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Study on the Microstructure and Mechanical Properties on Al/Carbon Fiber Reinforced Thermoplastic Dissimilar Friction Stir Lap Welding Joints

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Abstract

Friction stir welding (FSW) of dissimilar metals and polymers has shown some attractive applications in industrial fields such as drone tails and automotive parts. Adjusting process parameters is a fast and effective method to improve the tensile performance of joints. In this paper, the evaluation of friction stir lap welded joints between 6061-T6 aluminum alloy and carbon fiber reinforced thermoplastic (CFRTP) is conducted by studying the microstructure characteristics of the weld interface, SEM of the fracture surface, tensile and hardness analysis. The results indicate that the upper part of the weld cross-section joint experiences longer stirring and friction durations. The small metal fragments broken at the lower part of the joint are recombined into larger fragments. At high rotational speeds, the formation of welds is faster and more uniform. Metal fragments are further broken and refined and the molten CFRTP is uniformly mixed with Al alloy fragments in the stirring zone, which improvs the bonding property between two materials. Therefore, the value of tensile strength at 1800 rpm reaches 32.9 MPa, which is equivalent to 63.1% of CFRTP sheets.

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All data generated or analyzed during this study are included in this manuscript.

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Funding

This work was supported by the National Science Foundation of China (52005071, 51875072), Natural Science Foundation of Liaoning Province (2022-MS-342), and Liaoning Provincial Department of Education General Project (LJKZ0478).

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Authors and Affiliations

  1. College of Locomotive and Rolling Stock Engineering, Dalian Jiaotong University, Dalian, China

    Zhang Yuan, Yibo Sun & Haiwei Long

  2. Dalian Key Laboratory of Welded Structures and Intelligent Manufacturing Technology of Rail Transportation Equipment, Dalian, China

    Jianning Zhu, Li Zou & Xinhua Yang

Authors
  1. Zhang Yuan
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  2. Yibo Sun
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  3. Haiwei Long
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  4. Jianning Zhu
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  5. Li Zou
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  6. Xinhua Yang
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Contributions

YZ: Conceptualization, Writing original draft; YS: Investigation, Methodology; HL: Supervision, Resources; JZ: Validation; LZ: Supervision, Resources; XY: Project administration. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Yibo Sun.

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Yuan, Z., Sun, Y., Long, H. et al. Study on the Microstructure and Mechanical Properties on Al/Carbon Fiber Reinforced Thermoplastic Dissimilar Friction Stir Lap Welding Joints. J. of Materi Eng and Perform (2024). https://doi.org/10.1007/s11665-024-09482-8

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  • DOI: https://doi.org/10.1007/s11665-024-09482-8

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