Investigation of the fibre type influence on the energy desnity of the induction heating process through a semi-analytic method

Thomas Forstner, Christof Sommitsch, Fabian Fischer

Research output: Chapter in Book/Report/Conference proceedingConference contribution


The study investigated the induction welding of carbon fibre-reinforced Polyamide 66 with different types of carbon fibres
and fabrics. The major scope of the study was the plastification of the thermoplastic matrix as the first process step of the
continuous induction welding. A new semi-analytic method was created to simulate the dependence of the plastification
parameters (induction coil, power, weld velocity and coil-workpiece distance) on the fibre and fabric. Numerical and physical
methods of Duhovic [1] and Velthuis [2] were used to investigate the complete process of plastification and consolidation. This
kind of simulation uses the principle of the finite element method (FEM) [1]. The calculated results are strongly influenced on the
one hand by the simplification of the thermal conductivity of the fibre and the matrix in the composite material (constant shape
value, constant beam value) and on the other hand by the parameterization of the heat source.
The semi-analytic method uses the radial basic function and the physical correlation between the thermal losses and the
induced eddy currents at the electric conductive carbon fibers for the calculations. The calibration of the tool was done by testing
a series of plastification parameters for different kinds of fibre and fabrics. In-situ temperature measurements through
thermocouples and pyrometer were carried out for the melt zone in addition to destructive testing of the resulting joint.
Yarlagadda [3] and Ahmed [4] have investigated the induction heating of carbon fibres and have shown three kinds of heating
mechanisms: Joule loss/fibre heating, junction heating/dielectric hysteresis heating and junction heating/contact resistance
heating. The simulation model investigated the amount of heating based on these three mechanisms.
The semi-analytic model was created to use it for weldability check of material combinations and the pre-parameter setup for
induction welding at a fully automated production system of composite automotive structural parts [5]
Original languageEnglish
Title of host publicationProcedia Manufacturing 37
Subtitle of host publicationScience Direct, Elsevier
Publication statusPublished - 2019
EventICPNS 2019: 9th International Conference on Physical and Numerical Simulation of Materials Processing - HSE Moscow Institute of Electronica and Mathematics (MIEM HSE), Moscow, Russian Federation
Duration: 10 Oct 201915 Oct 2019


ConferenceICPNS 2019
CountryRussian Federation
Internet address

ASJC Scopus subject areas

  • Materials Science(all)

Fields of Expertise

  • Advanced Materials Science

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