This paper presents a comprehensive experimental study on the thermal aspects in resistance welding of thermoplastic composites. A special test set-up was developed to perform the experiments. Glass fiber reinforced polyetherimide was the material used for manufacturing the welding specimens. Stainless steel mesh was used for production of heating elements. The temperature distribution was monitored using type-K thermocouples connected to a data acquisition system. The main objective of the study was investigating a possible solution for the edge effect. Temperature profiles over the weld length and over the weld width were monitored. The focus was on the transient temperature profiles at the edges of the weld. The temperature distribution through the weld thickness was also monitored. The influence of factors like insulation and power level was investigated. Finally, conclusions are drawn and options for improving the temperature distribution and modification of the models are being discussed.

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