Ultrasonic welding of banana fiber based HDPE composites with energy directors

Joints are an integral element of any product and a source of failure under different loading environments. The current experimental investigation explores in detail the ultrasonic welding behavior of banana fiber/HDPE composites. The effect of fiber loading, type of energy directors and process parameters has been investigated on the mechanical and thermal behavior of the welded joints. The comparative assessment has been supported by the results of the dynamic mechanical analysis and the thermal conductivity of the fibers and HDPE. The mechanism of heat generation during welding process has been discussed. The TGA, DTG, DSC and FESEM analysis has been performed to substantiate the results. Composite adherends welded at optimum level of welding parameters with cross energy director profile depicted better load bearing characteristics. The short fibers also participated in the diffusion mechanism during welding. TGA and DTG results showed no significant effect on thermal stability of composites post welding.