Advances in welding of poly-aryl-ether-ketone (PAEK) polymers and carbon fiber-reinforced PAEK (CF/PAEK) composites

Poly-aryl-ether-ketone (PAEK) polymers and carbon fiber reinforced PAEK (CF/PAEK) composites are widely used in high-end fields such as medicine and aerospace engineering due to their outstanding comprehensive performance. Welding is recognized as a critical enabling technology for the large-scale application of these materials. This paper systematically reviews the research progress on mainstream resistance welding, ultrasonic welding, and induction welding of PAEK-based materials. Additionally, friction stir welding with substantial application potential for PAEK-based materials is ummarized. In terms of performance outcomes, current research indicates that all the three mainstream welding technologies can achieve reliable lap shear strength with values exceeding 40 MPa. Weld quality control can be achieved by optimizing welding parameters, designing intermediate elements, and designing tooling. Future research should focus on enhancing the process adaptability for welding large-scale and complex components and developing high-efficiency, multi-functional intermediate elements, thereby promoting the further industrial application of these welding technologies.