Direct Joining of Aluminum Alloy and Plastic Sheets by Friction Lap Processing

2014 ◽  
Vol 794-796 ◽  
pp. 395-400 ◽  
Author(s):  
Toshiya Okada ◽  
Souhei Uchida ◽  
Kazuhiro Nakata
Keyword(s):  
Aluminum Alloy ◽  
Solid State ◽  
Laser Welding ◽  
High Density Polyethylene ◽  
Dissimilar Materials ◽  
Dissimilar Metals ◽  
Metallic Material ◽  
Thermal Pressing ◽  
Mechanical Fastening ◽  
Joining Process

It was difficult to join dissimilar materials such as metallic material and polymer. Conventional joining processes of these materials were mechanical fastening, using adhesion, thermal pressing, laser welding and so on. These processes had disadvantages such as expensive apparatus, restriction of dimension of products and lack of anti-weather resistance.Friction Stir Welding (FSW), which was one of the solid state joinings, was available as a joining process for dissimilar metals. However, in case of joining metal and polymer, it was not available to use the tool for FSW. So we proposed Friction Lap Process to join a metallic material with a polymer and investigated mechanical and metallurgical properties of this dissimilar joint. Itwas described in this paper that joining mechanism is discussed with evaluation of microstructure at the interface between aluminum alloy and polymer. High density polyethylene was not able to be joined for as received aluminum alloy. Anodizing was effective to join with these materials.

Joining Mechanism of Dissimilar Materials such as Metal and Plastic Sheets by Friction Lap Joining

2016 ◽  
Vol 710 ◽  
pp. 149-154 ◽  
Author(s):  
Toshiya Okada ◽  
Kazuhiro Nakata ◽  
Masatoshi Enomoto
Keyword(s):  
Aluminum Alloy ◽  
Elevated Temperature ◽  
Acrylic Acid ◽  
Chemical Bonding ◽  
High Density Polyethylene ◽  
Functional Group ◽  
Dissimilar Materials ◽  
Metallic Material ◽  
Acid Copolymer ◽  
Acrylic Acid Copolymer

It is difficult to join dissimilar materials such as metallic material and polymer. We have investigated to join Aluminum alloy and high density polyethylene (PE) and ethylene acrylic acid copolymer (EAA) using Friction Lap Joining (FLJ) and then concluded EAA could be strongly joined with Aluminum alloy. PE could not be joined without anodizing. We have considered that EAA has a polar functional group, COOH. On the contrary, PE cannot be joined to an as-received aluminum alloy, because PE has no polar functional group. So, we have tried to confirm this mechanism with XPS and FTIR to investigate the interface between anodized surface and that of polymer. We find that the possibility of chemical bonding arises between O-H in COOH and O in Al2O3or O in C=O and O in Al2O3 at elevated temperature.

scholarly journals Dissimilar Metals Laser Welding between DP1000 Steel and Aluminum Alloy 1050

Metals ◽  
2019 ◽  
Vol 9 (1) ◽  
pp. 102 ◽  
Author(s):  
António Pereira ◽  
Ana Cabrinha ◽  
Fábio Rocha ◽  
Pedro Marques ◽  
Fábio Fernandes ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Laser Welding ◽  
Mechanical Tests ◽  
Welding Parameters ◽  
Dissimilar Metals ◽  
Butt Welding ◽  
Electron Microscopes ◽  
1050 Aluminum Alloy ◽  
Scanning Electron Microscopes

The welding of dissimilar metals was carried out using a pulsed Nd: YAG laser to join DP1000 steel and an aluminum alloy 1050 H111. Two sheets of each metal, with 30 × 14 × 1 mm3, were lap welded, since butt welding proved to be nearly impossible due to the huge thermal conductivity differences and melting temperature differences of these materials. The aim of this research was to find the optimal laser welding parameters based on the mechanical and microstructure investigations. Thus, the welded samples were then subjected to tensile testing to evaluate the quality of the joining operation. The best set of welding parameters was replicated, and the welding joint obtained using these proper parameters was carefully analyzed using optical and scanning electron microscopes. Despite the predicted difficulties of welding two distinct metals, good quality welded joints were achieved. Additionally, some samples performed satisfactorily well in the mechanical tests, reaching tensile strengths close to the original 1050 aluminum alloy.

Characterization o Solid-State Vortices Associated with the Friction-Stir Welding of Copper to Aluminum

1998 ◽  
Vol 4 (S2) ◽  
pp. 530-531
Author(s):  
R. D. Flores ◽  
L. E. Murr ◽  
E. A. Trillo
Keyword(s):  
Plastic Deformation ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Solid State ◽  
Weld Zone ◽  
Thick Plates ◽  
6061 Aluminum Alloy ◽  
Friction Stir ◽  
The Past ◽  
Joining Process

Although friction-stir welding has been developing as a viable industrial joining process over the past decade, only little attention has been given to the elucidation of associated microstructures. We have recently produced welds of copper to 6061 aluminum alloy using the technique illustrated in Fig. 1. In this process, a steel tool rod (0.6 cm diameter) or head-pin (HP) traverses the seam of 0.64 cm thick plates of copper butted against 6061-T6 aluminum at a rate (T in Fig. 1) of 1 mm/s; and rotating at a speed (R in Fig. 1) of 650 rpm (Fig. 1). A rather remarkable welding of these two materials results at temperatures measured to be around 400°C for 6061-T6 aluminum welded to itself. Consequently, the metals are stirred into one another by extreme plastic deformation which universally seems to involve dynamic recrystallization in the actual weld zone. There is no melting.

