Microstructure-property characterization of a friction-stir welded joint between AA5059 aluminum alloy and high density polyethylene

Khodabakhshi, F.; Haghshenas, M.; Sahraeinejad, S.; Chen, J.; Shalchi, B.; Li, J.; Gerlich, A.P.

doi:10.1016/j.matchar.2014.10.013

Cited by 99 publications

(98 citation statements)

References 39 publications

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“…Similar results were also reported in an USWed copper alloy [51]. Several other authors also observed the formation of fine grains near the faying surface during USW [15,32,33] and during friction stir welding (FSW) of aluminum alloys [50,52,53,54,55,56]. With an increasing amount of deformation, the dislocation density increases leading to the build-up of internal stored strain energy, which is the driving force for the initiation of recrystallization; the boundary migration and slip contributions are restrained by solute drag so that the lattice rotation develops progressively at grain boundaries.…”

Section: Resultssupporting

confidence: 79%

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Chen

Jiang

2017

Materials

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The aim of this study is to evaluate the microstructures, tensile lap shear strength, and fatigue resistance of 6022-T43 aluminum alloy joints welded via a solid-state welding technique–ultrasonic spot welding (USW)–at different energy levels. An ultra-fine necklace-like equiaxed grain structure is observed along the weld line due to the occurrence of dynamic crystallization, with smaller grain sizes at lower levels of welding energy. The tensile lap shear strength, failure energy, and critical stress intensity of the welded joints first increase, reach their maximum values, and then decrease with increasing welding energy. The tensile lap shear failure mode changes from interfacial fracture at lower energy levels, to nugget pull-out at intermediate optimal energy levels, and to transverse through-thickness (TTT) crack growth at higher energy levels. The fatigue life is longer for the joints welded at an energy of 1400 J than 2000 J at higher cyclic loading levels. The fatigue failure mode changes from nugget pull-out to TTT crack growth with decreasing cyclic loading for the joints welded at 1400 J, while TTT crack growth mode remains at all cyclic loading levels for the joints welded at 2000 J. Fatigue crack basically initiates from the nugget edge, and propagates with “river-flow” patterns and characteristic fatigue striations.

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Section: Resultssupporting

confidence: 79%

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Chen

Jiang

2017

Materials

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“…Each specimen surface was coated with a layer of gold (Au) to increase the solution of EDS test; as a result the Au element appeared in the ESD analysis. Moreover, the results of EDS contained the elements oxygen (O), aluminium (AL) and carbon (C), which represent the presence of the oxide layer in AA6061, AA6061 and polymer, respectively (Khodabakhshi et al, 2014). Two elements (AL and O) were found in the region of AA6061 as shown in Figures 11 and 12, Spectrum 1.…”

Section: Joints Energy Dispersive Spectroscopy (Eds)mentioning

confidence: 96%

“…The microstructure examination of joint indicated that the joining mechanism between the different materials at the interface line was attributed to a mechanical interlocking and secondary bounding between the two materials. The maximum tensile strength of the joint reached an approximate value of 9.8 MPa (49 per cent of polymer shear strength) (Khodabakhshi et al, 2014). Aluminium alloy AA2024-T3 sheet was joined with the carbon-fibre-reinforced polyphenylene sulphide by the friction spot process.…”

Section: Introductionmentioning

confidence: 99%

Friction spot lap joining of the anodized aluminium alloy 6061 with high-density polyethylene sheets

Ali

Hussein

2019

WJE

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Purpose The purpose of this paper is to join an anodized aluminium alloy AA6061 sheet with high-density polyethylene (HDPE) using friction spot process. Design/methodology/approach The surface of AA6061 sheet was anodized to increase the pores’ size. A lap joint configuration was used to join the AA6061 with HDPE sheets by the friction spot process. The joining process was carried out using a rotating tool of different diameters: 14, 16 and 18 mm. Three tool-plunging depths were used – 0.1, 0.2 and 0.3 mm – with three values of the processing time – 20, 30 and 40 s. The joining process parameters were designed according to the Taguchi approach. Two sets of samples were joined: the as-received AA6061/HDPE and the anodized AA6061/HDPE. Findings Frictional heat melted the HDPE layers near the lap joint line and penetrated it through the surface pores of the AA6061 sheet via the applied pressure of the tool. The tool diameter exhibited higher effect on the joint strength than processing time and the tool-plunging depth. Specimens of highest and lowest tensile force were failed by necking the polymer side and shearing the polymer layers at the lap joint, respectively. Molten HDPE was mechanically interlocked into the pores of the anodized surface of AA6061 with an interface line of 18-m width. Originality/value For the first time, HDPE was joined with the anodized AA6061 by the friction spot process. The joint strength reached an ideal efficiency of 100 per cent.

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“…However, the mechanical properties of the integrated structure must be comparable to the mechanical properties of the structure it replaced. Besides searching for compatible metal and polymer material pairs, a considerable amount of effort is made to convert and optimise existing joining technologies that can be automatized (for example friction stir welding [1][2][3], ultrasonic welding [4][5][6], laser welding [7][8][9][10], and also a combination of laser and ultrasonic welding [11]) to make them suitable for the mass production of integrated structures made from dissimilar materials. One factor that hinders this process is the fact that metals and polymers differ from each other both in physical structure and chemical composition and thus polymers and metals behave differently when joined together [12].…”

Section: Introductionmentioning

confidence: 99%

Mechanical and Optical Investigation of Laser Welded Structural Steel - Poly(methyl-Methacrylate) Hybrid Joint Structures

Csizér

Temesi

Molnár

2019

APP

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Modern welding processes that can easily be automated (such as friction stir welding, laser welding and ultrasonic welding) are gaining popularity in joining metal-polymer hybrid structures. This field of science is intensively studied around the globe, as a dependable, productive joining method that directly produces structurally sound joints between a metal and a polymer structure could unleash unforeseen possibilities in the vehicle industry. In our experiments, we manufactured hybrid steel-poly(methyl-methacrylate) (PMMA) joints with laser welding, using the 2p design of experiment method. We measured the effect of cellulose reinforcing fibres (in varying weight percentages) on the transparency and weldability of the PMMA material and the effect of welding parameters on the mechanical properties of the joints. We also examined the vicinity of the welded seam with scanning electron microscopy.

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Microstructure-property characterization of a friction-stir welded joint between AA5059 aluminum alloy and high density polyethylene

Cited by 99 publications

References 39 publications

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Microstructure and Mechanical Properties of an Ultrasonic Spot Welded Aluminum Alloy: The Effect of Welding Energy

Friction spot lap joining of the anodized aluminium alloy 6061 with high-density polyethylene sheets

Mechanical and Optical Investigation of Laser Welded Structural Steel - Poly(methyl-Methacrylate) Hybrid Joint Structures

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