An investigation of the resistance welding between carbon fiber (CF) rein-forced polyetherimide (PEI) and aluminium substrates (7075-T6 grade alloy) is presented. A three-dimensional transient finite element model (FEM) featuring heat transfer, consolidation and thermal degradation was used for simulating the process. Two mechanisms are distinguished in the consolidation model: (1) removal of the initial surface profile of the laminate modelled by the establishment of intimate contact between the two substrate surfaces and (2) penetration of the thermoplastic (TP) polymer in the micro-pores of the aluminium oxide surface modelled using a capillary flow model. The “optimal” welding time based on the maximum lap shear strength (LSS) was determined for various power levels and correlated to the bonding time predicted by the FEM. Consolidation quality and failure mechanisms were discussed in relation to processing parameters. The effect of the welding operation on overaging (annealing) of the aluminium alloy also was investigated. Experimental and simulated processing windows were constructed and correlated to each other. However, thermal degradation of PEI as predicted by the model did not correlate to a reduction in performance of the joint.
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