Resistance Welding of Elium(R) and LMPAEK(TM) based thermoplastic composites: Process-Data & Lap-Shear-Strength

Overview This dataset contains experimental data from resistance weldingexperiments performed on thermoplastic composite laminates. The datawere generated to validate a fully parametric electro‑thermalmulti‑physics modelling framework for resistance welding ofthermoplastic composites. The modelling framework simulates the electro‑thermal process usingJoule heating within COMSOL Multiphysics® and incorporates analyticalmicromodels for stainless steel and carbon fiber based heating elements.Equivalent thermo‑electric material properties are derived fromgeometry‑dependent rules of mixtures, while composite adherends arehomogenized to allow rapid adaptation to different material systemswithout extensive experimental characterization. The framework was validated experimentally using glass‑fiber reinforcedElium® laminates and carbon‑fiber reinforced low‑meltingpolyaryletherketone (Victrex LMPAEK™) laminates. Stainless steel meshesand carbon fiber fabrics were used as heating elements. Experimental measurements include: - welding machine process data(current, voltage, temperature etc.) - single lap shear (SLS) strengthmeasurements - infrared thermography measurements of the edge region(subset of experiments) The dataset supports validation of electro‑thermal simulations andanalysis of the relationship between thermal process parameters andjoint strength. ------------------------------------------------------------------------ Experimental Setup Resistance welding experiments were performed in a single lap shear(SLS) configuration. The adherends were positioned on an aluminum tooling and consolidatedusing a welding pressure of 5 bar, applied via a pneumatic cylinder.Maintaining a homogeneous clamping pressure was essential to minimizeelectrical contact resistance and ensure a uniform current densitydistribution. To mitigate overheating near the clamping regions, an active coolingsystem was used to generate forced convection. Cooling airflow conditions: - 325 L/min - 360 L/min These correspond approximately to 1 bar and 1.25 bar systempressure respectively for both clamping regions combined. ------------------------------------------------------------------------ Temperature Measurements Thermocouple - Type J thermocouple- Diameter: 0.1 mm- Sampling rate: 1 Hz- Measurement location: weld-line core temperature Infrared Thermography - Camera: FLIR SC600 series (Teledyne FLIR, Täby, Sweden)- Sampling rate: 25 Hz- Measurement location: edge region of the weld Thermography data are available only for selected experiments. ------------------------------------------------------------------------ Data Acquisition Machine process parameters were controlled and recorded using the PLCcontroller of the welding machine. Recorded signals include: - current excitation- voltage excitation- weld pressure- thermocouple temperature Machine data provide the full time-resolved process signals required toreconstruct the welding process. ------------------------------------------------------------------------ Materials Glass Fiber Reinforced Acrylic Resin Matrix: Elium® 151/191Fiber type: glass fiberTypical fiber volume fraction: 55 % Heating elements: - stainless steel mesh - carbon fiber fabric Carbon Fiber Reinforced LMPAEK Matrix: Victrex LMPAEK™Fiber type: carbon fiberFiber volume fraction: 62 % Heating element: - stainless steel mesh ------------------------------------------------------------------------ Dataset Structure File naming convention: RW_YYMMDD_V##\_ROLE.ext Where: - YYMMDD -- experiment date - V## -- experiment index ofthat day - ROLE -- type of data Example files: RW_250221_V04_machine_data.csvRW_250221_V04_lap_shear_results.xlsxRW_250221_V13_thermography_edge_temperature.csv ------------------------------------------------------------------------ Data Types Machine Data File pattern: \*\_machine_data.csv Contains time-resolved machine process signals such as: - current -voltage - thermocouple temperature - process control signals Machine data exist for all experiments. Lap Shear Results File pattern: \*\_lap_shear_results.xlsx Single lap shear testing performed according to: DIN EN 1465 Typical parameters: - overlap length - overlap width - crosshead speed Lap shear data are available for a subset of experiments. Thermography Data File pattern: \*\_thermography_edge_temperature.csv Contains temperature-time measurements of the edge region recorded viainfrared thermography using a FLIR SC600 series camera at 25 Hz. Available only for selected experiments. ------------------------------------------------------------------------ Metadata Files The dataset includes the following metadata files: datacite.json Contains dataset-level metadata according to the DataCite schema for DOIregistration. experiments_metadata.json Contains experiment-specific metadata including: - welding parameters -heating element description - adherend material properties - filemappings Experiments with identical parameters may be grouped together. rw_metadata_schema_v1.0.json Defines the domain-specific metadata schema used in this dataset. ------------------------------------------------------------------------ Citation If you use this dataset, please cite the associated publication and thedataset DOI. Dataset DOI: 10.5281/zenodo.18875080 ------------------------------------------------------------------------ License Creative Commons Attribution‑NoDerivatives 4.0 International (CC BY‑ND4.0) https://creativecommons.org/licenses/by-nd/4.0/ ------------------------------------------------------------------------ Contact Jan Yorrick Dietrich\dietrich [AAAATTTT] faserinstitut.deFaserinstitut Bremen e.V.