Simulating the induction welding process of thermoplastic composite materials for aircraft structures

Purpose This paper aims to use two different numerical approaches to simulate the induction welding process for a hybrid thermoplastic material, and the results have been validated experimentally. Design/methodology/approach The first approach used a numerical model that combines electromagnetism, heat transfer and solid mechanics in the same numerical environment using Hexagon Marc software. Simultaneously, a computationally efficient approach combined steady-state electromagnetism results at specific intervals in the Ansys EM suite with heat transfer and solid mechanics in Ansys Workbench. Findings The results from both numerical approaches showed a strong correlation with the experimental findings. Originality/value The current research offers valuable insights into enhancing induction welding procedures within the aerospace industry, as well as across broader industrial applications. The synergistic combination of numerical simulations and experimental validation served as a robust framework for future research endeavors aimed at enhancing the efficiency, reliability and quality of thermoplastic welding techniques.