Numerical Simulation and Experimental Study of Ultrasonic Welding of CF/PEEK Composites

ABSTRACT In this paper, ultrasonic technology is used to carry out welding experiments on CF/PEEK composites in the form of a single lap joint, and the optimal process conditions for ultrasonic welding of CF/PEEK composites are determined through the continuous optimization of welding amplitude, welding pressure, and other parameters. When the welding amplitude and welding pressure are 35 μm for 0.3 MPa, respectively, the welding strength of CF/PEEK composites is 32 MPa at this time. In addition, this paper also uses finite element software such as ANSYS to numerically simulate the heat generation process of ultrasonic welding of CF/PEEK composites and finds that viscoelastic heat has a greater potential for heat accumulation compared to frictional heat. When the viscoelastic heat is excited, the temperature at the welding interface can reach more than 400°C in a very short period of time (< 0.3 s). This study provides an important theoretical basis and practical guidance for the efficient welding of CF/PEEK composites and is also of great significance in promoting the development and application of ultrasonic welding technology in automotive, aerospace, and other fields.