Experimental and Numerical Analysis of Welded Thermoplastic Joints

Abstract

High-rate manufacturing technologies and processes are essential to meet the increasing global demand for lightweight, sustainable commercial aircraft. Thermoplastic materials play a key role in achieving this goal. Joining methods such as thermoplastic welding enable rapid part assembly and reduce the total weight of the structure due to minimal to no fasteners. As the aviation industry is exploring the potential to increasingly use welded thermoplastic structures, it is necessary to understand their structural performance under different loading conditions. Additionally, the industry’s need could also be addressed through well-established numerical modeling methodologies. Developing numerical methods validated with experimental data at the lower-mid building block level could help in predicting higher building block level experiments and eventually reduce the cost of the test matrix. In this research, welded thermoplastic joints are tested under single-lap shear loading conditions, and medium-fidelity modeling methodologies are developed to predict strength and weld failure mechanisms. These methods would eventually be used to validate welded thermoplastic structures under complex loading conditions at sub-component and component levels.