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<p>The joining of metal and polymer has great potential in structural lightweighting. This study employed continuous drive friction welding to join aluminum (Al 6061) and polyetheretherketone (PEEK) through rotary friction melt fastening. Various interface geometries, including bore, dovetail, and turned structures, were fabricated on the aluminum surface to enhance mechanical interlocking. This study emphasizes the importance of interface geometry and process optimization in rotary friction welding of Al 6061-PEEK joints. The turned interface exhibited the highest bending strength of 92&#xa0;MPa owing to superior mechanical interlocking and heat management. By optimizing the rotational speed of 4000&#xa0;rpm, axial pressure, and preheating, thermal degradation was minimized, enhancing joint performance. The innovative approach integrates tailored interface designs and optimized parameters to produce lightweight, high-strength, and thermally stable joints. This advancement addresses key challenges in automotive, aerospace, and medical manufacturing, demonstrating the potential of rotary friction welding for high-performance applications.</p>

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Tailored interface design for high-performance rotary friction welded Al/PEEK joints in lightweight structural applications

  • 期刊论文

  • 发表日期：

    2025年11月11日

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  • Chil-Chyuan Kuo,
  • Armaan Farooqui,
  • Hong-Wei Chen,
  • Song-Hua Huang

摘要

The joining of metal and polymer has great potential in structural lightweighting. This study employed continuous drive friction welding to join aluminum (Al 6061) and polyetheretherketone (PEEK) through rotary friction melt fastening. Various interface geometries, including bore, dovetail, and turned structures, were fabricated on the aluminum surface to enhance mechanical interlocking. This study emphasizes the importance of interface geometry and process optimization in rotary friction welding of Al 6061-PEEK joints. The turned interface exhibited the highest bending strength of 92 MPa owing to superior mechanical interlocking and heat management. By optimizing the rotational speed of 4000 rpm, axial pressure, and preheating, thermal degradation was minimized, enhancing joint performance. The innovative approach integrates tailored interface designs and optimized parameters to produce lightweight, high-strength, and thermally stable joints. This advancement addresses key challenges in automotive, aerospace, and medical manufacturing, demonstrating the potential of rotary friction welding for high-performance applications.