Ultrasonic Welding Forming and Compression Test Study of CF/PA6 Composite Lattice Structures

doi:10.3901/JME.260354

Abstract

Abstract: The forming and manufacturing of carbon fiber composite lattice structures have long relied on adhesive bonding and compression integrated molding processes. However, adhesive bonding is easily affected by environmental factors, and large residual stress is often introduced during compression molding, thus reducing the fatigue life of the structures. To address the above problems, a new ultrasonic welding forming process for carbon fiber lattice structures based on short carbon fiber reinforced nylon 6(CF/PA6) composites is proposed. First, 1×1 and 2×2 pyramidal lattice structures are successfully fabricated by using a self-built ultrasonic welding platform. Then, quasi-static compression experiments are carried out, and the compression failure mechanism is thoroughly analyzed by combining digital image correlation(DIC) technology and finite element mechanical modeling. The research results show that the load-bearing performance of the 1×1 integral lattice structure is significantly better than that of the separated structure, and the load-bearing capacity of the 2×2 structure increases nonlinearly with scale expansion, which can reach up to 16 560.9 N. The flat compression failure mode of this type of structure is different from the interface debonding of traditional adhesive structures or the node fracture of compression molded structures. It is mainly manifested as non-weld point dominated buckling fracture of members, and the welded joints show good mechanical properties.

Key words: carbon fiber reinforced composites, lattice structures, ultrasonic welding, compression failure mechanism, lightweight design

CLC Number:

TG453

XING Yu, ZHANG Tingting, LI Liukai, CUI Yinkui, LIANG Jianguo. Ultrasonic Welding Forming and Compression Test Study of CF/PA6 Composite Lattice Structures[J]. Journal of Mechanical Engineering, 2026, 62(14): 106-114.

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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.260354

http://www.cjmenet.com.cn/EN/Y2026/V62/I14/106

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