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

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Abstract

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.

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Authors and Affiliations

  1. Young Researchers and Elites Club, Science and Research Branch, Islamic Azad University, Tehran, Iran

    Hamed Aghajani Derazkola

  2. Department of Mechanical Engineering, Islamic Azad University, Kordestan Branch of Science and Research, Sanandaj, Iran

    Reza Kashiry Fard

  3. School of Metallurgical and Materials Engineering, College of Engineering, University of Tehran, P.O. Box 11155-4563, Tehran, Iran

    Farzad Khodabakhshi

Authors
  1. Hamed Aghajani Derazkola
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  2. Reza Kashiry Fard
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  3. Farzad Khodabakhshi
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Corresponding authors

Correspondence to Hamed Aghajani Derazkola or Farzad Khodabakhshi.

Additional information

Recommended for publication by Commission XVI - Polymer Joining and Adhesive Technology

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Derazkola, H.A., Kashiry Fard, R. & Khodabakhshi, F. Effects of processing parameters on the characteristics of dissimilar friction-stir-welded joints between AA5058 aluminum alloy and PMMA polymer. Weld World 62, 117–130 (2018). https://doi.org/10.1007/s40194-017-0517-y

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  • DOI: https://doi.org/10.1007/s40194-017-0517-y

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