On the sensitivity of ultrasonic welding of epoxy- to polyetheretherketone (PEEK)-based composites to the heating time during the welding process

This study aims at assessing the sensitivity of ultrasonic welding process for joining epoxy- to thermoplastic-based composites heating time. For that, carbon fibre (CF)/epoxy adherends with a co-cured PEI coupling layer were ultrasonically welded CF/polyetheretherketone (PEEK) different times. Process-induced changes in meso and microstructure these welds identified correlated weld strength. Subsequently, processing interval, i.e., range times resulting less than 10% decrease strength, was defined. As, expected, dissimilar composite joints more sensitive time CF/PEEK joints. However, this effect pronounced since relatively wide interval could be obtained provided that had sufficient thickness.