Effects of processing temperature on failure mechanisms of dissimilar aluminum-to-polymer joints produced by friction stir welding

Correia, Arménio N.; Santos, Paulo A.M.; Braga, Daniel F.O.; Cipriano, Gonçalo Pina; Moreira, Pedro; Infante, V.

doi:10.1016/j.engfailanal.2023.107155

Cited by 13 publications

(8 citation statements)

References 23 publications

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“…From a visual inspection of the surface of the weld seams and corresponding cross-sections, a few minor defects such as voids were observed, even though those did not have a significant impact on mechanical performance. The SZ macro-morphology of these joints evidenced an appreciably different and wider SZ compared to P1, characterized by a well-defined interface between the base materials and exhibiting two pronounced concavities that induced macro-mechanical interlocking between the base materials, a morphology also observed by Correia et al [9].…”

Section: Morphology Of Jointssupporting

confidence: 70%

“…When the base materials exhibit significant physicochemical differences, such as metals and polymers, these joints fall into what can be considered a new category of dissimilarity-Group IV. In this additional category, the joinability of the base materials is even more challenging, taking into consideration their very low miscibility, weldability, and substantially different melting temperatures [9]. Until recently, mechanical fastening, such as bolting and riveting, and adhesive bonding have been the joining methods of choice to link dissimilar materials that belong to Group IV [10].…”

Section: Introductionmentioning

confidence: 99%

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Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Correia

Santos

Braga

et al. 2023

JMMP

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An engineering grade polymer—glass fiber-reinforced polyphenylene ether blended with polystyrene—and an aluminum alloy—AA6082-T6—were joined by friction stir welding in an overlap configuration. A comprehensive analysis was conducted of the effects of the tool penetration by adjusting the pin length and the process control on the joints’ mechanical performance. To this end, a series of welds with a fixed 3° tilt angle, a travel speed of 120 mm/min, and 600 RPM of rotational speed was carried out. The analysis encompassed the mechanical strength of the fabricated joints and the mechanical energy input throughout the joining processes, the resulting cross-sectional interfaces, both on macro and micro scales, and the observed defects. The quasi-static shear tensile tests resulted in average tensile strengths varying between 5.5 and 26.1 MPa, representing joint efficiencies ranging from 10.1% to 47.4%, respectively. The joints that exhibited the lowest mechanical performance were fabricated with the highest level of tool penetration (higher pin length) with the process being position-controlled, while the best performance was recorded in joints welded with the lowest tool penetration and a force-controlled process. Nonetheless, the joint welded with a 2 mm long pin and position-controlled process exhibited a mechanical strength comparable with the highest one with a significantly lower standard deviation, a promising attribute for technological industrialization. In this way, it was found that the tool penetration, controlled by adjusting the pin length, played a significant role in the development of the joints’ morphology and, consequently, mechanical performance, whereas the process control exhibited a minor influence on the mechanical performance of the joints, but a considerable effect on process repeatability.

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Section: Morphology Of Jointssupporting

confidence: 70%

Section: Introductionmentioning

confidence: 99%

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Correia

Santos

Braga

et al. 2023

JMMP

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“…The processing temperatures were measured both on the AS and RS of the joints, and the average values are listed in Table 6 . As observed by Correia et al [ 40 ] and Silva et al [ 43 ], the average processing temperature is higher on the advancing side, which is a behavior that can be explained by a more intense stirring flow on this side of the processing centerline.…”

Section: Resultsmentioning

confidence: 53%

“…Since the DoE was designed with three factors (tilt angle, rotational speed, and travel speed) and two levels, a total of eight (2 3 = 8) composite joints with different parameter settings were fabricated. The range associated with each independent variable under analysis was based on previous research carried out by Correia et al [ 19 , 40 ]. The numerical expressions that relate the joining parameters to both mechanical strength and processing temperature are expected in the form of Equation (1).…”

Section: Resultsmentioning

confidence: 99%

“…The processing temperature during the FSJ process is one of the key factors enabling the fabrication of sound metal–polymer composite joints. The temperature build-up predominantly originates from two thermo-mechanical effects: (a) heat generation due to friction between the tool (shoulder and pin) and the base materials and (b) heat release due to base materials’ plastic flow [ 40 , 41 , 42 ].…”

Section: Resultsmentioning

confidence: 99%

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Thermo-Mechanical Characterization of Metal–Polymer Friction Stir Composite Joints—A Full Factorial Design of Experiments

Correia,

Gaspar,

Cipriano

et al. 2024

Polymers

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With the increasing demand for lighter, more environmentally friendly, and affordable solutions in the mobility sector, designers and engineers are actively promoting the use of innovative integral dissimilar structures. In this field, friction stir-based technologies offer unique advantages compared with conventional joining technologies, such as mechanical fastening and adhesive bonding, which recently demonstrated promising results. In this study, an aluminum alloy and a glass fiber-reinforced polymer were friction stir joined in an overlap configuration. To assess the main effects, interactions, and influence of processing parameters on the mechanical strength and processing temperature of the fabricated joints, a full factorial design study with three factors and two levels was carried out. The design of experiments resulted in statistical models with excellent fit to the experimental data, enabling a thorough understanding of the influence of rotational speed, travel speed, and tool tilt angle on dissimilar metal-to-polymer friction stir composite joints. The mechanical strength of the composite joints ranged from 1708.1 ± 45.5 N to 3414.2 ± 317.1, while the processing temperature was between 203.6 ± 10.7 °C and 251.5 ± 9.7.

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Optimization of hybrid friction stir welding of PMMA: 3D-printed parts and conventional sheets welding efficiency in single- and two-axis welding traces

Petousis

Mountakis

Vidakis

2023

Int J Adv Manuf Technol

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Herein, the feasibility of joining with the friction stir welding (FSW) process 3D-printed parts made of poly(methyl methacrylate) (PMMA) with extruded PMMA sheets is investigated. A full factorial design method is followed, with two control parameters, i.e., tool rotational and travel speed, and three levels each. The hybrid joints produced were subjected to tensile and flexural loading and the corresponding properties were optimized with statistical modeling tools. Regression analysis provided prediction models for the five output metrics. The temperature was monitored throughout the experimental process. Samples were inspected with optical and scanning electron microscopy and their morphological characteristics were correlated with the joining conditions. The optimized FSW parameters were used for joining PMMA 3D-printed parts with sheets with two-axis joining seams. The produced hybrid joints were more than sufficient in their mechanical properties. The highest welding efficiency achieved in the tensile tests was 1.36, by the sample welded with 900 rpm and 6 mm/min. The sample welded with the same conditions achieved also the highest welding efficiency in the flexural tests (0.98). The findings presented proven the efficiency of the hybrid PMMA joints studied and have direct industrial applications for efficient component production. Graphical Abstract

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Effects of processing temperature on failure mechanisms of dissimilar aluminum-to-polymer joints produced by friction stir welding

Cited by 13 publications

References 23 publications

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints

Thermo-Mechanical Characterization of Metal–Polymer Friction Stir Composite Joints—A Full Factorial Design of Experiments

Optimization of hybrid friction stir welding of PMMA: 3D-printed parts and conventional sheets welding efficiency in single- and two-axis welding traces

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