A comparative evaluation between flat and traditional energy directors for ultrasonic welding of CF/PPS thermoplastic composites

Energy directors, responsible for local heat generation in ultrasonic welding, are neat resin protrusions traditionally moulded on the surfaces to be welded. This study evaluates an alternative energy directing solution for ultrasonic welding of thermoplastic composites based on the usage of a loose flat layer of neat resin at the welding interface, referred to as 'flat energy director'. Analysis of dissipated power, displacement of the sonotrode, welding energy and time as well as weld strength compared to more traditional energy directing solutions showed that flat energy directors, which significantly simplify ultrasonic welding of thermoplastic composites, do not have any substantial negative impact in the welding process or the quality of the welded joints.