Friction Spot Joining of High-Density Poly-Ethylene to A Stepped Pre-Holed Aluminum Alloy AA5052


Ammar A. Nasser†, Sabah Khammass Hussain†*, Abbas S. Alwan‡


† Engineering Technical College – Baghdad, Middle Technical University, Baghdad, Iraq.
‡ College of Electrical Engineering Technical, Middle Technical University, Baghdad, Iraq.

Corresponding Author Email: sabah.kh1974@yahoo.com

This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

This research aims to study the mechanism of joining between two dissimilar materials, aluminium alloy AA5052 of (2) mm thickness with polymer type high-density polyethylene (HDPE) of (5) mm thickness, utilizing friction spot joining (FSpJ) technique. All samples were made with dimensions (25 * 100) mm. A pre-hole was made in aluminium alloy with a diameter (5) mm and depth of the same thickness as an aluminium alloy of (2) mm, and another hole with a diameter of (8) mm and a depth of (1) mm, same centre as the first hole. The holes were made in the aluminium alloy centre with dimensions (25*25) mm. The aluminium sample was placed over the polymer sample during the clamping and joining process. The process parameters included the rotating speed of the tool of 900, 1120, 1400 and 1800 RPM, pre-heating time of 5, 10, 15, and 20 sec, and plunging depth of the tool of 0.1, 0.2, 0.3, and 0.4 mm. The polymer was extruded through the aluminium hole after applying the parameters to the joint, and a mechanical overlap was obtained between them. The effect of process parameters on the joint’s shear force was analyzed, and its area calculated on the polymer side. The tests were applied [visual examination, tensile shear force, Scanning Electron Microscope (SEM), and Elemental Mapping of Microstructures (EM)]. The hole diameter exhibited the highest effect on the joint shear force, followed by the rotating speed, pre-heating time, and plunging depth. The results showed that the samples failed in the joint zone in the shear force test and the highest shear force was (1050) N, and the lowest shear force was (150) N.