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Abstract
In this paper, innovative resistance element welding (REW) technology for joining galvanized steel sheets to thermoplastics (PMMA) is introduced. The essence of the innovation is in the use of a special bimetallic joining element consisting of the core made of a Sn60Pb solder, and the sleeve made of a Cu tube. During resistance heating, the solder melts, thus allowing the formation of a metallurgical joint with galvanized steel sheet. Since Sn60Pb solder melting occurs at temperatures (from 183 to 190 °C) be-low the thermal decomposition temperature of most thermoplastics (for PMMA above 300 °C), there is no thermal destruction of the PMMA material around the joint. The mechanical fixation of the thermo-plastic material at the overlap joint is provided by the sleeve made of Cu tube which has a substantially higher strength than a Sn60Pb solder.
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