Heat Transfer Modelling of Friction Stir Lap Welding of PP Plastics and 6061 Aluminium Alloy

Abstract

Structures with dissimilar materials can make full use of the advantages of each material. However the welding of the aluminum alloy plate and plastic plate are difficult due to high difference in melting point. The friction stir lap welding method is selected in this paper. The numerical model was built to study the heat transfer behavior inside the plates, as the temperature plays an important role in determine the weld quality. The model was validated through experimentally measured temperature results. The influence of welding process parameters such as welding speed, tool rotating speed and downward feed was analyzed. It was found that under the welding speed of 100r/min and downward feed of 0.3mm/s, sound weld was produced.