ISW [EN] | Technologies | 2021| Groupe Institut de Soudure

Innovative Solutions for Welding (ISW) of thermoplastic composites parts
Institut de Soudure Group and Arkema, in partnership with Hexcel, Latecoere and Stelia Aerospace (France) have jointly won the 2020 JEC Innovation Award for Aeronautics with their Innovative Solutions of Welding (ISW) of thermoplastic composites parts.
This solution has been co-developed by Institut de Soudure Group and Arkema respectively providing expertise in welding technology and high performance polymers.
The use of thermoplastic composites in aeronautics is a big challenge for the coming years and requires a welding technology showing good mechanical performance with cost effectiveness.
The innovation consists in the design and the set-up of a very high performance process that allows welding of any thermoplastic matrix reinforced with fiber.
The ISW is mainly dedicated to high quality joining of high performance thermoplastic (PEKK) reinforced with carbon fiber but can be applied to any other matrix (from PA to PAEK) and fiber (glass, aramid…).
ISW allows welding join coefficients of about 85% compared to raw material, without any foreign object at the welding line after operation.
ISW solution is based on the use of a susceptor that is linked to and moves with the induction coil in the welding head as well as an interface ply of unreinforced or low-fiber-volume pure thermoplastic matrix, which can be tailored per application.
The welding head generates cooling under pressure of the substrates to ensure compaction of the welding line. Temperature is sensed with a laser pyrometer which actually measures the edge of the susceptor from the side, in order to know exactly the temperature at the interface. A cooling device blowing air on the welding surface in pressure maintains this temperature below the crystallisation temperature, so there is no risk of de-compaction once pressure is released.
This innovative head with mobile susceptor is very compact to allow precise and complex access. ISW is designed to be fully automated with the welding head attached to a 6-axis robotic arm.
Key Benefits
High performance welding (join coefficient of 85% min)
Reduction of post operation (no adhesives or tapes and chemical products)
Reduction of weight
No susceptor remaining at welding join
Dynamic and fully automated/monitored solution
Ecological impact : use of recyclable material and low ernergy consumption due to a very localized heating
Can be used with any thermoplastic matrix and any fiber.

=========================
Production : Composites Expert,
Post-production : Direction Technique
==============================