Poly（aryl ether ketone）（PAEK） thermoplastic composites exhibit exceptional impact resistance and possess significant application potential in the aerospace industry. To address mechanical performance limitations of PAEK composites fabricated through automated in-situ placement, this study systematically investigates the impacts of post-processing parameters-including temperature, pressure and time-on pore elimination and mechanical properties. Utilizing the automated fiber placement, PAEK prepregs are processed into laminates. A viscosity-pressure-time coupling model is formulated through differential scanning calorimetry（DSC）, rheological assessments and mechanical characterizations. The results demonstrate the model predicts reasonably pore elimination across varying process parameters and the critical post-processing temperature is identified as 340 ℃. The pore elimination is facilitated rapidly due to low and stable resin viscosity at 340-360 ℃. The post-processing pressure significantly influences pore removal efficiency, with a critical pressure of 0.7 MPa at 360 ℃ and requiring 60 min for complete pore elimination. Higher pressures lead to only marginal performance enhancements. The time dependency of material performance depends on pressure: at 0.7 MPa and 360 ℃, full pore elimination is achieved within 60 min, whereas at 1.6 MPa, the required time is reduced to 20 min. At 0.7 MPa, 360 ℃ and 60 min, the tensile strength, flexural strength and interlaminar shear strength are 2844, 1653 MPa and 103 MPa, respectively.

Thermoplastic composites（TPCs）have exhibited immense potential in aerospace applications, attributed to their exceptional toughness, weldability, recyclability, and efficient processing cycles. However, the manufacturing of complex structures is hindered by the high melting points and viscosities of their constituent resins. Resistance welding, leveraging Joule heating to induce interfacial melting and bonding, emerges as a viable alternative to mechanical fastening and adhesive bonding. This review delves into the fundamental principles underlying resistance welding, strategies for optimizing key process parameters, recent advancements in heating elements, and large-scale welding techniques, such as sequential and continuous resistance welding. The findings indicate that optimizing process parameters and improving heating elements can significantly enhance joint strength. To achieve engineering application of resistance welding technology, further research should be focused on process stability, reliability of welded joints, large-scale welding, and other issues.