Table 2.
Summary of selected researches on ultrasonic welding of thermoplastic composites to thermoplastic composites.
| Ultrasonic Welding of Thermoplastic Composites to Thermoplastic Composite | ||||||||||
|---|---|---|---|---|---|---|---|---|---|---|
| Year | Author | Material System | Factors Studied | ED | Weld Time | Weld Pressure/Force | Amplitude | Frequency | Optimised Weld Strength | Reference |
| 2001 | Liu et al. | GF/PP | Effect of ED, weld time and weld pressure | TED, RED, SHED | 0.25 s, 0.3 s, 0.33 s | 2.5, 3, 3.5 bar | 25, 36, 40 µm | 20 kHz | 13.77 MPa | [76] |
| 2002 | Liu et al. | GF/Nylon 6 | Effect of ED, weld time and weld pressure | TED, RED, SHED | 0.25 s, 0.32 s, 0.4 s | 2, 3, 4 bar | 25, 36, 40 µm | 20 kHz | 17.11 MPa | [37] |
| 2010 | Villegas et al. | CF/PEI_CF/PEI | NA | Triangular ED | 3.5 s | 4 MPa | 50 µm | 20 kHz | 32–36 MPa | [41] |
| 2014 | Villegas et al. | CF/PEI | Effect of weld pressure | Flat ED (0.25 mm) | Displacement mode | 300 N and 1500 N | 51.8 and 86.2 µm | 20 kHz | 37.3 MPa | [83] |
| 2015 | Villegas et al. | CF/PPS | Effect of ED | TED, Flat | Displacement mode | 1000 N | 86.2 µm | 20 kHz | 37.1 MPa | [90] |
| 2016 | Senders et al. | CF/PPS | Effect of ED | Flat ED (0.08, 0.16, 0.24 mm) | Displacement mode | 1000 N | 86.2 µm | 20 kHz | 36.5 MPa | [95] |
| 2017 | Palardy et al. | CF/PEI | Effect of ED | Flat ED (0.5, 0.25, 0.06 mm) | Displacement mode | 1000 N | 86.2 µm | 20 kHz | 37.3 MPa | [96] |
| 2017 | Villegas et al. | CF/PPS | NA | TED | Displacement mode | 1000 N | 86.2 µm | 20 kHz | 37.1 MPa | [97] |
| 2017 | Zhi et al. | CF/PA 66 | Effect of weld energy/ thermal decomposition | NA | NA | 0.17 MPa | NA | 20 kHz | NA | [98] |
| 2017 | Zhi et al. | CF/PA66 | Effect of moisture content/ Amplitude | NA | NA | 0.17 MPa | NA | 20 kHz | NA | [99] |
| 2017 | Zhi et al. | CF/PA66 | Effect of pre-heating | NA | NA | 0.17 MPa | NA | 20 kHz | NA | [100] |
| 2017 | Lu et al. | CF/Nylon 66 | Effect of repair on welded joint | NA | NA (Energy controlled mode) | NA | NA | 20 kHz | NA | [101] |
| 2018 | Zhi et al. | CF/PA 66 | Effect of weld time and weld pressure | NA | 1.3 s, 1.7 s, 2.1 s, 2.5 s, 2.9 s, 3.3 s | 0.13, 0.14, 0.15, 0.17, 0.2 MPa | 25 µm | 20 kHz | NA | [102] |
| 2018 | Gao et al. | CF/Nylon 66 | Feasibility to weld 4 mm-thick laminate | No ED | 1.3 s, 1.7 s, 2.1 s, 2.5 s, 2.9 s, 3.3 s | 0.13, 0.14, 0.15, 0.17, 0.2 MPa | NA | 20 kHz | 5.2 kN | [103] |
| 2019 | Goto et al. | CF/PA6 | Effect of energy | Flat ED (0.3 mm) | NA (Energy controlled mode) | 940 N | 90 µm | 15 kHz | 40 MPa | [50] |
| 2019 | Tao et al. | CF/PEEK | Effect of weld time | Flat ED (0.45 mm) | 0.7 s, 0.8 s, 0.9 s, 1 s, 1.1 s | 0.3 MPa | 25 µm | 60 kHz | 28 MPa | [51] |
| 2019 | Kalyan Kumar et al. | GF/PA | Effect of weld time | NA | 0.5 s, 0.55 s, 0.6 s | 4 Bar | NA | 20 kHz | 3.1 kN | [104] |
| 2020 | Bhudolia et al. | CF/Elium® | Fatigue response | NA | NA | NA | NA | 20 kHz | NA | [105] |
| 2020 | Bhudolia et al. | CF/Elium® | Effect of weld time | Semicircular ED | 0.5 s, 1 s, 1.5 s, 2 s | 3 bar, 4 bar, 5 bar | 48.75 µm | 20 kHz | 17.5 MPa | [106] |
| 2020 | Choudhury et al. | Bamboo fiber/ PLA | Effect of weld time, hold time, weld pressure | NA | 1 s, 3 s, 5 s, 7 s, 9 s | 1 bar, 2 bar, 3 bar, 4 bar, 5 bar | NA | 20 kHz | 3.7 kN | [107] |