研究了制造工艺对电阻焊热塑性复合材料皮芯结构元件设计和性能的影响。制造结果集中于热塑性塑料芯的固结，以及使用双聚合物粘合技术将芯电阻焊接到面板上。焊接石墨/PEEK热塑性复合材料的实验研究表明，接头强度对非等温过程历史极其敏感。性能结果包括结构元件的弯曲试验和用于量化设计允许值的试件试验。展示了一种设计方法，该方法将传统应力分析与非等温过程模型结合起来，预测蒙皮/核心结构的性能，以获得接头强度允许值。

THE INFLUENCE OF MANUFACTURING ON THE DESIGN AND PERFORMANCE OF RESISTANCE WELDED THERMOPLASTIC COMPOSITE SKIN/CORE STRUCTURAL ELEMENTS IS INVESTIGATED. MANUFACTURING RESULTS FOCUS ON THE CONSOLIDATION OF THERMOPLASTIC CORES AND THE RESISTANCE WELDING OF THE CORE TO THE FACE SHEETS USING DUAL POLYMER BONDING TECHNOLOGY. EXPERIMENTAL STUDIES ON WELDING GRAPHITE/PEEK THERMOPLASTIC COMPOSITES HAVE SHOWN THAT JOINT STRENGTH IS EXTREMELY SENSITIVE TO THE NON-ISOTHERMAL PROCESS HISTORY. PERFORMANCE RESULTS INCLUDE FLEXURAL TESTING OF STRUCTURAL ELEMENTS AND COUPON TESTS TO QUANTIFY DESIGN ALLOWABLES. A DESIGN METHODOLOGY IS DEMONSTRATED THAT PREDICTS THE PERFORMANCE OF THE SKIN/CORE STRUCTURE THAT COMBINES TRADITIONAL STRESS ANALYSIS WITH A NON-ISOTHERMAL PROCESS MODEL FOR JOINT STRENGTH ALLOWABLES.