Nanomechanical analysis of friction welded similar PEEK/aluminum nanocomposites: Effect of metal particle reinforcement

Abstract

Aluminum (Al), poly(etheretherketone) (PEEK) thermoplastics, and their individual composites have widely been used in many industries, including aerospace and biomedical fields. However, the joining process of those composites has not been explored much to date. In this context, the friction welding process (FWP) could be used as an alternative since it has the ability to join high‐strength components with minimal distortion. Therefore, the present study aimed to develop PEEK/Al nanocomposites with varying Al concentrations of 10, 20, 30, and 40 vol% using powder metallurgical technique and further joined the similar composition composites by FWP. Then, the effect of reinforced particle concentrations on the physical, morphological, structural, thermal, and micromechanical behaviors of the joined nanocomposites has been characterized by microscopy, X‐ray diffraction, differential scanning calorimetry, and nanoindentation tests. The concentrations of the reinforcement were found to have a significant effect on the crystallinity, melting temperature, glass transition temperature, and thereby micromechanical properties. The results were analyzed and correlated precisely for all the welded nanocomposites systematically. The interdiffusion mechanism was found to be involved in improving the mechanical properties of the present nanocomposites. The highest elastic modulus (13.91 GPa) or nanohardness (0.31 GPa) was obtained for the rotatory part of the PEEK/Al40 nanocomposites at 80 mN load. But, the applied load of 40 mN was the best loading condition due to the uniform change in modulus and nanohardness of all the nanocomposites. Therefore, the present alternative joining method of the PEEK/Al nanocomposites might be used for aerospace components.Highlights Development of PEEK/aluminum with 10, 20, 30 and 40 vol% Al nanocomposites. Friction welding of similar composite material, PEEK/Al‐PEEK/Al nanocomposites. Microstructural, thermal, and nanomechanical analyses. Effect of metal particle reinforcement on the friction welded nanocomposites. FW PEEK/Al40 nanocomposite is found to be the best.