Abstract
Thermoplastic composites enable weldable, recyclable aircraft structures, but thermal mismatch between metals and polymers can introduce detrimental residual stresses. This study develops a finite element method (FEM) framework to predict residual stress fields in resistance-welded joints between aluminum 7075 and carbon-fiber-reinforced polyamide 6 (PA6). Transient thermal analyses with multilinear, temperature-dependent properties were coupled to mechanical analyses; contact conditions transitioned from frictional to bonded at PA6 melting. Three thermal cycles (20°C→220°C→20°C, 20°C→240°C→20°C, 20°C→260°C→20°C) were examined to assess peak-temperature effects. The simulations show stress contours that decay with distance from the bond and reveal pronounced peaks in both normal and shear components at weld edges, consistent with shear-lag theory. Within the bonded interior, average stresses are relatively low, whereas edge concentrations identify likely sites for debonding or delamination initiation. The magnitude of residual stresses increases with thermal gradient, underscoring the need for parameter control during welding. The FEM outputs will be validated against uniaxial tension and three-point bending tests on welded specimens, with future work quantifying fatigue-life reduction under combined thermal and mechanical cycling. The results highlight mitigation priorities for bonded repairs and hybrid aerospace structures, including process-curve tuning (current/pressure/cooling) and edge-region design measures.