Preprint Article Version 1 This version is not peer-reviewed

Evaluation of Solid Phase Joining Using Friction Stir Welding Technique between Aluminum 6061 and Polymer-Based Composites

Version 1 : Received: 28 August 2024 / Approved: 28 August 2024 / Online: 29 August 2024 (16:58:20 CEST)

How to cite: ALI, N.; Abadeen, Z. U.; Qureshi, Y. Evaluation of Solid Phase Joining Using Friction Stir Welding Technique between Aluminum 6061 and Polymer-Based Composites. Preprints 2024, 2024082044. https://doi.org/10.20944/preprints202408.2044.v1 ALI, N.; Abadeen, Z. U.; Qureshi, Y. Evaluation of Solid Phase Joining Using Friction Stir Welding Technique between Aluminum 6061 and Polymer-Based Composites. Preprints 2024, 2024082044. https://doi.org/10.20944/preprints202408.2044.v1

Abstract

Solid-phase joining is a technique used to fuse two materials by applying heat and pressure, causing plastic deformation without reaching the melting point. This method is applicable for similar and dissimilar materials, including metals, polymers, and ceramics, without the need for filler material. Among the various methods, Friction Stir Welding (FSW) is preferred for joining dissimilar materials due to its solid-state process, which enhances mechanical properties, metallurgical compatibility, and reduces distortion. FSW is particularly effective for materials with significant differences in melting points. The current project focuses on assessing the strength and mechanical properties of FSW joints between aluminum and polymer-based composites. FSW was selected for its ability to produce fine-grained, strong welds free from fusion-related defects such as porosity and cracks. Applications in sectors like automotive, aerospace, and shipbuilding are explored, with impact, hardness, and tensile tests conducted to evaluate joint performance. This comprehensive study includes literature review, fabrication, testing, and tool design to ensure a thorough understanding of dissimilar joint properties.

Keywords

FSW (Friction Stir Welding); IMc (Intermetallic Compounds); UTM (Universal Testing Machine); RPM (Revolutions Per Minute); HAZ (Heat Affected Zone); WZ (Weld Zone); BM (Base Metal); CNC (Computer Numeric Control); EDM (Electrical Discharge Machine)

Subject

Chemistry and Materials Science, Other

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