Resistance welding is an alternative process to mechanical fastening and adhesive bonding in joining thermoplastic composites. The resistance welding procedure involves the Joule heating of a heating element located between two adjoining thermoplastics. The application of heat causes the material in the interface between two surfaces to melt. The current stops then and the interfacing surfaces bound under a compaction pressure, while cooling. This results in a fusion bond between the two components. A fuzzy logic controller is designed and implemented in real-time using the temperature estimate as the feedback signal. The result is a controller capable of maintaining the weld temperature within 10% of the reference temperature.

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