Experimental characterisation and statistical modelling of woven carbon fibre weld conductors for electrical resistance welding of thermoplastic composites

Abstract

Resistance welding of high-performance thermoplastic composites is a promising joining technique for the structural assembly of aerospace components. Knowledge of the weld conductor resistance as a function of its dimensions, as well as external boundary conditions such as contact preparation and pressure, can be used to scale welding parameters. This paper presents a comprehensive review on the weld conductor contact preparation, length, width and contact pressure dependent resistance with respect to the Toray 5HS T300JB carbon woven prepreg 281 gsm fibre architecture. The study is based on a 4-wire resistance measurement of the carbon fibre fabric weld conductors and was conducted to provide a solid basis for defining the weld conductor’s resistance, considering the dependence on length, width and contact pressure. The experimentally determined resistance values were approximated using linear and non-linear regression functions and combined into a general formulation with respect to the investigated carbon fibre fabric architecture. The least squares fit of experimental versus model data confirmed a very high model confidence. Thus, the model allows a simplified transfer of electrical properties for process pre-design and scaling considering weld conductors with the same fibre architecture.