Thermoplastic Resistance Welding for Complex Interfaces

Abstract

This study presents an experimental campaign focused on the adaption of the resistance welding process for complex shaped welding interfaces. The resistance welding process uses a conductor (called welding element) to melt the interfaces of two welding partners when applied with electrical power. The baseline welding element consists of a carbon fiber fabric. By using carbon fiber fabrics, the welding interfaces are limited to rectangular shapes. To enable unrestricted design freedom this study investigates novel conductors based on single carbon fiber rovings. As quality criteria the temperature homogeneity of the new welding elements was analysed as well as the reproducibility of the initial resistance. Welds were performed on the base of single lap shear configurations. The joints were inspected by water coupled phased array ultrasonic and microcuts as well as mechanically tested. The adapted welding process serves as a technology to manufacture complex stiffened structures and enable thermoplastic repair strategies.