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Article

Numerical Investigation of Residual Stresses in Welded Thermoplastic CFRP Structures

1
Institute of Aircraft Design and Lightweight Structures, Technische Universität Braunschweig, Ottenbecker Damm 12, 21684 Stade, Germany
2
Institute of Production Engineering and Machine Tools, Leibniz Universität Hannover, Ottenbecker Damm 12, 21684 Stade, Germany
*
Author to whom correspondence should be addressed.
J. Compos. Sci. 2021, 5(2), 45; https://doi.org/10.3390/jcs5020045
Received: 5 January 2021 / Revised: 22 January 2021 / Accepted: 29 January 2021 / Published: 2 February 2021
(This article belongs to the Special Issue Polymer Composites and Fibers)
Using thermoplastics as the matrix in carbon fiber-reinforced polymers (CFRP) offers the possibility to make use of welded joints, which results in weight savings compared to conventional joining methods using mechanical fasteners. In this paper, the resulting temperature distribution in the material due to resistance welding is investigated by transient finite element (FE) simulations. To examine the effects on the component structure, a numerical modeling approach is created, which allows determining the residual stresses caused by the welding process. It is shown that the area of the structure, especially near the joining zone, is highly affected by the process, especially in terms of residual stresses. In particular, the stresses perpendicular to the fiber direction show failure relevant values up to a maximum of 221 MPa, which might lead to the formation of microcracks in the matrix. In turn, that is assumed to be critical in terms of the fatigue of welded composite structures. Thus, the suggested modeling approach provides residual stresses that can be used to determine their effects on the strength, structural stability, and fatigue of such composite structures. In a subsequent step, these findings could play an important role in the design process of thermoplastic composite structures. View Full-Text
Keywords: resistance welding; finite element modeling; residual stress; thermoplastics; polymer–matrix composites (PMCs); thermomechanical behavior resistance welding; finite element modeling; residual stress; thermoplastics; polymer–matrix composites (PMCs); thermomechanical behavior
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MDPI and ACS Style

Nagel, L.; Herwig, A.; Schmidt, C.; Horst, P. Numerical Investigation of Residual Stresses in Welded Thermoplastic CFRP Structures. J. Compos. Sci. 2021, 5, 45. https://doi.org/10.3390/jcs5020045

AMA Style

Nagel L, Herwig A, Schmidt C, Horst P. Numerical Investigation of Residual Stresses in Welded Thermoplastic CFRP Structures. Journal of Composites Science. 2021; 5(2):45. https://doi.org/10.3390/jcs5020045

Chicago/Turabian Style

Nagel, Lukas, Alexander Herwig, Carsten Schmidt, and Peter Horst. 2021. "Numerical Investigation of Residual Stresses in Welded Thermoplastic CFRP Structures" Journal of Composites Science 5, no. 2: 45. https://doi.org/10.3390/jcs5020045

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