Active Metal Joining of Thermoplastic Matrix Composites

Joining of thermoplastic matrix composites to form large panels in strucutrs by fastening, adhesive bonding or resistance induction welding produces joints that can be the "weak link" resulting in failure. A hybrid technique involving a laser beam will be studied in this Phase I effort. The objective of this research is to metallurgically join thermoplastic matrix composites such as PEEK reinforced with AS4, or IM 7/IM 8 fibers using a rapid thermal processing (RTP), active-metal alloy technique. These composites are expected to be used in several modules and components such as fenders, doors, structural panels in automobiles and package housings for the electronics in many commercial and defense systems. The joints produced using these methods are expected to be sound and result in components with high structural intgrity. Destructive tests are proposed in Phase I to evaluate the joint quality and performance. This method would allow for the introduction of intelligent manufacturing systems that could facilitate the rapid production of large sized panels/joints at low costs. In Phase II, further refinement of the processing parameters is expected so that scale up to commercialization would be feasible.