Thermo-Mechanical Characterization of Metal-Polymer Friction Stir Composite Joints-A Full Factorial Design of Experiments

• Published in: Polymers 2024-02, Vol.16 (5), p.602
• Main Authors: Correia, Arménio N, Gaspar, Beatriz M, Cipriano, Gonçalo, Braga, Daniel F O, Baptista, Ricardo, Infante, Virgínia
• Format: Article
• Language: English
• Subjects: Adhesive bonding; Alloys; Aluminum alloys; Aluminum base alloys; Analysis; Chemical bonds; Design of experiments; Dissimilar metals; Emission standards; Factorial design; Factorial experiment designs; Fiber reinforced polymers; Fibrous composites; Friction; Friction stir welding; Fuel cells; Glass fiber reinforced plastics; Glass fibers; Heat resistance; Identification and classification; Impact strength; Manufacturing; Mechanical properties; Metal fatigue; Oxidation; Polyethylene; Polymers; Process parameters; Statistical models; Thermal properties
• ISSN: 2073-4360; 2073-4360
• DOI: 10.3390/polym16050602

With the increasing demand for lighter, more environmentally friendly, and affordable solutions in the mobility sector, designers and engineers are actively promoting the use of innovative integral dissimilar structures. In this field, friction stir-based technologies offer unique advantages compared with conventional joining technologies, such as mechanical fastening and adhesive bonding, which recently demonstrated promising results. In this study, an aluminum alloy and a glass fiber-reinforced polymer were friction stir joined in an overlap configuration. To assess the main effects, interactions, and influence of processing parameters on the mechanical strength and processing temperature of the fabricated joints, a full factorial design study with three factors and two levels was carried out. The design of experiments resulted in statistical models with excellent fit to the experimental data, enabling a thorough understanding of the influence of rotational speed, travel speed, and tool tilt angle on dissimilar metal-to-polymer friction stir composite joints. The mechanical strength of the composite joints ranged from 1708.1 ± 45.5 N to 3414.2 ± 317.1, while the processing temperature was between 203.6 ± 10.7 °C and 251.5 ± 9.7.