High power ultrasound was used in order to mould thermoplastic composites in a process including the simultaneous fibers impregnation and plies consolidation. An experimental equipment, made of an ultrasonic device implemented on a filament winding machine, was developed. During winding, a titanium horn is put in contact with thermoplastic layer and its melting point is reached. Several cylindrical speciments were fabricated and their physical, mechanical and morphological properties were investigated. Temperature field obtained during in-situ consolidation through heat generated by ultrasonic waves propagation was modeled using finite element (FE) analysis in order to optimize process parameters
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