116 Joining process of A5052/plastics dissimilar materials laser welding and its strength

2009 ◽  
Vol 2009.46 (0) ◽  
pp. 31-32
Author(s):  
Kosei Oyama ◽  
Yukio Miyashita ◽  
Yuichi Otsuka ◽  
Yoshiharu Mutoh ◽  
Hironori Tanaka
Keyword(s):  
Laser Welding ◽  
Dissimilar Materials ◽  
Joining Process

Analysis and Correlation of Output Parameters against Input Parameters for Friction Stir Welding of Three Dissimilar Aluminum Alloy

2018 ◽  
Vol 1146 ◽  
pp. 38-43
Author(s):  
Ana Boşneag ◽  
Marius Adrian Constantin ◽  
Eduard Niţu ◽  
Cristian Ciucă
Keyword(s):  
Mechanical Properties ◽  
Aluminum Alloy ◽  
Friction Stir Welding ◽  
Arc Welding ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Friction Stir ◽  
Welding Joints ◽  
Aluminum Plates ◽  
Joining Process

Friction Stir Welding, abbreviated FSW is an innovative joining process. The FSW is a solid-state welding process with a lot of advantages comparing to the traditional arc welding, such as the following: it uses a non-consumable tool, it results of good mechanical properties, it can use dissimilar materials and it have a low environmental impact. First of all, the FSW process was developed to join similar aluminum plates, and now, the technology was developed and the FSW process is used to weld large types of materials, similar or dissimilar. In this paper it is presented an experimental study and the results of it, which includes the welding of three dissimilar aluminum alloy, with different chemical and mechanical properties. This three materials are: AA2024, AA6061 and AA7075. The welding joints and the welding process were analyzed considering: process temperature, micro-hardness, macrostructure and microstructure.

203 Laser Welding of Steel and Aluminum Alloy Dissimilar Materials

2001 ◽  
Vol 2001.9 (0) ◽  
pp. 53-54
Author(s):  
Ikutaro Nakagawa ◽  
Yukio MIYASHITA ◽  
Jin-Quan XU ◽  
Yoshiharu MUTOH ◽  
Masatoshi AKAHORI
Keyword(s):  
Aluminum Alloy ◽  
Laser Welding ◽  
Dissimilar Materials

scholarly journals Experimental Investigation and Analysis of Tensile Strength of Dissimilar Friction Welded Joints of Aluminium 6061 and Mild Steel

2021 ◽  
Vol 9 (VII) ◽  
pp. 3455-3462
Keyword(s):  
Solid State ◽  
Mild Steel ◽  
Friction Welding ◽  
Research Work ◽  
Engineering Application ◽  
Welding Process ◽  
Dissimilar Materials ◽  
Vital Role ◽  
Rotating Speed ◽  
Joining Process

Nowadays, the joining process plays a vital role in every field of engineering application. Various similar and dissimilar materials are joined by many joining processes to a formed complex component. In all joining processes, welding is a very popular and effective joining process that gives permanent joint. In this process material to be joined is under influence of heat which is produced with aid of external (flame) and internal (friction) mediums. Further, there are types of welding process called friction welding which is solid-state welding, in that process friction had developed between materials having relative motion thus sufficient heat also produced, and welding is performed in solid-state. In recent time’s friction welding is widely used in automobile, aeronautical, structural, marine, etc areas due to its flexibility demand for various materials. In this research work, the aluminium 6061 and mild steel are joined by friction welding by varying the rotating speed of lathe chuck, friction time, burn-off length, and the joint is examined by a tensile test to check its strength. Taguchi’s orthogonal array was used to design the experiment and at the end, the ANOVA test is carried out for the optimization of process parameters.

Effect of Operational Parameters on AA2014 Friction Stir Weldments Using Plain Cylindrical Tool

2014 ◽  
Vol 592-594 ◽  
pp. 216-223
Author(s):  
Nallavelli Ramesh ◽  
K. Palaksha Reddy
Keyword(s):  
Aluminum Alloy ◽  
Solid State ◽  
Fusion Welding ◽  
Basic Material ◽  
Welding Parameters ◽  
Zone Formation ◽  
Friction Stir ◽  
Structural Applications ◽  
Tool Pin ◽  
Joining Process

Aluminum alloys are mostly used for high strength structural applications utilized in aircraft structure, trucks body, military vehicles, bridges and weapons manufacture. Conventional fusion welding of aluminum alloy produces porosity and hot cracks in the welded joint due to incorrect selection of consumables and parameters, which may lead to lower weld toughness and defects in the mechanical properties. The mostly adopted method for welding AA 2014-T6 is solid state joining process. Friction stir welding (FSW) is an emerging solid state of joining process which avoids bulk melting of the basic material, hot cracking and porosity. The welding parameters and tool pin profile play a major role in deciding weld quality. In this investigation, an attempt has been made to understand the various influences of tool rotational speed, welding speed and pin profile of the tool on friction stir processed (FSP) zone formation in joining of AA2014 aluminum alloy. High Carbon High Chromium steel tool of plain cylindrical pin profile is used to fabricate the joints. The average grey relation grade for each level of each factor are calculated and it was found that the optimal settings of the levels of factors Tool rotation speed (A), Weld speed (B) and Tilt angle (C) are A1-B3-C3. The findings from these investigations will be presented and discussed.

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