Effects of Welding Parameters and Film Thickness on the Joint Performance of CF/PA6 Resistance Welding with Perforated Stainless-Steel Mesh

Thermoplastic composite resistance welding boasts stable process, low cost and reliable quality, making it a dependable joining technique for such materials. This process employs a heating element (HE) as the sole heat source and therefore, it is critical in controlling the welding process. This study proposed a perforated stainless-steel mesh (SSM) as the HE and investigated the effect of welding parameters and insulation film thickness on the joint performance of resistance welded carbon-fiber-reinforced polyamide 6 (CF/PA6). The results showed that the joint lap shear strength (LSS) increased first then decreased as the welding pressure, welding time and welding current increased. The maximum LSS reached 24.4 MPa when 0.2-mm-thick films were used. The joint failure mode was identified as blocky fiber peeling with compromised fiber continuity for the joints welded with 0.1-mm-thick and 0.3 mm-thick PA6 films. For the joints made with 0.2-mm-thick PA6 films, the joint failure mode was characterized by resin peeling from the fiber surface.