included in
current aeronautic programs. Thermoplastic composite technology intends to achieve improved properties and low cost
processes. Welding of detail parts permits to obtain assemblies with weight reduction and cost saving. Currently, joining
composite materials is a matter of intense research because traditional joining technologies are not directly transfer-
able to composite structures. Fusion bonding and the use of thermoplastic as hot melt adhesives offer an alternative
to mechanical fastening and thermosetting adhesive bonding. Fusion bonding technology, which originated from the
thermoplastic polymer industry, has gained a new interest with the introduction of thermoplastic matrix composites,
which are currently regarded as candidate for primary aircraft structures. This paper reviewed the state of the art of the
welding technologies devised to aerospace industry, including the ¿elds that Universidade Estadual Paulista -~lio de
Mesquita Filho and Universidade de São Paulo are deeply involved.
Keywords: Aircraft structural joint, Thermoplastic composite, Welding technology.
J. Aerosp. Technol. Manag., São José dos Campos, Vol.4, No 3, pp. 255-265, Jul.-Sep., 2012 255
Costa, A.P. et al.
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,oƚ ŵĞůƚ ĂdŚĞsiǀĞs
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sibƌĂƟon ǁĞůding
/nduĐƟon ǁĞůding
DiĐƌoǁĂǀĞ ǁĞůding uĂů ƌĞsin bonding
,oƚ ƉůĂƚĞ ǁĞůding
,oƚ gĂs ǁĞůding
* DQG * EXVLQHVV MHWV DQG$LUEXV %HOXJD WUDQVSRUW hůƚƌĂsoniĐ ǁĞůding iĞůĞĐƚƌiĐ ǁĞůding
ZĞsisƚĂnĐĞ ǁĞůding
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256 J. Aerosp. Technol. Manag., São José dos Campos, Vol.4, No 3, pp. 255-265, Jul.-Sep., 2012
A Review of Welding Technologies for Thermoplastic Composites in Aerospace Applications
J. Aerosp. Technol. Manag., São José dos Campos, Vol.4, No 3, pp. 255-265, Jul.-Sep., 2012 257
Costa, A.P. et al.
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DWWKHERQGLQJOLQHVHSDUDWHV¿EHUVIURPWKHFRQVROLGDWHG 6WUXFWXUDOHOHPHQWVSURGXFHGE\WKLVPHWKRGFRPSDUHGIDYRU-
laminates. A capacitor is then created and dielectric heat- DEO\WRWKRVHPDQXIDFWXUHVE\DXWRFODYHFRFRQVROLGDWLRQ
ing occurs due to the movement of charge and rotation of 7KHH[DPSOHVDERYHVKRZWKDWLQGXFWLRQKHDWLQJFDQEH
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ZKHUH WKH ¿EHU¿EHU FRQWDFW LV KLJK FURVVRYHU SRLQWV
LQWKHFDVHRIZRYHQIDEULFV7KLVWKHRU\H[SODLQVZK\ Microwave welding
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reported in the literature to weld thermoplastic composites
.Xet al., 2003; Wise and Froment, 2001; Chung-Yuan et al.,
1999; Vodicka, 1996).
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ZKHQLUUDGLDWHGE\PLFURZDYHV+RZHYHUWKHLQVHUWLRQRID
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KHDWLQJWRWDNHSODFH,IWKHMRLQWLVVXEMHFWHGVLPXOWDQHRXVO\
to microwaves and an applied P melting of the surrounding
SODVWLFUHVXOWVDQGDZHOGLVIRUPHG6XLWDEOHLPSODQWVLQFOXGH
PHWDOVFDUERQRURQHRIDUDQJHRIFRQGXFWLQJSRO\PHUVEXW
ZKLFKHYHULVVHOHFWHGEHFRPHVDFRQVXPDEOHLQWKHZHOGLQJ
SURFHVV<RXVHISRXUet al..Xet al., 2003; Wise and
)LJXUH6 FKHPDWLF LOOXVWUDWLRQ RI D PDJQHWLF ¿HOG DQG HGG\ Froment, 2001; Chung-Yuan et al., 1999; Vodicka, 1996).
FXUUHQWJHQHUDWHGE\DHOHFWURPDJQHWLFFRLO.DJDQDQG The particular advantage of microwave welding over other
1LFKROV IRUPVRIZHOGLQJLVLWVFDSDELOLW\WRLUUDGLDWHWKHHQWLUHFRPSR-
QHQW DQG FRQVHTXHQWO\ SURGXFH FRPSOH[ WKUHHGLPHQVLRQDO
A special type of induction welding is the so-called MRLQWV:HOGVDUHW\SLFDOO\FUHDWHGLQOHVVWKDQPLQXWH:LVH
(PDZHOGERQGLQJ +HUH WKHUPRSODVWLF SDVWHV ZLWK PHWDO and Froment, 2001).
