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Improving appearance and mechanical strength of aluminum-polypropylene/talc composite friction stir joint using a novel tool design

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Abstract

In this research, friction stir joining of aluminum-polypropylene/talc composite was investigated due to the numerous applications of aluminum-polymer joints in automotive and aerospace industry. A novel tool design, including a rotary/stationary holder, was used to improve the appearance and mechanical performance of friction stir lap joints by preventing the mixed molten polymer and aluminum particles from exiting the stirred zone. Effect of tool transverse speed on the joint microstructure and strength was investigated. Using the rotary/stationary holder, tensile-shear strength of the joints increased (by ~ 45 to ~ 220% at various transverse speeds). Since during the tensile-shear test all joints failed from the aluminum/stirred zone interface, joint strength was affected by the formation of anchor-like aluminum pieces in the composite substrate as the mechanical locks, reaction layer at the joint interface, and large voids near the aluminum/stirred zone interface. Joining at the optimum transverse speed led to the highest tensile-shear peak load of 315 N.

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Funding

The authors would like to acknowledge the economic support received from the Iran National Science Foundation (Grant No. 97011444).

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Sharif University of Technology, Azadi St, Tehran, Iran

    Hosseinali Shiravi, Mojtaba Movahedi & Ashkaan Ozlati

Authors
  1. Hosseinali Shiravi
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  2. Mojtaba Movahedi
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  3. Ashkaan Ozlati
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All authors contributed to the study conception and design, material preparation, data collection and analysis, and manuscript preparation. All authors read and approved the final manuscript.

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Correspondence to Mojtaba Movahedi.

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Shiravi, H., Movahedi, M. & Ozlati, A. Improving appearance and mechanical strength of aluminum-polypropylene/talc composite friction stir joint using a novel tool design. Int J Adv Manuf Technol 121, 3717–3730 (2022). https://doi.org/10.1007/s00170-022-09581-7

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