One-, two- and three-dimensional transient heat transfer finite element models are developed to simulate the resistance welding process of pre-consolidated unidirectional AS4 carbon fibre reinforced Poly-ether-ether-ketone (APC-2/AS4) laminates with a metal mesh heating element, in a lap-shear configuration. The finite element models are used to investigate the effect of process and material parameters on the thermal behaviour of the coupon size welds, yielding to a better understanding of the process. The 1-D model determines: (a) the importance of including the latent heat of PEEK, and (b) the through-thickness temperature gradient away from the edges, for different tooling plate materials. The 2-D model simulates the cross-section of the process, considering the convective and irradiative heat losses from the areas of the heating element exposed to air. The 3-D model includes the heat conduction along the length of the laminates, to fully depict the thermal behaviour of the welds. Finally, the models are compared with experimental data.

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