Dissimilar welding

Friction stir welding

FSW of Aluminum with PP : Joining different parts is one of the crucial components of designing/engineering of materials. Presently, the current energy efficient low weight automotive and aerospace components consist of a different class of materials, such as metals, polymers, ceramics, etc. Joining these components remains a challenge. Here, we demonstrate metal (aluminum) and polymer (Polypropylene, pp) joining using mechanical friction. The detailed characterization clearly demonstrates that atomically locked interfaces are formed in such joining and no chemical bonds are formed during the joining.

Modeling and simulation

Modeling of Dissimilar FSW: A heat transfer numerical model is developed for friction stir welding of dissimilar materials Al 6061 and AZ31 alloy. Thermophysical properties were experimentally determined for the stir zone and compared with the base alloys. Experimentally determined thermo-physical properties of the stir zone are not strictly the average values of the base alloys but exhibit a complex relationship with the microstructural features and the intermixing of Al and Mg in the weld region.