The effects of misaligned adherends on static ultrasonic welding of thermoplastic composites

Ultrasonic welding is a promising joining technique for thermoplastic composite parts. On the way towards upscaling and industrialisation of this technology, it crucial to understanding how affected by manufacturing tolerances. The objective research presented in paper was investigate influence that misaligned adherends have on static ultrasonic composites. Different angles were created changing clamping configuration. results showed increasing angle between decreases power consumed increases process time while decreasing weld uniformity risk overheating. These effects associated impact different configurations cyclic strain energy director during process. Decreasing top bending stiffness distance found significantly reduce adverse adherend misalignment quality.