Effects of processing parameters on the characteristics of dissimilar friction-stir-welded joints between AA5058 aluminum alloy and PMMA polymer

• Published in: Welding in the world Vol. 62; no. 1; pp. 117 - 130
• Main Authors: Derazkola, Hamed Aghajani, Kashiry Fard, Reza, Khodabakhshi, Farzad
• Format: Journal Article
• Language: English
• Published: Berlin/Heidelberg Springer Berlin Heidelberg 01.01.2018; Springer Nature B.V
• Subjects: Aluminum; Aluminum base alloys; Attitude (inclination); Chemical bonds; Chemistry and Materials Science; Design parameters; Dissimilar material joining; Dissimilar materials; Friction stir welding; Lap joints; Magnesium base alloys; Materials Science; Mechanical properties; Metallic Materials; Morphology; Polymers; Polymethyl methacrylate; Process parameters; Research Paper; Solid Mechanics; Tensile strength; Theoretical and Applied Mechanics; Welded joints; Tilt angle; AA5058; Friction-stir welding; Dissimilar joint; PMMA; Plunge depth
• ISSN: 0043-2288; 1878-6669
• DOI: 10.1007/s40194-017-0517-y

In this research, newly modified solid-state friction-stir welding (FSW) technology was employed to bond the sheets of an aluminum-magnesium alloy (AA5058) and poly-methyl-methacrylate (PMMA) in a lap-joint design. Effects of processing parameters including tool rotational speed ( w ), traverse velocity ( v ), tilt angle and plunge depth on the surface morphology, materials flow pattern, microstructural characteristics, and mechanical properties of the dissimilar FSWed joints were studied. The geometry of U-antler macro-mechanical interlocking and interfacial micro- and nano-scale chemical bonding was mainly controlled by the tool tilting angle. A sound dissimilar weld with the highest tensile strength of around 45 MPa was attained at an optimum working window containing w  = 1600 rpm, v  = 25 mm/min, tool tilt angle of 2°, and plunge depth of 0.2 mm. Fracture of dissimilar lap joints occurred during transverse tensile-shear testing from the weld-polymer interface with a maximum strength ratio of ~ 60% by detachment of aluminum U-antler from the solidified polymer.