SDUWLFOHV DUH H[WUXGHG LQ YDULRXV VKDSHV GHSHQGLQJ RQ WKH 2QHGUDZEDFNRIPLFURZDYHHQHUJ\LVWKDWKRPRJHQHRXV
ZHOGLQJ]RQHJHRPHWU\DVWKH\IRUPWKHERQGLQJEHWZHHQ PDWHULDOKHDWLQJLVRQO\SRVVLEOHZLWKVLPSOHJHRPHWULHVRU
the joining parts. The Emaweld-process is fast compared to WKURXJKWKHHODERUDWHDGDSWDWLRQRIWKHUDGLDWLRQHTXLSPHQWWR
conventional induction welding. However, due to the metal WDVNDWKDQG7KLVWHFKQLTXHKRZHYHULVSHUIHFWO\VXLWDEOHIRU
SDUWLFOHVLQWKHZHOGLQJ¿OOHUHYHQVPDOOFUDFNVOHDGWRQRWFKHV what are normally straight-line heating tasks in the welding of
in the welding zone thus reducing the mechanical properties ¿OPVDQGVKHHWLQJ.Xet al., 2003; Wise and Froment, 2001;
RIWKHMRLQW+RXet al. 1999). Chung-Yuan et al., 1999; Vodicka, 1996).
$VIRUYLEUDWLRQZHOGLQJVLQJOHODSMRLQWVKHDUVWUHQJWKVRI +HDWLQJLQDPLFURZDYH¿HOGHVVHQWLDOO\WDNHVSODFHE\WKH
RUGHURI03DKDYHDOVREHHQUHSRUWHGIRULQGXFWLRQZHOGHG following physical processes, depending on the target material:
336FDUERQ¿EHUODPLQDWHV$GGUHVVHGLQYHVWLJDWLRQVFRPSDU- SRODUL]DWLRQKHDWLQJSRODUPDWHULDOHOHFWULFDOUHVLVWDQFHKHDWLQJ
ing resistance and induction welding showed that, under HOHFWULFDOO\FRQGXFWLYHPDWHULDOVKHDWLQJWKURXJKWKH0D[ZHOO
equivalent heating conditions, induction welded specimens :DJQHUHIIHFWPXOWLSKDVHPDWHULDOVEOHQGV¿OOHGPDWHULDOV
GLVSOD\HGKLJKHUVKHDUVWUHQJWKV.DJDQDQG1LFKROV LRQSRODUL]DWLRQHOHFWURO\WHVVDOLQHVROXWLRQVDQGFHUDPLFVDW
*UXPPDQ$LUFUDIW/DERUDWRULHV.DJDQDQG1LFKROV KLJKWHPSHUDWXUHVHOHFWURQSRODUL]DWLRQ.Xet al., 2003; Wise
UHSRUWLQGXFWLRQKHDWLQJDVKLJKO\VXLWDEOHIRUERWKWKHFRQVWUXF- and Froment, 2001; Chung-Yuan et al., 1999; Vodicka, 1996).
WLRQDQGUHSDLURIFDUERQ¿EHUUHLQIRUFHGWKHUPRSODVWLFSDUWVRIWKH &RQWLQXRXV PLFURZDYH ZHOGLQJ FDQ EH XVHG IRU EXWW
)$DLUFUDIWKRUL]RQWDOVWDELOL]HUOHDGLQJHGJHGHPRQVWUDWLRQ welding of joint elements with low, medium and high
258 J. Aerosp. Technol. Manag., São José dos Campos, Vol.4, No 3, pp. 255-265, Jul.-Sep., 2012
A Review of Welding Technologies for Thermoplastic Composites in Aerospace Applications
)LJXUH6FKHPDWLFVHWXSIRUUHVLVWDQFHZHOGLQJSURFHVV$JHRUJHV
and Ye, 2002).
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and the power circuit is critical to the resistance welding
process. In order to introduce adequate current into the
KHDWLQJ HOHPHQW VHYHUDO ZD\V KDYH EHHQ XVHG LQFOXGLQJ
)LJXUH6FKHPDWLF VHWXS IRU PLFURZDYH KHDWLQJ <RXVHISRXU GLUHFWFODPSLQJRQWKHSUHSUHJFODPSLQJRQWKHEDUH¿EHUV
et al., 2004). SUHSUHJ GLSSHG LQWR OLTXLG PHWDO EDWK FODPSLQJ RQ WKH
EDUH ¿EHUV SDLQWHG ZLWK D VLOYHU ¿OOHG HSR[\ FRPSRXQG
The technique is still in the development stages and, as among others. Instead of using continuous power during the
such, there are currently no reported industrial applications. SURFHVV WKH SRZHU FDQ EH DSSOLHG LQ WKH IRUP RI LQWHQVH
However, it is anticipated that microwave welding may prove pulses. This process is called impulsive resistance welding
WREHVXLWDEOHIRUMRLQLQJDXWRPRWLYHXQGHUERG\FRPSRQHQWV DQGUHTXLUHVOHVVHQHUJ\WRPHOWWKHPDWUL[GXHWRORZHUKHDW
and aerospace parts. ORVVHV%DOOHet al., 2009).
