Research Output
Microwave welding with SiCNW/PMMA nanocomposite thin films: enhanced joint strength and performance
Microwave welding of thermoplastic using silicon carbide nanowhiskers as susceptor effect of heating duration
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Publication
Most previously reported susceptors for microwave welding are in powder form. In this study, a thin-film susceptor was employed due to its uniform heating rate and ease of handling. Silicon carbide nanowhisker (SiCNW) were incorporated into a poly(methyl methacrylate) (PMMA) matrix to create a nanocomposite thin film, which served as the susceptor. The microwave welding process involved three straightforward steps: fabrication of the PMMA/SiCNW nanocomposite thin film, application of the nanocomposite film to the target area, and subsequent microwave heating. Upon cooling, a robust microwave-welded joint was formed. The mechanical properties and microstructure of the welded joints were characterized using single-lap shear tests, three-point bending tests, and scanning electron microscopy. Results demonstrated that the shear strength and elastic modulus of the welded joints were optimized with increased heating time and SiCNW filler loading. This optimization is attributed to the formation of a SiCNW-filled polypropylene (PP) nanocomposite layer of increasing thickness at the welded joint interface. However, the incorporation of SiCNW also constrained the mobility of the PP chains, reducing the joint’s flexibility. Furthermore, the welded joint formed with the PMMA/SiCNW nanocomposite thin-film susceptor exhibited an 18.82% improvement in shear strength compared to joints formed with a powdered SiCNW susceptor. This study not only demonstrates the potential of PMMA/SiCNW nanocomposite thin films as efficient susceptors for microwave welding but also paves the way for developing high-performance polymer-based composite joints with improved mechanical properties for applications in the automotive, aerospace, and construction industries.
Publication
Microwave welding is becoming more popular than conventional joining methods due to its advantages such as rapid and localised heating as well as applicable to components with complicated geometry. Previously reported susceptor, such as carbonaceous materials and conductive polymers, are toxic and the welding process involving these susceptors is time-consuming. Because of its exceptional microwave absorption and biocompatibility, silicon carbide nanowhiskers (SiCNWs) was employed as the microwave susceptor for microwave welding. Microwave welding in this study comprises of only three simple steps: SiCNWs suspension preparation, SiCNWs application and microwave heating. The weld strength of welded joint was then characterised using tensile test and energy dispersive x-ray spectroscopy equipped scanning electron microscopy (EDS-SEM) to study its mechanical properties and cross-section microstructure. The influence of microwave irradiation time was studied in this study, and it is found that the weld strength rose with the extension of microwave irradiation time, until a maximum weld strength of 1.61 MPa was achieved by 17 s welded joint. The development of SiCNWs reinforced PP nanocomposite welded joint layer is responsible for the enhanced weld strength. Prolonged heating duration may also result in flaws such as void formation at the welded joint, which subsequently lowered the weld strength to 0.60 MPa when the heating duration was extended to 20 s. In sum, a strengthen welded joint can be formed with rapid microwave heating under the proper control of heating duration.