Ultrasonic Welding of PEEK Plates with CF Fabric Reinforcement—The Optimization of the Process by Neural Network Simulation

Abstract

The optimal mode for ultrasonic welding (USW) of the “PEEK–ED (PEEK)–prepreg (PEI impregnated CF fabric)–ED (PEEK)–PEEK” lap joint was determined by artificial neural network (ANN) simulation, based on the sample of the experimental data expanded with the expert data set. The experimental verification of the simulation results showed that mode 10 (t = 900 ms, P = 1.7 atm, τ = 2000 ms) ensured the high strength properties and preservation of the structural integrity of the carbon fiber fabric (CFF). Additionally, it showed that the “PEEK–CFF prepreg–PEEK” USW lap joint could be fabricated by the “multi-spot” USW method with the optimal mode 10, which can resist the load per cycle of 50 MPa (the bottom HCF level). The USW mode, determined by ANN simulation for the neat PEEK adherends, did not provide joining both particulate and laminated composite adherends with the CFF prepreg reinforcement. The USW lap joints could be formed when the USW durations (t) were significantly increased up to 1200 and 1600 ms, respectively. In this case, the elastic energy is transferred more efficiently to the welding zone through the upper adherend.