Mechanical and microstructural aspects of the hybrid joint of PP-C30S and 2219 aluminum alloy

• Published in: Results in physics 2020-12, Vol.19, p.103629, Article 103629
• Main Authors: Memon, S., Paidar, M., Sadreddini, S., Cooke, K., Babaei, B., Ojo, O.O.
• Format: Article
• Language: English
• Subjects: 2219 aluminum alloy; Polymers; Reaction layer; Weld strength
• ISSN: 2211-3797; 2211-3797
• DOI: 10.1016/j.rinp.2020.103629

•A determined and specified reaction layer was created around the threaded hole and between the substrates, irrespective of the process type.•Various frictional heat and adhesion force was generated during processes.•Maximum Tensile/shear strength of 436 N and Cross-tension strength of 148 N have been gained from the THFSSW process due to the larger reaction layer and dominant mechanical interlocking between the polymer and the threaded hole within the aluminum plate. In this work, 2219 aluminum alloy and PP-C30S sheets are welded using Threaded-hole Friction Stir Spot Welding (THFSSW) and Probeless Friction Stir Spot Welding (PFSSW). The results revealed that the reaction layers were produced between the aluminum and polymer, irrespective of the process type. However, a larger reaction layer was formed in the THFSSW joint (37 µm) as compared to that of the PFSSW joint (24 µm), and this consequently in conjunction with the induced mechanical interlocking resulted in the increment of the weld strength from 290 N to 436 N. This implies that various frictional heat and adhesion force was generated during processes.