Fusion Bonding of Polymer Composites (Hardcover, 2002 ed.)

1. Introduction.- 1.1 Advanced Thermoplastic Matrix Composites (TMPCs).- 1.2 Joining Technology for Composite Materials.- 1.3 References.- 2. The State of the Art in Fusion Bonding of Polymer Composites.- 2.1 Introduction.- 2.2 Traditional Technologies.- 2.2.1 Mechanical Fastening.- 2.2.1.1 Bolted/Riveted Joints.- 2.2.1.2 Integral Fit Joint Technology.- 2.2.2 Adhesive Bonding.- 2.2.3 Solvent Bonding.- 2.3 Fusion Bonding Technology.- 2.3.1 Introduction.- 2.3.2 Fusion Bonding Techniques.- 2.3.2.1 Bulk Heating.- 2.3.2.2 Fractional Heating.- 2.3.2.3 Electromagnetic Heating.- 2.3.2.4 Two-stage Techniques.- 2.4 Joining of Dissimilar Materials.- 2.4.1 Introduction.- 2.4.2 Metal Substrates.- 2.4.2.1 Surface Preparation.- 2.4.2.2 Fusion Bonding of TPMCs and Metal Substrates.- 2.4.3 TSMC Substrates.- 2.4.3.1 TP Hybrid Interlayer.- 2.4.3.2 TP Film Co-cure.- 2.5 Comparative Assessment.- 2.5.1 Joint Performance.- 2.5.1.1 Strength.- 2.5.1.2 Durability.- 2.5.2 Process Performance.- 2.5.2.1 Cost and Processing Time.- 2.5.2.2 Quality.- 2.5.2.3 Suitability to Automation/Production Environment.- 2.5.2.4 Minimal Surface Preparation.- 2.5.3 Process Adaptability.- 2.5.3.1 Flexibility.- 2.5.3.2 Large-scale Joining.- 2.5.3.3 Portability/Application to Repair.- 2.5.4 Environmental Aspects.- 2.5.4.1 Reprocessing/Recycling.- 2.5.4.2 Environmental Friendliness.- 2.6 Concluding Remarks.- 2.7 References.- 3. Heat Transfer in Fusion Bonding.- 3.1 Introduction.- 3.2 Heat Generation.- 3.2.1 Ultrasonic Welding.- 3.2.2 Induction Welding.- 3.2.3 Resistance Welding.- 3.2.3.1 Joule Heating.- 3.2.3.2 IRW.- 3.3 Heat Transfer.- 3.3.1 Modelling the Geometry through the FEM.- 3.3.2 Heat Transfer Theory.- 3.3.3 Modelling of Interfaces Between Plies.- 3.3.4 Non-uniform Heating.- 3.3.5 Improvement of Heat Transfer in Penetration Area.- 3.4 Modelling Thermal Degradation.- 3.4.1 Approximation of Thermal Degradation.- 3.4.2 Thermal Degradation Kinetic Model.- 3.5 Aspects Influencing Heat Transfer in Resistance Welding.- 3.5.1 Material Properties.- 3.5.2 Basic Results for Heat Transfer.- 3.5.3 Effect of Latent Heat.- 3.5.4 Effect of Rough Contact Surfaces.- 3.5.5 Non-uniform Heat Generation in Resistance Welding.- 3.6 Simulations of Resistance Welding.- 3.6.1 Temperature Uniformity in Welding Interface.- 3.6.2 Processing Windows.- 3.6.3 Heat Transfer to Laminate.- 3.6.4 IRW.- 3.6.4.1 In-air HE.- 3.6.4.2 Embedded HE.- 3.7 Concluding Remarks.- 3.8 References.- 4. Consolidation Mechanisms.- 4.1 Introduction.- 4.2 Basic Mechanisms for Fusion Bonding.- 4.2.1 Consolidation Mechanisms.- 4.2.2 Intimate Contact Model.- 4.2.3 Autohesion Model.- 4.2.4 Non-isothermal Bonding Process.- 4.3 Simulations of Consolidation for Resistance Welding.- 4.3.1 Material Properties.- 4.3.2 Effect of Surface Roughness on Intimate Contact.- 4.3.3 Processing Windows.- 4.3.4 Effect of Consolidation Pressure on Intimate Contact.- 4.3.5 IRW.- 4.3.5.1 Simulations of Consolidation.- 4.3.5.2 Comparison with Experimental Data.- 4.4 De-consolidation Phenomenon.- 4.5 Concluding Remarks.- 4.6 References.- 5. Crystallisation Kinetics.- 5.1 Introduction.- 5.2 Description of Crystallisation Kinetics and Crystal Melting Kinetics Models.- 5.2.1 Ozawa's Crystallisation Kinetics Model.- 5.2.2 Velisaris and Seferis' Crystallisation Kinetics Model.- 5.2.3 The Choe and Lee Crystallisation Kinetics Model.- 5.2.4 Icenogle's Crystallisation Kinetics Model.- 5.2.5 The Maffezzoli et al. Crystal Melting Kinetics Model.- 5.3 A Transient Crystallinity Model for Resistance Welding.- 5.4 Simulations of the Crystallinity Level.- 5.4.1 Crystallisation Kinetics.- 5.4.2 Crystallisation Kinetics Coupled with Crystal Melting Kinetics....- 5.4.3 Influence of Environmental Temperature.- 5.4.4 Influence of Latent Heat of Crystallisation and Crystal Melting....- 5.4.5 Evaluation of the CF-PP/PP Welding Configuration.- 5.5 Concluding Remarks.- 5.6 References.- 6. Processing-Microstructure-Property Relationship.- 6.1 Introduction.- 6.2 Experi