Development of Joining Methods of Thermoplastic Composites for Aerospace Applications

Fiber-reinforced thermoplastic matrix composite laminates pose great potential for current and future aircraft components. Thermoplastic composites' recyclability, long shelf life, resistance to environmental conditions, and high toughness properties are rapidly increasing their application areas. In addition, its environmental hazardous is much lower compared to thermosets. Thermoplastic composites have gained an important position in aviation due to these properties. In this study, some joining methods that can be used for a thermoplastic matrix composite aircraft structure have been experimentally examined. The methods were compared by performing a single lap shear test (ASTM D5868) at the coupon level. In addition, details about a novel ultrasonic welding machine that performs the welded joining method are also given. Results show that the joint strength of thermoplastic composites can be tailored by the chosen method and corresponding parameters.