Simulation of induction welding process for glass fiber thermoplastic composites in aerospace applications

Abstract

The use of high-performance thermoplastic composite material has increased. It is therefore relevant to study in depth their joining processes and to determine the joining parameters allowing for good mechanical performance. The current study focuses on the induction welding technology as one of the most promising method for this purpose. To understand physical background of inductive welding of thermoplastic composites and to propose methods for optimizing the process, a three dimensional finite element model of the induction heating process for induction welding of glass fiber polyetherimide (GF/PEI) is developed using the COMSOL Multiphysics® software. The model takes into account a stainless steel mesh net susceptor placed at the welding interface of the two adherends to be welded. The eddy-currents in the susceptor being generated by time-varying external magnetic field, provide heat at the welding interface, where it is needed. The model predicts the temperature rise within the material during the heating of welding process. Also, a sensitivity analysis is performed aiming at identifying the parameters and properties that have the greatest effect on temperature. These are input current, frequency, distance between coil and susceptor and electrical conductivity of the susceptor.