Work

Effect of process temperatures on joining aluminum alloy (AA5052) to polypropylene (PP) by friction lap welding

Year: 2024

Type: article

Abstract: The joining of aluminum alloy 5052 (AA5052) and polypropylene (PP) by friction lap welding (FLW) was investigated under different process temperature conditions. Welding experiments were conducted at different tool rotational speeds, and the process temperatures were monitored using an infrared camera and thermocouples. The temperature distribution at the cross-section was determined using a validated numerical model. The joint quality was assessed by measuring tensile shear strength and examining the joint morphology. It was found that interfacial temperatures in the range of 156°C to 316°C were optimal for achieving effective mechanical interlocking, attributed to the appropriate flow of molten PP into the textured aluminum alloy surface. Temperatures below 130°C resulted in inadequate PP flow, leading to poor joint formation, while temperatures above 316°C caused over-melting of PP, bubble formation, and approached the PP initial decomposition limit. Raman spectroscopy showed that the process temperatures did not cause significant chemical bonding and that mechanical interlocking was the main contributing joining mechanism.

Source: Journal of Materials Research and Technology

DOI: 10.1016/j.jmrt.2024.10.107

Authors: Abdelrahman I. Hosny, J. Sheikh-Ahmad, F. Almaskari, K. Khan, S. Deveci, Ahmed I. Alhatti

Institutions: Khalifa University of Science and Technology, Western New England University

Language: English

Topic: Advanced Welding Techniques Analysis

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

Open Access status: gold

Estimated APC paid: $1,430

Funder: Khalifa University of Science, Technology and Research