Friction-stir lap-joining of aluminium-magnesium/poly-methyl-methacrylate hybrid structures: thermo-mechanical modelling and experimental feasibility study

References

• Oliveira PHF, Amancio-Filho ST, dos Santos JF, et al. Preliminary study on the feasibility of friction spot welding in PMMA. Mater Lett. 2010;64:2098–2101. doi: 10.1016/j.matlet.2010.06.050
   Web of Science ®Google Scholar
• Cole GS, Sherman AM. Light weight materials for automotive applications. Mater Charact. 1995;35:3–9. doi: 10.1016/1044-5803(95)00063-1
   Web of Science ®Google Scholar
• Amancio-Filho ST, dos Santos JF. Joining of polymers and polymer–metal hybrid structures: recent developments and trends. Polym Eng Sci. 2009;49:1461–1476. doi: 10.1002/pen.21424
   Web of Science ®Google Scholar
• Bilici MK, Yükler Aİ, Kurtulmuş M. The optimization of welding parameters for friction stir spot welding of high density polyethylene sheets. Mater Des. 2011;32:4074–4079. doi: 10.1016/j.matdes.2011.03.014
   Web of Science ®Google Scholar
• Grujicic M, Sellappan V, Omar MA, et al. An overview of the polymer-to-metal direct-adhesion hybrid technologies for load-bearing automotive components. J Mater Process Technol. 2008;197:363–373. doi: 10.1016/j.jmatprotec.2007.06.058
   Web of Science ®Google Scholar
• Bergmann JP, Stambke M. Potential of laser-manufactured polymer-metal hybrid joints. Phys Procedia. 2012;39:84–91. doi: 10.1016/j.phpro.2012.10.017
   Google Scholar
• Mackwood AP, Crafer RC. Thermal modelling of laser welding and related processes: a literature review. Opt Laser Technol. 2005;37:99–115. doi: 10.1016/j.optlastec.2004.02.017
   Web of Science ®Google Scholar
• Matheny MP, Graff KF. 11 – Ultrasonic welding of metals. In: Gallego-Juárez JA, Graff KF, editors. Power ultrasonics. Oxford: Woodhead Publishing; 2015. p. 259–293.
   Google Scholar
• Yan P, Güngör ÖE, Thibaux P, et al. Tackling the toughness of steel pipes produced by high frequency induction welding and heat-treatment. Mater Sci Eng A. 2011;528:8492–8499. doi: 10.1016/j.msea.2011.07.034
   Web of Science ®Google Scholar
• Min J, Li Y, Li J, et al. Friction stir blind riveting of carbon fiber-reinforced polymer composite and aluminum alloy sheets. Int J Adv Manuf Technol. 2015;76:1403–1410. doi: 10.1007/s00170-014-6364-8
   Web of Science ®Google Scholar
• Gao X, Liu Y, Lan C, et al. Laser-induced infrared characteristic analysis for evaluating joint deviation during austenitic stainless steel laser welding. Int J Adv Manuf Technol. 2017;88:1877–1888. doi: 10.1007/s00170-016-8892-x
   Web of Science ®Google Scholar
• Al-Sanea SA. Mixed convection heat transfer along a continuously moving heated vertical plate with suction or injection. Int J Heat Mass Transf. 2004;47:1445–1465. doi: 10.1016/j.ijheatmasstransfer.2003.09.016
   Web of Science ®Google Scholar
• He X, Gu F, Ball A. A review of numerical analysis of friction stir welding. Prog Mater Sci. 2014;65:1–66. doi: 10.1016/j.pmatsci.2014.03.003
   Web of Science ®Google Scholar
• Abibe AB, Amancio-Filho ST, dos Santos JF, et al. Mechanical and failure behaviour of hybrid polymer–metal staked joints. Mater Des. 2013;46:338–347. doi: 10.1016/j.matdes.2012.10.043
   Web of Science ®Google Scholar
