Fatigue performance characterisation of resistance-welded thermoplastic composites

This study investigates the fatigue performance of resistance-welded thermoplastic composites. Lap shear specimens consisting of unidirectional carbon fibre/poly-ether-imide (CF/PEI), unidirectional carbon fibre/poly-ether-ketone-ketone (CF/PEKK) and 8-harness satin weave fabric glass fibre/poly-ether-imide (GF/PEI) composites were resistance-welded using a metal mesh heating element. The specimens were fatigue-tested at various percentages of their static lap shear strengths at a load ratio R = 0.1 and frequency f = 5 Hz. The fatigue performances of resistance-welded semi-crystalline (PEKK) and amorphous (PEI) composites were compared and the failure modes of the specimens were described. The stiffness degradation was monitored during the tests in order to evaluate the damage accumulation in the specimens. Linear stress-life (S–N) curves were obtained for all three materials when plotted on a semi-log scale. Interlaminar failure modes, involving tearing of the heating element and damage to the adherends were observed. The indefinite fatigue lives of CF/PEKK and CF/PEI welded specimens were obtained at 25% of their static lap shear strengths. The indefinite fatigue life of the GF/PEI welded specimens was obtained at 20% of the static lap shear strength.