Vibration-Assisted Thermal Repairing of Thermoplastic Composites

Machine, Science & engineering

UNMET NEED

Thermoplastics are becoming increasingly popular due to their recyclability and ease of processing. The thermoplastic composite market itself is valued above 30 B$ and continues to grow at 7% CARG. Sectors such as aerospace & defence, transportation or oil & gas are increasingly turning to these high-performance materials for new composite parts assembly and repair methods that align with waste reduction targets and more sustainable manufacturing and life-cycle management practices. However, welding and repairing thermoplastic parts takes time and often requires considerable skills and resources, not to mention the acquisition and maintenance of expensive equipment.

While factors like raw material costs still limit the adoption of thermoplastics, the high cost of replacing high-end composite parts compared to repair costs presents a significant opportunity. In industries like aerospace where this tipping point is commonly reached, the introduction of automated, low-cost, high-performance welding processes could drive the increased adoption of thermoplastics.

TECHNOLOGY OVERVIEW

The team led by Professor Shadmehri at Concordia University has developed a novel method for welding thermoplastic parts below their melting point. Combining oriented vibration and low external heating it induces shear thinning between the original parts and a compatible layer, acting as a strong adhesive. The advantages include preserving the original parts’ shape, mechanical properties and preventing fiber misalignment in composite materials. Laboratory results of CF-PEEK specimens demonstrated a 22% increase in lap shear strength at 25 MPa and a 35% reduction in void content, on par with high quality gluing equivalent.

By collaborating with an innovative market leader, we aim to identify the key features to tackle in order to integrate and to develop this novel repair/welding technology. This solution would elevate performance standards, minimize defects from unskilled workers, and reduce processing time, opening new business opportunities for the welding and repair of larger components without the need for costly autoclave equipment.

COMPETITIVE ADVANTAGES

Maintain part integrity (no melting)
In place operation & versatility of part size
Prevent misalignment of fiber reinforced thermoplastic
Possibility of in-field repair

BUSINESS OPPORTUNITY

Co-development partnerships for technology maturation
Admissible to research/industry government grants for technological development

MARKET APPLICATIONS

Thermoplastic & composite repair and welding
High-end aerospace parts manufacturing and assembly

IP PROTECTION

US Provisional Patent Application

CONTACTS

Farjad Shadmehri

PRINCIPAL INVESTIGATOR
Associate Professor, Department of Mechanical, Industrial & Aerospace Engineering
Concordia University

Andréa Arias

CONTACT
Director of Technology Transfer, Sciences and Engineering
C 1-514-360-3079 X 134
andrea.arias@axelys.ca