Investigations on the Joining of dissimilar metalpolymer composite using eccentric weave friction stir Welding process

Abstract

Metal and polymer joining has many industrial and aerospace newlineapplications. The hybrid composite joints help to reduce the weight of newlinestructural and thermal stability components. PEEK (Poly ether-ether- newlineKetone) has a higher thermal stability than thermoplastic joints with newlinemetallic phases. These polymeric compounds need alloying to metallic newlinephases like aluminium. To join these two dissimilar metals, their newlinehardness must be uniform. Joining dissimilar materials poses challenges newlinedue to differences in mechanical, thermal, and chemical properties. The newlinetraditional joining methods of adhesive bonding, riveting, clinching, and newlinefastening provide only limited strength. newlineSo a metal joining under visco-plastic stage is required. One of newlinethe most widely used methods is friction stir welding. It only acts as an newlineadhesive structure when joining metallic and polymeric substances, so a newlinebinder is required. A nano additive like carbonaceous materials can help newlinestrengthen the weldment joint. Carbonaceous materials provide strong newlinemechanical properties even at high temperatures. MWCNTs have newlineexcellent mechanical and microstructural properties. The addition of newlineeccentric weave friction stir attachment to aluminium and Poly-Ether- newlineEther-Ketone (PEEK) alloy changes the micro and macro structural newlinedefects. The results of various tool pin profiles in the square, spherical, newlineand spiral shapes were revealed. The attachment method parameters newlinewere 1500 and 2000 rpm, 1.0 mm and 2.0 mm tool pin movement step newlinesize, and weaving rates of 100 and 150 mm/min. These include tool newlineii newlinespeed, feed rate, tool pin offset and axial force. The output responses in newlinefactorial representation with regression models were developed using newlinecentral composite design and Response Surface Methodology (RSM). newlineUltimate Tensile Strength (UTS), impact strength, and newlinevolumetric dispersion are responses. Mechanical, microstructural, and newlineX-ray testing evaluated the tool movement pattern and power pin profile newlinebenefits. Weaving rate of 150mm/min and sq. tool pin profile newlinecombination provide high