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<p>Metal-plastic hybrid structures are gaining popularity in the aerospace, automotive, medical, and construction industries. One key obstacle to their widespread utilization is the difficulty of bonding polymers to metals. Friction stir welding (FSW) has the ability to overcome the majority of the challenges and obstacles encountered in traditional joining procedures for such structures. In this study, FSW was utilized to create overlap joints between aluminum alloy (AA6061) and Nylon 6/6 (PA66). The FSW tool is used to generate aluminum fragments that combine with the molten thermoplastic to create a joint. Mechanical interlocking is observed in cross-sections between the chipped aluminum and the surrounding nylon sheet. The maximum force reported for FSW specimen was 875 N. Moreover, digital image correlation (DIC) analysis reveals local strain concentration at the advancing side of the stir zone (SZ). The results also showed an interaction layer at the aluminum-plastic interface that was primarily composed of carbon, oxygen, and aluminum.</p>

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Experimental investigations of joining 6061 aluminum alloy (AA6061) and wear resistant nylon 6/6 (PA66) sheets by friction stir lap welding

  • 期刊论文

  • 发表日期：

    2025年10月8日

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  • Ali A. Barakat,
  • Basil M. Darras,
  • Mahmoud Awad,
  • Mohammad A. Nazzal

摘要

Metal-plastic hybrid structures are gaining popularity in the aerospace, automotive, medical, and construction industries. One key obstacle to their widespread utilization is the difficulty of bonding polymers to metals. Friction stir welding (FSW) has the ability to overcome the majority of the challenges and obstacles encountered in traditional joining procedures for such structures. In this study, FSW was utilized to create overlap joints between aluminum alloy (AA6061) and Nylon 6/6 (PA66). The FSW tool is used to generate aluminum fragments that combine with the molten thermoplastic to create a joint. Mechanical interlocking is observed in cross-sections between the chipped aluminum and the surrounding nylon sheet. The maximum force reported for FSW specimen was 875 N. Moreover, digital image correlation (DIC) analysis reveals local strain concentration at the advancing side of the stir zone (SZ). The results also showed an interaction layer at the aluminum-plastic interface that was primarily composed of carbon, oxygen, and aluminum.