The Soudure Group has collaborated with institutions such as the Arkema Institute to develop innovative welding solutions (ISW) for thermoplastic composite parts.
Innovative welding solutions for thermoplastic composite parts
The solution was jointly developed by the Soudure Group and the Arkema Institute and provides expertise in welding technology and high-performance polymers, respectively.
In the next few years, the use of thermoplastic composite materials in the aerospace field is a huge challenge, requiring a welding technology with good mechanical properties and cost-effectiveness.
The innovation lies in the design and setting of a very high-performance process that can weld any fiber-reinforced thermoplastic matrix. ISW is mainly dedicated to the high-quality connection of high-performance thermoplastics (PEKK) reinforced with carbon fibers, but can also be applied to any other substrate (from PA to PAEK) and fibers (glass, aramid …).
Compared with the raw material, the welding connection coefficient of ISW is about 85%, and there is no foreign matter on the welding line after the operation.
The ISW solution is based on the use of a pedestal, which is linked to and moved with the induction coil in the welding head, and the interface layer of a pure thermoplastic matrix without reinforcement or low fiber content can be customized according to the application.
The welding head is cooled under the pressure of the substrate to ensure the compaction of the welding line.
The relevant person explained: "We use a laser pyrometer to sense the temperature, which actually measures the edge of the base from the side. Therefore, we know exactly the temperature at the interface. We also have a cooling device that applies to the welding surface Pressure to ensure that the pressure is below the crystallization temperature, so once the pressure is released, there is no danger of compaction. "
This innovative head with movable base is very compact and can perform precise and complex operations. The design of ISW is fully automated, with the welding head mounted on a 6-axis robotic arm.
The main advantage:
1. High performance welding (minimum connection coefficient is 85%)
2. Reduce later operations (do not use adhesives, tapes and chemical products)
3. Reduce weight
4. There is no base at the welded joint
5. Dynamic and fully automatic / monitored solutions
6. Ecological impact: Due to local heating, the use of recyclable materials and reduced energy consumption
7. Can be used with any thermoplastic matrix and any fiber.
Several developments of aviation structural parts
The Soudure Group is responsible for welding the stringers to the skin using a dynamic induction welding process. This project is the beginning of the development of induction welding of aviation structural parts.
On this basis, the Soudure Group has developed this new technology, which aims to improve the weaknesses of traditional sensing technology: from the beginning of 2019, some major aviation companies have begun feasibility studies. Starting in 2020, the main goal is to increase the maturity of the technology and participate in specific aviation projects to obtain certification.