Characteristics of resistance welding of lap shear coupons.: Part II. Consolidation

A consolidation model based on transient three-dimensional heat transfer for the resistance welding of thermoplastic-matrix composite lap-shear specimens is established. The consolidation occurring in the resistance welding process was studied in terms of intimate contact and autohesion processes. Effects of power level on the time to achieve full intimate contact were determined. The influence of the consolidation pressure on the degree of intimate contact was investigated. Different welding configurations of lap-shear specimens were evaluated, i.e. APC-2 laminate/PEEK film, APC-2 laminate/PEI film and CF–PEI laminate/PEI film. The bonding time was compared with experimental electrified times, and close agreement was obtained. Local thermal degradation in the heating element was discussed for high power levels. A processing window for the CF–PEI/PEI configuration was established, which showed close agreement with that determined experimentally.