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Influence of the rotation speed on the interface microstructure and joining quality of aluminum alloy 6061/CF-PPS joints produced by refill friction stir spot welding

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Abstract

The application of lightweight materials in automotive industry creates the demand to develop reliable and cost-effective solutions for joining hybrid material parts and assemblies. In this work, the microstructure and mechanical properties of the dissimilar joint between aluminum alloy 6061 (AA6061) and carbon fiber-reinforced polyphenylene sulfide (CF-PPS) processed by refill friction stir spot welding (RFSSW) were investigated. The results show that the joining between AA6061 and CF-PPS is attributed to the combined effect of mechanical interlocking and adhesive bonding. The rotation speed affects the porosity at the AA6061/CF-PPS interface which is the governing factor of the joints’ peak load during the lap-shear test. Varying rotation speed from 1000 to 1400 rpm, it illustrated that the lap-shear joints produced under 1200 rpm possess the highest peak load of 1460 N. Besides, it is observed that the joints produced with 1200 rpm have a thicker adhesive layer, which possess a strong mechanical interlocking effect. The failure mechanism for the joints includes cohesive and adhesive fracturing. Under the optimized rotation speed, the fracturing surface of the sample possess dimples with fiber pull-outed fibers, which infers a ductile failure.

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Funding

This research work was financially supported by the Beijing Municipal Natural Science Foundation (Grant No. 3202002), China-CEEC Joint Education Project for Higher Education (Grant No. 2021113), 2021–2022 Sino-Poland Inter-governmental S&T Cooperation Projects (Grant No. 13), the National Natural Science Foundation of China (Grant Nos. 51905300 and 52074017), and the International Research Cooperation Seed Fund of Beijing University of Technology (Grant Nos. 2021A14 and 2021B27).

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Authors and Affiliations

  1. Faculty of Materials & Manufacturing, Beijing University of Technology, Beijing, 100124, China

    Hong Li, Xu-sheng Liu, Yu Zhang, Tao Yuan & Zhuo-xin Li

  2. Faculty of Materials Science and Technology in Trnava, Slovak University of Technology in Bratislava, 91724, Trnava, Slovakia

    Erika Hodúlová & Beáta Šimeková

  3. Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, 02-524, Warsaw, Poland

    Mariusz Bober & Jacek Senkara

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  1. Hong Li
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  2. Xu-sheng Liu
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  3. Yu Zhang
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  4. Tao Yuan
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  9. Zhuo-xin Li
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Correspondence to Hong Li or Yu Zhang.

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Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process

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Li, H., Liu, Xs., Zhang, Y. et al. Influence of the rotation speed on the interface microstructure and joining quality of aluminum alloy 6061/CF-PPS joints produced by refill friction stir spot welding. Weld World 66, 923–933 (2022). https://doi.org/10.1007/s40194-022-01258-9

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  • DOI: https://doi.org/10.1007/s40194-022-01258-9

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