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Continuous development of lightweight materials in automobile and aircraft parts has increased the demand for hybrid materials and allied processes. In the present investigation, the friction stir welding of Aluminium 5754 to polypropylene is examined. Friction stir welding is done with a tapered threaded pin by varying the rotating tool speed while keeping welding traverse speed, plunge depth, and tool tilt angle as constant. The effect of process variables on bonding strength and bonding mechanism is investigated. A maximum shear joint strength of 4.2 MPa was achieved at a tool rotational speed of 900 rpm and a traverse welding speed of 60 mm/min due to minimal thermal degradation of the joint. Scanning Electron Microscopy (SEM) analysis of the cross-sectional area of the weld exhibits micro and macro mechanical interlocks and the reduced gap at the metal-polymer interface, which considerably improves the joint strength. The microhardness studies have shown significant improvement in hardness in the stir zone compared to the base polymer. Elemental area mapping analysis at the weld interface indicates intricate material intermixing during the joining process.

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Feasibility Study on the Bonding Mechanism and Mechanical Characteristics of Friction Stir Welded Aluminium 5754 to Polypropylene Hybrid Joints

  • 会议论文

  • 发表日期：

    2025年

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  • S. J. Adarsh,
  • Manoj George,
  • Bibin Jose,
  • Kurian Antony

摘要

Continuous development of lightweight materials in automobile and aircraft parts has increased the demand for hybrid materials and allied processes. In the present investigation, the friction stir welding of Aluminium 5754 to polypropylene is examined. Friction stir welding is done with a tapered threaded pin by varying the rotating tool speed while keeping welding traverse speed, plunge depth, and tool tilt angle as constant. The effect of process variables on bonding strength and bonding mechanism is investigated. A maximum shear joint strength of 4.2 MPa was achieved at a tool rotational speed of 900 rpm and a traverse welding speed of 60 mm/min due to minimal thermal degradation of the joint. Scanning Electron Microscopy (SEM) analysis of the cross-sectional area of the weld exhibits micro and macro mechanical interlocks and the reduced gap at the metal-polymer interface, which considerably improves the joint strength. The microhardness studies have shown significant improvement in hardness in the stir zone compared to the base polymer. Elemental area mapping analysis at the weld interface indicates intricate material intermixing during the joining process.