Temperature control for induction welding of carbon fiber reinforced polyetheretherketone (CF/PEEK) composite material via thermal conduction plate
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摘要: 研究了碳纤维增强聚醚醚酮(CF/PEEK)复合材料感应焊接中厚度方向及焊接面内的温度分布及调控。基于对温度分布结果的分析，使用导热板结合真空袋压的方式对CF/PEEK进行感应焊接，结合使用合适的功率及加热时间，测试了焊接件的单搭接强度，观测分析了焊接件的断裂形貌。结果表明，导热板对层合板表层和边缘均有良好的散热效果；焊接功率越低，焊接面的加热均匀性增加，但是会延长加热时间。在真空袋中对层合板上表面和两侧添加导热板，在输出功率示数为600时感应焊接300 s，焊接件的单搭接剪切强度达到41.57 MPa。Abstract: The temperature distribution along the thickness direction and along the weld line for carbon fiber reinforced polyetheretherketone (CF/PEEK) composite was recorded and optimized. According to the temperature distribution result, the induction welding of CF/PEEK laminates was carried out with appropriate power and heating time, with the help of vacuum bag and properly placed thermal conduction plates. The single lap strength of the welded sample was tested, and the fracture morphology of the weld area was observed and analyzed. The results show that the thermal conduction plates have a good heat dissipation effect around the surfaces of the laminates. The lower the welding power, the more uniform the heating of the welding area, but the heating time will be extended. Under the optimized processing parameters of power of 600 and heating time of 300 s in vacuum bag, and intentionally placed thermal conduction plates above the top surface and along the lateral sides, the single lap shear strength of the part reaches 41.57 MPa.
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图 1 碳纤维增强聚醚醚酮(CF/PEEK)层合板测温示意图
Figure 1. Schematic diagram of temperature measurement of carbon fiber reinforced polyetheretherketone (CF/PEEK) laminate ((a) Photograph by infrared thermal imager from one side of the laminates; (b) Diagram of thermocouple placement)
图 2 导热板下各功率CF/PEEK层合板侧面厚度方向上红外测温温度随时间变化曲线((a) 功率500；(b) 功率800；(c) 功率1100；(d) 红外热成像图；(e) 功率1 100无导热板；(f) 不同时间和位置到达395℃的时间)
Figure 2. Variation of temperature with time obtained by the infrared thermal imager for different spots along the thickness direction of CF/PEEK laminates under a heat conduction plate with different power output ((a) Power of 500; (b) Power of 800; (c) Power of 1100; (d) Infrared thermography; (e) Power of 1100 without heat conduction plate; (f) Time of reaching 395℃ at various power and position)
图 3 有导热板无真空袋 (a) 及有导热板有真空袋时 (b) CF/PEEK层合板焊接面内中间区域及边缘区域温度随时间变化曲线
Figure 3. Time-dependent temperature curve of the central and edge areas of the welding area for CF/PEEK laminates with heating conduction plate without a vacuum bag (a) and with a vacuum bag (b)
图 4 模拟升温场景中热电偶和红外热像仪的测温对照(样品：PEEK；热源：控温热台)
Figure 4. Comparison of temperature measurement by thermocouple or infrared thermal imager in simulated scenarios (Sample: PEEK; Heat source: Hot stage)
图 5 不同条件下CF/PEEK焊接件的断面形貌((a) 功率500、加热98 s；(b) 功率800、加热48 s；(c)功率1 100、加热19 s)和不同条件下CF/PEEK焊接件的上表面形貌((d) 功率1 100、无导热板、加热19 s；(e) 功率1 100、有导热板、加热19 s)
Figure 5. Fracture morphologies of CF/PEEK welded laminates ((a) Power of 500, heating time of 98 s; (b) Power of 800, heating time of 48 s; (c) Power of 1 100, heating time of 19 s) and top surface morphology of the welded laminates ((d) Power of 1 100, heating time of 19 s, without a heating conduction plate; (e) Power of 1 100, heating time of 19 s, with a heating conduction plate)
图 6 不同条件下CF/PEEK焊接件的断面SEM图像((a)~(b) 功率500中间区域；(c)~(d) 功率500边缘区域；(e)~(f) 功率800边缘区域；(g)~(h)功率1 100边缘区域)
Figure 6. SEM observation on fracture images of CF/PEEK welded laminates with a heating conduction plate and vacuum bag ((a)-(b) Power of 500, central area; (c)-(d) Power of 500, marginal area; (e)-(f) Power of 800, marginal area; (g)-(h) Power of 1 100, marginal area)
图 7 CF/PEEK焊接件断面形貌((a)功率500、加热200 s；(b) 功率600、加热200 s；(c) 功率600、加热300 s)
Figure 7. Fracture morphologies of CF/PEEK welded laminates ((a) Power of 500, heating time of 200 s; (b) Power of 600, heating time of 200 s; (c) Power of 600, heating time of 300 s)
表 1 CF/PEEK焊接件接头单搭接剪切强度(LSS)
Table 1. Single lap shear strength (LSS) of CF/PEEK welded joints
Condition Average LSS/MPa Standard deviation Power of 500, 98 s 30.06 0.55 Power of 800, 48 s 22.35 1.87 Power of 1 100, 19 s 18.28 1.13 
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表 2 额外给层合板两侧添加导热板后CF/PEEK焊接件接头LSS
Table 2. LSS of CF/PEEK welded joints after adding heating conduction plates to both sides of the laminate
Condition Average LSS/MPa Power of 500, 200 s 26.40 Power of 600, 200 s 36.30 Power of 600, 300 s 41.57
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