• Blaga L, Bancilă R, dos Santos JF, et al. Friction riveting of glass-fibre-reinforced polyetherimide composite and titanium grade 2 hybrid joints. Mater Des. 2013;50:825–829. doi: 10.1016/j.matdes.2013.03.061
   Web of Science ®Google Scholar
• Balle F, Wagner G, Eifler D. Ultrasonic spot welding of aluminum sheet/carbon fiber reinforced polymer – joints. Materialwiss Werkstofftech. 2007;38:934–938. doi: 10.1002/mawe.200700212
   Web of Science ®Google Scholar
• Balle F, Wagner G, Eifler D. Ultrasonic metal welding of aluminium sheets to carbon fibre reinforced thermoplastic composites. Adv Eng Mater. 2009;11:35–39. doi: 10.1002/adem.200800271
   Web of Science ®Google Scholar
• Balle F, Eifler D. Statistical test planning for ultrasonic welding of dissimilar materials using the example of aluminum-carbon fiber reinforced polymers (CFRP) joints. Materwiss Werksttech. 2012;43:286–292. doi: 10.1002/mawe.201200943
   Web of Science ®Google Scholar
• Goushegir SM, dos Santos JF, Amancio-Filho ST. Friction spot joining of aluminum AA2024/carbon-fiber reinforced poly(phenylene sulfide) composite single lap joints: microstructure and mechanical performance. Mater Des. 2014;54:196–206. doi: 10.1016/j.matdes.2013.08.034
   Web of Science ®Google Scholar
• Goushegir SM, dos Santos JF, Amancio-Filho ST. Influence of process parameters on mechanical performance and bonding area of AA2024/carbon-fiber-reinforced poly(phenylene sulfide) friction spot single lap joints. Mater Des. 2015;83:431–442. doi: 10.1016/j.matdes.2015.06.044
   Web of Science ®Google Scholar
• Mitschang P, Velthuis R, Didi M. Induction spot welding of metal/CFRPC hybrid joints. Adv Eng Mater. 2013;15:804–813. doi: 10.1002/adem.201200273
   Web of Science ®Google Scholar
• Khodabakhshi F, Haghshenas M, Chen J, et al. Bonding mechanism and interface characterisation during dissimilar friction stir welding of an aluminium/polymer bi-material joint. Sci Technol Weld Join. 2017;22:182–190. doi: 10.1080/13621718.2016.1211583
   Web of Science ®Google Scholar
• Khodabakhshi F, Haghshenas M, Sahraeinejad S, et al. Microstructure-property characterization of a friction-stir welded joint between AA5059 aluminum alloy and high density polyethylene. Mater Charact. 2014;98:73–82. doi: 10.1016/j.matchar.2014.10.013
   Web of Science ®Google Scholar
• Khodabakhshi F, Ghasemi Yazdabadi H, Kokabi AH, et al. Friction stir welding of a P/M Al–Al2O3 nanocomposite: microstructure and mechanical properties. Mater Sci Eng A. 2013;585:222–232. doi: 10.1016/j.msea.2013.07.062
   Web of Science ®Google Scholar
• Mishra RS, Ma ZY. Friction stir welding and processing. Mater Sci Eng R. 2005;50:1–78. doi: 10.1016/j.mser.2005.07.001
   Web of Science ®Google Scholar
• Khodabakhshi F, Gerlich AP, Simchi A, et al. Cryogenic friction-stir processing of ultrafine-grained Al–Mg–TiO2 nanocomposites. Mater Sci Eng A. 2015;620:471–482. doi: 10.1016/j.msea.2014.10.048
   Web of Science ®Google Scholar
• Nandan R, DebRoy T, Bhadeshia HKDH. Recent advances in friction-stir welding – process, weldment structure and properties. Prog Mater Sci. 2008;53:980–1023. doi: 10.1016/j.pmatsci.2008.05.001
   Web of Science ®Google Scholar
