ArticleMaterials (Basel, Switzerland)2025
Analysis of Thermally Induced Residual Stress in Resistance Welded PC/CF Composite to Aluminum.
Article in Materials (Basel, Switzerland), 2025. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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6 authors.
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Abstract
Thermoplastic composites are growing in popularity in the aerospace and automotive industries; they enable weldable and recyclable structures. Resistance welded hybrid thermoplastic and metal joints are attractive for rapid assembly, but the thermal mismatch between metals and polymers introduces residual stresses, which can drive edge debonding and compromise durability. This study presents fabricated single-lap PC/CF-Al7075 coupons with measured mid-span bow resulting from welding, evaluated bond quality by step-heating thermography, and an evaluated framework for residual stress prediction using Ansys complemented by a bimetal analytical check. Three thermal cycles were examined with different temperature gradients (200, 220, 240 °C): the measured bow was 16.5 mm and remained constant, whereas analytical calculation increased with ΔT similarly to the FEM prediction. The current FEM under predicted the bow (Mean Absolute Percentage Error is 21%), showing stress contours that decay with distance from the bond and revealing pronounced peaks in both σ
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