7KLVZHOGLQJSURFHVVFDQDOVREHFDUULHGRXWXQGHUHLWKHU
Resistance welding constant load or displacement control. The method can
produce lap shear strength values greater than 33 MPa, and
5HVLVWDQFHZHOGLQJKDVEHHQFRQVLGHUHGDYHU\SURPLVLQJ KDVEHHQXVHGLQRUGHUWRZHOG3((.DQG3(,ODPLQDWHVE\WKH
joining technique for aerospace application. This process is 86$LU)RUFH:DQJet al., 2006).
UHODWLYHO\IDVWZHOGLQJWLPHVIURPWRPLQXWHVUHTXLUHV
J. Aerosp. Technol. Manag., São José dos Campos, Vol.4, No 3, pp. 255-265, Jul.-Sep., 2012 259
Costa, A.P. et al.
260 J. Aerosp. Technol. Manag., São José dos Campos, Vol.4, No 3, pp. 255-265, Jul.-Sep., 2012
A Review of Welding Technologies for Thermoplastic Composites in Aerospace Applications
/%: KDV EHHQ HQYLVLRQHG DV D VXLWDEOH WHFKQLTXH IRU /%:WHFKQLTXHUDWKHUWKDQDOWHUQDWLYHWHFKQRORJLHV/DEHDV
joining thin, as well as medium to thick thermoplastic et al., 2010). LBW allows joining thermoplastics, provided
components used in the aeronautic sector. Moreover, size, WKDWRQHRIWKHPDWHULDOVWRSPDWHULDOLVWUDQVSDUHQWWRODVHU
JHRPHWULFDO UHTXLUHPHQWV DQG VSHFL¿FDWLRQV RI DHURQDXWL- UDGLDWLRQDQGWKHRWKHUERWWRPPDWHULDOLVDEVRUEHQWHQRXJK
FDOSDUWVDUHFODLPHGWREHPRUHHDVLO\IXO¿OOHGE\DSSO\LQJ IRUWKHZHOGLQJWRWDNHSODFHRWKHUZLVHRQO\EXWWMRLQWVZLOOEH
DOORZHGZKLFKLVQRWDQDWWUDFWLYHSRVVLELOLW\IRUFRQWLQXRXV
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GLUHFWFRQWDFWSULRUWRZHOGLQJ7KHODVHUEHDPLVWUDQVPLWWHG
WKURXJKWKH¿UVWPDWHULDODQGLVWRWDOO\DEVRUEHGZLWKLQWKH
VXUIDFH RI WKH DEVRUELQJ PDWHULDO 'LUHFW FRQWDFW EHWZHHQ
ERWK SDUWV HQVXUHV KHDWLQJ RI WKH WUDQVSDUHQW SDUW E\ KHDW
FRQGXFWLRQIURPWKHDEVRUELQJSDUW)LJ:HOGLQJRFFXUV
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joining separate parts ensuring full continuity of the resin
Figure 7. Schematic of infrared lamp welding system conceived system without the addition of an adhesive system and avoid-
to join thermoplastic laminates highlighting the infrared LQJDOVRULYHWLQVWDOODWLRQOHDGLQJWRDQXPEHURIVXEVWDQWLDO
radiation source, polymer parts deployment and pressing advantages, such as cost savings, weight reduction, and
SODWHV <RXVHISRXU et al., 2004; Ageorges et al., 2001; PDQXIDFWXULQJF\FOHWLPHUHGXFWLRQDVZHOODVDFFHSWDEOH
Potente et al., 1993). ERQGVWUHQJWK/DEHDVet al., 2010).
Only few studies of the application of LBW process for
the joining of structural thermoplastic composites such as
FDUERQ3((.RUFDUERQ336DUHDYDLODEOHLQWKHOLWHUDWXUH
VRWKDWUHOLDEOHDSSOLFDWLRQRI/%:WHFKQRORJ\IRUMRLQLQJ
primary aeronautic parts made of thermoplastic composites
VWLOO UHTXLUHV VLJQL¿FDQW GHYHORSPHQW DQG LQYHVWLJDWLRQ
/DEHDVet al., 2010).
