The Mechanical Performance of Resistance Welded Thermoplastic Composite Double Overlap Joint Tested Under Static and Fatigue Loading

ABSTRACT The results of testing resistance welded joints using double lap shear (DLS) specimens are presented. The welded joints of polyetheretherketone reinforced with carbon 5‐harness satin weave (CF/PEEK) were made using two steel meshes with wire diameters of 0.04 mm and 0.1 mm. Additionally, the impact of welding with thin glass fabric (48 gsm) as an electrical insulator on joint strength was investigated. The specimens with selected process parameters were then fatigue‐tested at various percentages of their static shear strengths at a load ratio R = 0.1 and frequency f = 10 Hz. The performances of resistance welded DLS‐B specimens were compared with the current state of art, especially in the context of the use of SLS specimens. The failure modes of the specimens were presented, and a linear stress‐life (S–N) curve was drawn and analyzed.