Welding Journal Research Supplement
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Quality Prediction in Long-Lap Continuous Ultrasonic Welding of Thermoplastic
Composites Acoustic behavior during continuous ultrasonic welding is simulated, and a model is proposed for predicting welding quality
Abstract
Continuous ultrasonic welding is an efficient and precise technology widely used for joining composite materials. However, compared to ultrasonic single-point welding, continuous ultrasonic welding exhibits lower joint quality, posing significant challenges for quality control. This study focuses on the joint quality of continuous ultrasonic welding. Based on the acoustic wave transmission principle, the acoustic behavior during continuous ultrasonic welding is simulated, and a model is proposed for predicting welding quality. Welding pressure, welding speed, and the radiation radius of welding energy are key factors influencing weld quality. The heating process of continuous ultrasonic welding is simulated using the finite element method, and the energy attenuation characteristics and heat distribution during welding are analyzed to validate the quality prediction model. Experimental verification further confirms the model’s accuracy. The results demonstrate that under stable welding conditions, the model reliably predicts welding quality, offering an effective solution for quality assessment in continuous ultrasonic welding of thermoplastic composites.