Tolerance management for resistance-welded, carbon fiber reinforced high performance thermoplastics

Abstract

This bachelor thesis investigates the potential of 3D-printed shims for tolerance compensation in welds of fiber-reinforced high-performance thermoplastics2. The aim of this work is to empirically examine the strength and quality characteristics of these joints. Thus it shall demonstrate the applicability of electrical resistance welding in combination with 3D printing technologies. The experiments show that the tensile shear strength under nearly pure shear loads is independent of shim thickness and is comparable to values found in literature. Under more complex stress conditions, the thickness of the shim significantly influences the strength. The welding process has proven to be highly reliable, with the main challenges arising from the 3D printing process. Ultimately, the combination of both technologies is a promising approach that should be invastigated further. The potential benefits for lightweight construction manufacturing are considerable