COMPOSITE INDUCTION WELDING EQUIPMENT

Through partnership with CETMA and SYNERGO from Italy we worked together in the maturation of Induction Welding as a joining technique for thermoplastic composite parts. The technology outstands as one of the more consistent for joining parts taking advantages of thermoplastic resins properties, thus avoiding the use of rivets or other mechanical joints. Now after research projects, for example, like welding a keel beam aircraft structure, welding rotorcraft structural parts or welding door frames aircraft structures, we are ready to offer you a comprehensive package so you can do your own way, discover the power of use induction welding, in terms of automation, cost effectiveness, weight reduction and strength results. Whether you need to develop from scrap or start a serial production qualification, we can provide a solution for you. We adapt to be you partner all the way form application development to supply of the hardware systems full of data processing for your data science implementation toward continuous improvement. This approach will be extremely useful for you to implement Digitization and Digitalization in your company.

OUR PARTNERS:

Induction Welding
Induction Welding

AFFORDABLE COMPOSITE JOINING WITHOUT RIVETS
The Technology:
 Induction Welding for joining composite parts

Sectors: Aeronautic, Space, Automotive, Naval, Wind Energy, Hydrogen Systems, ...

It uses inductive heating for melting down polymer matrix in the joining zone. The components to be welded are submitted to an alternating electromagnetic field with a frequency around five hundred KHz. When there are electrically conductive loops in the component, e.g., due to carbon fiber reinforcement, eddy currents are induced, resulting in efficient, localized heating of the laminate.

When the part is made with glass fiber reinforcements which are electrically non-conductive, extrinsic electromagnetic susceptors, e.g. metal grids, must be incorporated to the composite array to convert the magnetic energy into thermal energy.                

In the case of ferromagnetic materials, hysteresis effects contribute further to heating. The heating is based on two mechanisms, namely, the energy dissipation due to Joule heating and energy dissipation due to magnetic hysteresis. The heat generation is described by the equation Q = I * I * R * t => Q = Heat; I = Current; R = Resistance; t = time.

CHARACTERISTICS OF INDUCTION WELDING : 

  • Fast and clean process.

  • Can be applied to complex geometries with irregular contoured surfaces.

  • Weld can be re-opened by induction re-heating which makes it possible to open an assembly for internal repair, part replacement, and repair defective welds. 

  • With right parameters it delivers high values of G1c and SLS values

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Induction Welding Solutions: 3 Axis compact machine for flat shapes or 6 degree of freedom robotic system for extraordinarily complex shapes

Sectors: Aeronautic, Space, Automotive, Naval, Wind Energy, Hydrogen Systems, ...

The supplied solutions are all automatic machines for welding


Composites parts with following characteristics:

  • Welding area: Up to 1 x 1 m for compact; Robot model dependent for robotic arm)

  • Electromagnetic induction patented system.

  • Suitable for:

    • Thermoplastics welding

    • Thermosetting materials joining

    • Heat activated glue bonding

    • Joining of several materials, as carbon fiber composites and aluminum​

Systems allow allows to get extremely high mechanical properties of the joint, without drawbacks typical of other welding techniques (no need of metallic mesh between parts to be welded).​

Pieces can be reworked or repaired; no special environment is required to operate. Immediate equipment turns on - turn off and exceptionally low power comsumption.

Machines are result of our research for an innovative process and a new generation of equipment for welding of composites. They are designed based on computer Electrophysics simulations FEM, laboratory test and measurement of mechanical proprieties of welded parts, noting high values of mechanical and fatigue resistance.

With ouir partners we supply the full comprehensive solution as follows: support, knowledge, specialized laboratory, competence to evaluate any specific requirement and business intelligence market approach. together with the focus on Data Science and predictions for total quality system.

We supply solutions adapting to your needs. Let us know your application!

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Main specifications of compact system:

Gantry machine
Controlled e.g. induction heating and cooling
Digital control of applied force and process temperature by optical pyrometer or camera
3 x NC axis movement. X-Y strokes: 1000 mm Z stroke: 250 mm
PLC Motion control
User friendly HMI interface

LAN & USB socket

Software License panel PC Windows

ELECTRICAL AND SUPPLIES :

  • Main supply: 3x400 Vac 50-60Hz

  • 3 poles + GND socket 32A CEE IEC309

  • Power consumption: max. 10 Kva

  • Compressed air 6Kg/cm2 connection

Example of assemblies welded with our Induction Welding solutions

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