Resistance welding of thermoplastic composites using novel heating element of graphite film

The application of thermoplastic composites has advanced structural lightweight, necessitating effective methods for achieving stable joints. In this study, a laser-ablated graphite film was developed as a novel heating element, introducing an innovative approach to the resistance welding of carbon fiber-reinforced polyamide 66 (CF/PA66) thermoplastic composites. Systematic experiments and analyses verified the performance of the graphite heating element in providing uniform heat and efficient welding during the process. Through systematic experiments and analysis, the graphite heating element demonstrated uniform heat generation and high welding efficiency. The use of this heating element enhanced resin flow and improved the temperature distribution uniformity at the welding interface. Moreover, it eliminated the need for dissimilar metallic materials, thereby reducing stress concentrations and minimizing edge effects during the welding process. This novel heating element shows great potential for resistance welding of thermoplastic composites, offering a groundbreaking solution for joining high-performance and lightweight structures.