Impact of Thermal Input on Induction Welding of CF/PPS Composites: Design of a Welding Process Window with Multiphysical Coupling

doi:10.3901/JME.2025.18.076

Abstract

Abstract: A three-dimensional transient multiphysics finite element model is developed for carbon fiber-reinforced thermoplastic composite CF/PPS based on the electromagnetic-thermal coupling theory, systematically simulating the dynamic evolution of the temperature field at the welding interface. The model’s validity is verified using an independently constructed induction welding experimental platform, combined with single-lap shear tests and scanning electron microscopy (SEM) observations, showing a deviation of less than 8% between model predictions and experimental data. The distribution pattern of the temperature gradient along the thickness direction at the welding interface is also revealed. The results indicate that under a 20 A current, the effective molten width increases linearly with welding time within 30 s. However, when the welding time exceeds 30 s, local temperatures surpass the thermal decomposition threshold of the resin matrix (～400 ℃), leading to thermal degradation defects at the interface and a significant reduction in shear strength (from 18.6 MPa to 12.3 MPa). Through multiscale experimental characterization and multiphysics coupling analysis, a quantitative relationship between heat input parameters and resin melting behavior is established. Appropriate heat input promotes uniform resin melting and the formation of a dense interface, whereas excessive heat input induces resin pyrolysis, carbonization, and porosity defects. A novel process optimization model based on a temperature window is proposed, elucidating the correlation between heat input, interface fusion, and mechanical performance. This provides a theoretical basis for precise control of the process window in CF/PPS composite induction welding. The findings not only expand the theoretical framework of thermoplastic composite welding but also offer a new technological pathway for the efficient manufacturing of lightweight aerospace structures.

Key words: carbon fiber composites, induction welding, numerical simulation, mass and heat transfer, multiscale analysis

CLC Number:

TG161

SHEN Liangliang, XIAO Juan, XU Jian, JIAN Xigao, LIN Jianfeng, REN Zhiying. Impact of Thermal Input on Induction Welding of CF/PPS Composites: Design of a Welding Process Window with Multiphysical Coupling[J]. Journal of Mechanical Engineering, 2025, 61(18): 76-85.

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