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Joining of AA5052 to CF/PEEK by friction lap welding

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Abstract

The joining of aluminum alloy AA5052 and carbon-fiber-reinforced polyether ether ketone (CF/PEEK) by friction lap welding was investigated under different conditions of surface texturing and process temperatures. The joint quality was evaluated by measurement of the tensile shear force and examination of the joint morphology. The aluminum alloy underwent two different types of surface texturing—mechanical engraving and sandblasting. The welding experiments were then conducted under different tool rotational speeds for each. The temperatures across the weld line were measured during the welding process using thermocouples mounted at specific locations. The temperature distribution at the interface was determined by an inverse heat conduction method. It was found that the temperatures at the interface exceeded the melting temperature of PEEK for all testing conditions but was always below PEEK thermal degradation temperature. It was also found that joint performance of mechanically engraved samples increased with the increase of interface temperatures. This was attributed to the increased mechanical interlocking due to the flow of melted PEEK into the engraved sample’s surface features. The joint strength of sandblasted samples did not change considerably with interface temperatures.

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Data and numerical model associated with this study is available upon request by contacting the corresponding author.

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Funding

This work was funded in part by a Competitive Internal Research Award CIRA 2020–084 from Khalifa University of Science and Technology.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Western New England University, Springfield, MA, 01119, USA

    Jamal Sheikh-Ahmad

  2. Department of Mechanical Engineering, Khalifa University of Science and Technology, Abu Dhabi, United Arab Emirates

    Jamal Sheikh-Ahmad

  3. UMR 5312, University of Toulouse III Paul Sabatier, Institut Clément Ader, CNRS, Toulouse, France

    Redouane Zitoune, Claire Morel & Jean-François Ferrero

  4. Groupe de Physique Des Matériaux, Normandie Univ, UNIROUEN, INSA Rouen, CNRS, Avenue de L’Université, 76801, Saint Etienne du Rouvray Cedex, France

    Benoit Vieille

Authors
  1. Jamal Sheikh-Ahmad
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  2. Redouane Zitoune
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  3. Claire Morel
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  4. Jean-François Ferrero
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  5. Benoit Vieille
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Contributions

All authors contributed to the study conception and design. Material preparation and experiments were performed by Sheikh-Ahmad and Zitoune. Data collection and analysis were performed by Sheikh-Ahmad, Zitoune, and Vieille. The first draft of the manuscript was written by Sheikh-Ahmad and Zitoune and reviewed by Morrel, Ferrero, and Vieille. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jamal Sheikh-Ahmad.

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Sheikh-Ahmad, J., Zitoune, R., Morel, C. et al. Joining of AA5052 to CF/PEEK by friction lap welding. Int J Adv Manuf Technol 132, 1137–1150 (2024). https://doi.org/10.1007/s00170-024-13457-3

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  • DOI: https://doi.org/10.1007/s00170-024-13457-3

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