Dissimilar friction stir welding between polycarbonate and AA 7075 aluminum alloy

Abstract

In this paper, the effects of process parameters, such as the tool rotational and traverse speeds, on temperature evolution and the microstructural and mechanical properties of dissimilar friction stir welding between 3 mm thick AA 7075 aluminum alloy and polycarbonate (PC) plates were investigated. The tool rotational and traverse speeds were varied from 3000 to 3500 rpm and 50 to 150 mm min−1, respectively. The joint fabricated at 3250 rpm and 100 mm min−1 yielded a highest tensile load of 586 N. Microstructural analysis of the stir zone revealed an interlock phenomenon, the transportation of AA 7075 in polycarbonate, and the absence of ceramic-type (carbide, hydride or oxide) compounds. Microhardness (HV) measurement on the weld zone showed an uneven distribution due to the complicated microstructure of the welded joint. The maximum temperatures of 164°C and 66°C were obtained at 3250 rpm and 100 mm min−1 at a distance of 5 mm away from the welding centerline in the AA 7075 and PC side, respectively.

Multi sensor based strategies for accurate prediction of friction stir welding of polycarbonate sheets

“…11 The ultimate tensile strength and elastic modulus were determined by using an universal tensile testing machine whereas the thermal properties was provided by the manufacturer which was found to be almost same as per previous works. 11,29,30 All these properties have been indicated in Table 1. The dimension of base plate was 100 mm × 100 mm × 6 mm, and friction stir butt welding experiments were performed by using a 2-ton computerized numerically controlled (CNC) FSW machine (WS004, ETA Technology Pvt.…”

Joining of dissimilar materials by friction stir welding

“…Ratanathavorn et al [30] studied the microstructures of dissimilar joint performed by FSW between aluminum alloy (AA 6111) and thermoplastic. Recently, Moshwan et al [ 31] presented details about the microstructures of dissimilar joint between polycarbonate and AA 7075 aluminum alloy obtained by FSW. However, due to different material physiology and morphology, some difficulties faced researchers on microstructures characterization of metal/polymer joint.…”

Effect of tool geometry on loads developing in friction stir spot welds of polycarbonate sheets

“…Dashatan et al [24] investigated FSSW for joining ABS with PMMA sheets. Moshwan et al [25] produced hybrid polycarbonate/AA7075 joints by FSW while Liu et al [26] joined polyamide (PA) to AA6061 by friction lap welding. Husain et al [27] optimized the processing conditions for joining PA sheets.…”