Modeling and Homogenized Simulation of Metal‐Mesh Heating Elements for Resistance‐Welded Thermoplastic Composites

ABSTRACT Thermoplastic resin‐based composites, owing to their excellent mechanical properties and processability, have been widely employed in lightweight structural applications, where the performance of joining techniques directly affects structural reliability. This study predicts the electrical and mechanical performance of metal‐mesh heating elements used in resistance welding. A 304 stainless‐steel mesh was selected as the heating element, and glass fiber reinforced polypropylene (GF/PP) composite was used as the matrix system. Theoretical modeling was adopted to derive functional models for the electrical resistance and equivalent tensile performance of the mesh, which were further validated through static tensile experiments and ABAQUS finite element simulations. The results indicate that the developed resistance prediction model shows an error of less than 6%, while the mechanical performance prediction error is within 10%. The tensile response of the heating element was reasonably captured, while the apparent fracture strength showed a deviation below 15% under the present gripping condition. The findings indicate that the proposed functional models demonstrate a certain degree of prediction accuracy and engineering applicability, offering theoretical support for the design and performance optimization of thermoplastic composite resistance‐welded structures.