Abstract

Thermoplastic composite joints show many advantages in comparison to conventional fasteners. However, thermoplastic welding of primary aircraft structures is still a certification issue. Long and extensive fatigue and test campaign is required for a depth understanding of damage progression. In fact, scarce historical data are currently available and the joint fatigue performances are extremely sensitive to numerous welding process parameters.

In this context, Structural Health Monitoring (SHM) technologies consists of a built-in sensors network providing real-time condition and the damage state of a structure. SHM brings several benefits. First of all, SHM ensures safety in-flight through continuously assessing damages and alerting if strength reduction approaches acceptable limits. The data obtained are useful for future structure retrofitting and new developments. Moreover, SHM has the potential to support and speed up the certification of thermoplastic composite joint. SHM data give added value to each individual fatigue test contributing to a greater understanding of damage progression and making fatigue campaign shorter and more efficient.

In the present work, both quasi-static as well as fatigue tests were conducted to evaluate performances of thermoplastic induction welded joints. Strain gauges and purpose-designed electromagnetic-based SHM sensor were integrated into the specimens in order to collect useful data during tests in three main cases: lap-joint specimens manufactured (i), (ii) with two different set of process parameters and (iii) with an artificially generated lack of weld at the joint interface. The approach proposed and data collected by the sensors has provided valuable information for understanding damage propagation in this kind of joint.

Abstract

One of the main advantages of using reinforced thermoplastic materials is the possibility of joining different parts by welding. Welding process avoids the use of mechanical joints, which increase the weight of the component and the manufacturing time; as well as adhesive joints, where it is difficult to ensure their quality.

Welded joints are of special interest when applied in assembly processes with a high production rate. However, welded joints on high-rate components require research into new materials, processes, and inspection techniques. In this line, the present work analyzes the results obtained from different welded joints through heating by electrical resistance without contact. This characterization study includes mechanical, microstructural and physical-chemical properties analysis, as well as its evaluation through non-destructive inspection techniques. As a result, a deeper knowledge of the materials and processes has been obtained, including the effect of the different welding processing parameters.

Different opening mode mechanical tests are presented in this study, as well as thermal analysis by differential scanning calorimetry to evaluate the effect of temperature and time applied during the welding process on the final properties. The quality of the process in the different joining elements has been verified with inspection by means of infrared thermography, correlating indications in the level of IR radiation with localized variations microscopy features (i.e.: amount of resin). In addition, a microstructural study has been carried out to assess the fiber/resin content of the material in the joint areas, as well as a complementary analysis using computed tomography and ultrasound.