On the capabilities of static resistance welding of carbon fiber-reinforced thermoplastic composites

Abstract

Welding technologies for the assembly of carbon fiber-reinforced thermoplastics offer enormous potential for the production of fast, reliable and material-compatible joints forming an integral assembly. Static resistance welding is one of the most mature and yet often underestimated joining technologies for thermoplastic composites. Extensive research has been carried out to increase the robustness, reliability and range of applications of the static resistance welding process based on a carbonfiber heating element. The potential of the technology has been demonstrated on a full scale in the assembly of aerospace components. In this publication, we focus on the process capabilities and discuss the possibilities of preferential weld seam formation, weld continuity, mechanical performance, advanced process control capabilities and applicability for aircraft production. We take an application-related approach on maturing the technology.