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Polymer-metal-hybrid components show a high potential regarding to lightweight applications. In particular, due to their fundamental differences in chemical and physical properties, new approaches must be developed for common industrial joining processes. In this study a new approach in order to characterize the joining zone formation for thermal direct joining based on resistance spot welding is reported. The feasibility of joining in half-section set-up using a coaxial electrode arrangement was investigated. The impact of the welding parameters on the joining zone formation was investigated. The parameters influencing the melting layer formation were pointed out.