Experimental Investigations of Friction Stir Welded Metal-Polymer Hybrid Structure

Abstract

In the last decade, there has been a surge in interest in hybrid structures, particularly those that combine aluminum or magnesium alloys with polymeric materials. Mechanical fastening, riveting, and bonding are examples of traditional methods of joining metals and polymers. However, these methods have several limitations such as extended curing times, low dependability joints, and stress concentration. The fundamental difficulty in combining metals and plastics is the considerable disparity in structure and surface energy between both materials, which is a crucial reason that makes a sound connection difficult to produce. To overcome the limitations of traditional joining methods, a different approach to combining different materials is required. In comparison to traditional methods, friction stir welding as a joining technique for metal-to-polymer hybrid connections is a promising alternative. Recently, there has been a growing interest in research projects aimed at determining the feasibility of employing friction stir welding for joining dissimilar materials. The purpose of this thesis is to investigate friction stir welding of AA6061 aluminum alloy sheets to Polyamide 6 (PA6). In this work, the impact of welding parameters on the mechanical, microstructural, and material flow of the hybrid joint was addressed. A comprehensive evaluation of the process based on a multidimensional sustainability assessment model, as well as comparisons to other conventional joining techniques such as adhesive bonding and self-piercing riveting were addressed.