With the growing demand for lightweight and sustainable manufacturing in the aviation industry

thermoplastic composites have emerged as a major alternative to traditional metallic materials due to their high strength

recyclability

and high-efficiency forming characteristics. As a core method for the integrated assembly of thermoplastic composite components

welding technology has thus garnered significant industry attention for its advantages over mechanical fastening and adhesive bonding

including the reduction of fiber damage and enhanced structural integrity. Therefore

this paper systematically reviews the research advances and current applications of thermoplastic composite welding technologies in aviation. It focuses on the process principles

research progress

and aerospace application cases of five key techniques: Laser welding

resistance welding

induction welding

ultrasonic welding

and conduction welding. Additionally

this paper discussed future trends and research priorities for thermoplastic composite welding technologies.