Processability of Bindered Dry-Fibre Tapes in Ultrasonic Spot Welding and Double Diaphragm Forming for High-Volume Manufacturing

This book addresses key challenges in achieving reliable and cost-efficient manufacturing of carbon fibre composite structures. It leverages automated preforming and forming technologies for unidirectional bindered dry-fibre tapes, enabling scalable production of lightweight components for aerospace and automotive applications. The core is the systematic evaluation of Ultrasonic Spot Welding as a rapid, repeatable, and energy-efficient method for tape fixation. Upon analyzing the influence of material characteristics and processing parameters on lap shear strength and preform quality, the book presents the Double Diaphragm Forming approach as a near-net-shape, resource-efficient forming method, with particular emphasis on tape friction interface behavior, and the mitigation of bridging effects and forming defects. By combining rigorous experimental investigation and a process-oriented analysis, this work provides novel insights into material selection and forming optimization. It also establishes a foundation for high-volume sequential dry-fibre tape preforming, thus contributing to the advancement of next-generation lightweight composite manufacturing. The research described in this book was carried out as a joint PhD work between Swinburne University of Technology, Australia, and University of Stuttgart, Germany.