This review paper presents the current progress in the development of resistance welding techniques for thermoplastic composites, with a particular emphasis on their application in hybrid joints, such as those involving thermosetting composites and metals. Resistance welding, a fusion bonding method, offers significant advantages over adhesive bonding and mechanical joining by eliminating the need for additional adhesive materials and enabling integration into automated manufacturing processes. The study highlights the unique benefits of resistance welding, including lower energy consumption compared to other methods and its compatibility with automated manufacturing, which can reduce production costs by up to 40%. Key findings from the literature indicate that resistance welding is particularly effective in achieving strong, durable joints for complex and large structures, such as those used in the aerospace industry. The review also identifies the main challenges associated with resistance welding, including temperature control, current leakage in carbon-fiber-reinforced polymers, and potential corrosion when using metal meshes. To address these challenges, various strategies are discussed, including surface treatments, the use of nanocomposites, and the integration of carbon nanotubes. The review concludes by emphasizing the need for further research to optimize welding parameters and to develop non-destructive testing methods for industrial applications, ensuring the reliability and long-term performance of welded joints.

Carbon fibre-reinforced polymers (CFRPs) are commonly used in aviation, automotive and renewable energy markets, which are constantly growing. Increasing the production of composite parts leads to increased waste production and a future increase in end-of-life components. To improve the recyclability of CFRPs, new materials that fit in with the idea of a circular economy should be used as a composite matrix. One such material is a commercially available thermoplastic liquid resin, Elium® (Arkema, France). In this work, the authors investigated how the mechanical recycling process affects the properties of thermoplastic-based carbon fibre composites. CFRPs with neat Elium® resin and resin modified with 0.02 wt.% single-walled carbon nanotubes or 0.02 wt.% multi-walled carbon nanotubes were manufactured using the resin infusion process. Afterwards, prepared laminates were mechanically ground, and a new set of composites was manufactured by thermopressing. The microstructure, mechanical, thermal and electrical properties were investigated for both sets of composites. The results showed that mechanical grinding and thermopressing processes lead to a significant increase in the electrical conductivity of composites. Additionally, a sharp decrease in all mechanical properties was observed.