REMARKABLE CONCLUSIONS
J. Aerosp. Technol. Manag., São José dos Campos, Vol.4, No 3, pp. 255-265, Jul.-Sep., 2012 261
Costa, A.P. et al.
DSSOLFDWLRQ GHSHQGLQJ RQ LWV VSHFL¿F UHTXLUHPHQWV )XVLRQ Ageorges, C. et al. ³$GYDQFHV LQ IXVLRQ ERQGLQJ
ERQGLQJPHWKRGVSUHVHQWDKXJHSRWHQWLDOIRUYROXPHLQWHQVLYH WHFKQLTXHV IRU MRLQLQJ WKHUPRSODVWLF PDWUL[ FRPSRVLWHV D
applications in which short processing cycles are necessary. UHYLHZ´&RPSRVLWHV3DUW$9RO1RSS
7KHVHERQGLQJSURFHVVHVRIIHUDGGLWLRQDODGYDQWDJHVLQFOXGLQJ
reduced surface preparation requirements, reprocessing, recy- Ageorges, C. et al.³([SHULPHQWDOLQYHVWLJDWLRQRIWKH
FODELOLW\DQGLPSURYHGLQWHJULW\GXUDELOLW\$PRQJWKHYDULRXV UHVLVWDQFHZHOGLQJIRUWKHUPRSODVWLFPDWUL[FRPSRVLWHV3DUW
WHFKQLTXHVRIWKLVFDWHJRU\WKHPRVWPDWXUHRQHVDUHXQGRXEW- ,KHDWLQJHOHPHQWDQGKHDWWUDQVIHU´&RPSRVLWHV6FLHQFHDQG
edly the ultrasonic, induction and the resistance welding. 7HFKQRORJ\9RO1RSS±
Process integration is a critical aspect of joining technol-
ogy. Particular requirements of each joining techniques should Arici, A.A., 2007, “Effect of hygrothermal aging on poly-
EHFROODWHGLQGHVLJQVFRGHVLQRUGHUWRLQWHJUDWHWKHVHUHTXLUH- HWKHULPLGHFRPSRVLWHV´-RXUQDORI5HLQIRUFHG3ODVWLFVDQG
ments at the very early stage of the design process. &RPSRVLWHV9RO1RSS
,QVLGHRIWKLVFRQWH[WVLQFH81(63DQG863KDYHJHW
involved in development and/or application of welding technolo- Balle, F. et al., 2009, “Ultrasonic metal welding of aluminium
JLHVLQDHURVSDFH¿HOG(PSKDVLVRIWKHZRUNLQ81(63LVLQ VKHHWVWRFDUERQ¿EUHUHLQIRUFHGWKHUPRSODVWLFFRPSRVLWHV´
the development of the resistance welding technology associated $GYDQFHG(QJLQHHULQJ0DWHULDO9RO1RSS
ZLWKWKHHQYLURQPHQWDOLQÀXHQFHRQWKHWKHUPDODQGPHFKDQL-
cal properties of thermoplastic laminates, whereas USP is in Bates, P.J. et al.³6KHDUVWUHQJWKDQGPHOWGRZQEHKDY-
the forefront of IR lamp welding methodology and advanced LRU RI UHLQIRUFHG SRO\SURS\OHQH DVVHPEOLHV´ &RPSRVLWHV
destructive and nondestructive characterization of the joints. 3DUW$9RO1RSS
0RVW RI WKH GDWD LQ WKLV SDSHU ZHUH REWDLQHG IURP WKH
literature, since this manuscript is a state-of-the-art review. Botelho, E.C. et al., 2005 “Processing and hygrothermal effects
Therefore, such data do not provide information for deals of RQ YLVFRHODVWLF EHKDYLRU RI JODVV ¿EHUHSR[\ FRPSRVLWHV´
UHSHDWDELOLW\RUUHSURGXFLELOLW\DQGWKH\DUHXVHIXORQO\IRU -RXUQDORI0DWHULDO6FLHQFH9RO1RSS
an initial mapping of potential techniques over a wide range
RIZHOGSURFHVVLQJFRQGLWLRQVDQGSDUDPHWHUVWREHXVHGLQ Botelho, E.C. et al.³0HFKDQLFDOEHKDYLRURIFDUERQ
DHURVSDFH¿HOG ¿EHUUHLQIRUFHGSRO\DPLGHFRPSRVLWHV´&RPSRVLWHV6FLHQFH
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Acknowledgements
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from Fundação de Amparo à Pesquisa do Estado de São Paulo ODPLQDWHV´ -RXUQDO RI$SSOLHG 3RO\PHU 6FLHQFH 9RO
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GH3HVVRDOGH1tYHO6XSHULRU&$3(6 Botelho, E.C. et al., 2002, “Study of polyamide 6/6 synthesis
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