PARAMETRIC OPTIMISATION OF RESISTANCE WELDING THERMOPLASTICS-BASED COMPOSITES VIA COMPUTATIONAL AND EXPERIMENTAL APPROACHES

In this study, the resistance welding process for carbon fibre reinforced thermoplastic composites (FRTPC) has been parametrically investigated through simulation and experiment processes. Heat transfer of resistance welding was studied computationally to generate optimum welding parameters. By applying a transient three-dimensional heat transfer model on COMSOL Multiphysics, evolution of temperature in the joint during welding process was simulated with various combinations of power densities and clamping distances. From different combinations of parameters, two main characteristics of heat transfer were revealed, which consequently resulted in various melting degree, uniformity of temperature upon welding interface, and heat penetrating through laminates in thickness direction. Based on optimum parameters, experimental welding tests were conducted, and mechanical tests showed that lap shear strength is proportional to melting degree but is independent of thermal penetration.