The main target of this project is to increase the velocity of the induction welding process of continuous carbon fiber reinforced thermoplastic composites, especially organo sheets, as well as to improve the joining quality to autoclave level.
Within the DFG project “Process optimization of induction welding of continuous carbon fiber reinforced thermoplastics using process simulation“ inductive heating tests with carbon fiber reinforced organo sheets were performed. The used fabric reinforcement structures differ in their textile parameters in order to determine their influence on the inductive thermal behavior. Based on the gained results, the laminate structure of the joining partners were optimized in particular for induction welding. This is to ensure that the energy input in the joining zone is much higher than in the near-surface areas. To further intensify this heating characteristic, the coil facing surface is additionally actively cooled down to prevent the melting of the surface during the welding process and consequently a possible delamination. Preliminary tests with compressed air as cooling medium were already successful. For higher process speeds alternative cooling methods will be investigated. Further project goals are the prediction of the achievable joint strength of an induction welded joint for given boundary conditions and the theoretical predefinition of process parameters for new material combinations.