Production of Aluminium-Polymer Joints by Friction Stir Spot Welding

• Published in: Journal of Manufacturing and Materials Processing Vol. 8; no. 4; p. 179
• Main Authors: Pereira, Miguel A R, Galvão, Ivan, Costa, José D M, Amaro, Ana M, Leal, Rui M
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 01.08.2024
• Subjects: Adhesive bonding; Alloys; aluminium alloy; Aluminum; Bond strength; Clamping; friction stir spot welding (FSSW); Friction stir welding; Geometry; Joining; Locking; Mechanical properties; Metals; Morphology; Performance evaluation; pinless tool; polyamide 6 (PA6); Polyamide resins; Polymers; Polyvinyl chloride; Shear strength; Shear tests; Spot welding; Stress concentration; Welded joints
• ISSN: 2504-4494
• DOI: 10.3390/jmmp8040179

The joining of AA6082-T6 and polyamide 6 using pinless friction stir spot welding was investigated in this study. The influence of the clamping frame geometry was studied and the welds produced were characterized based on their morphology and mechanical performance. The morphological analysis was evaluated based on the comparison of the different joining areas and on the presence of defects in the resolidified layer of the polymer. In turn, the mechanical performance of the joints was evaluated by tensile-shear testing. Additionally, the influence of plunge depth parameter was studied for the clamping frame geometry providing the best mechanical performance. While the clamping frame geometry had a greater impact on the size of the joining areas, therefore influencing the micro-mechanical interlocking mechanisms, the plunge depth mainly affected the plunging of the aluminium into the polymeric material, therefore affecting the macro-mechanical interlocking mechanism. The strongest joints, which failed for a load of about 2700 N, were produced with the clamping frame geometry that restricted the welding zone the least, and used the highest plunge depth.