• Amancio-Filho ST, Bueno C, dos Santos JF, et al. On the feasibility of friction spot joining in magnesium/fiber-reinforced polymer composite hybrid structures. Mater Sci Eng A. 2011;528:3841–3848. doi: 10.1016/j.msea.2011.01.085
   Web of Science ®Google Scholar
• Yusof F, Miyashita Y, Seo N, et al. Utilising friction spot joining for dissimilar joint between aluminium alloy (A5052) and polyethylene terephthalate. Sci Technol Weld Join. 2012;17:544–549. doi: 10.1179/136217112x13408696326530
   Web of Science ®Google Scholar
• Liu FC, Nakata K, Liao J, et al. Reducing bubbles in friction lap welded joint of magnesium alloy and polyamide. Sci Technol Weld Join. 2014;19:578–587. doi: 10.1179/1362171814Y.0000000228
   Web of Science ®Google Scholar
• Ratanathavorn W, Melander A. Dissimilar joining between aluminium alloy (AA 6111) and thermoplastics using friction stir welding. Sci Technol Weld Join. 2015;20:222–228. doi: 10.1179/1362171814Y.0000000276
   Web of Science ®Google Scholar
• Shahmiri H, Movahedi M, Kokabi AH. Friction stir lap joining of aluminium alloy to polypropylene sheets. Sci Technol Weld Join. 2017;22:120–126. doi: 10.1080/13621718.2016.1204171
   Web of Science ®Google Scholar
• Jamshidi Aval H, Serajzadeh S, Kokabi AH, et al. Effect of tool geometry on mechanical and microstructural behaviours in dissimilar friction stir welding of AA 5086-AA 6061. Sci Technol Weld Join. 2011;16:597–604. doi: 10.1179/1362171811Y.0000000044
   Web of Science ®Google Scholar
• Nandan R, Roy GG, Lienert TJ, et al. Three-dimensional heat and material flow during friction stir welding of mild steel. Acta Mater. 2007;55:883–895. doi: 10.1016/j.actamat.2006.09.009
   Web of Science ®Google Scholar
• Arora A, Nandan R, Reynolds AP, et al. Torque, power requirement and stir zone geometry in friction stir welding through modeling and experiments. Scr Mater. 2009;60:13–16. doi: 10.1016/j.scriptamat.2008.08.015
   Web of Science ®Google Scholar
• Zhu X, Chao Y. Numerical simulation of transient temperature and residual stresses in friction stir welding of 304L stainless steel. J Mater Process Technol. 2004;146:263–272. doi: 10.1016/j.jmatprotec.2003.10.025
   Web of Science ®Google Scholar
• Zhang Z, Chen JT, Zhang ZW, et al. Coupled thermo-mechanical model based comparison of friction stir welding processes of AA2024-T3 in different thicknesses. J Mater Sci. 2011;46:5815–5821. doi: 10.1007/s10853-011-5537-1
   Web of Science ®Google Scholar
• Abibe AB, Sônego M, dos Santos JF, et al. On the feasibility of a friction-based staking joining method for polymer–metal hybrid structures. Mater Des. 2016;92:632–642. doi: 10.1016/j.matdes.2015.12.087
   Web of Science ®Google Scholar
• Zhang J, Shen Y, Li B, et al. Numerical simulation and experimental investigation on friction stir welding of 6061-T6 aluminum alloy. Mater Des. 2014;60:94–101. doi: 10.1016/j.matdes.2014.03.043
   Web of Science ®Google Scholar
• Smithells metals reference book. 8th ed. Gale WF, Totemeier TC, editors. Oxford: Elsevier Inc.; 2004.
   Google Scholar
• Arora A. Thermomechanical conditions and stresses on the friction stir welding tool [Phd thesis]. The Pennsylvania State University The Graduate School; 2011.
   Google Scholar
• Nandan R. Computational modeling of heat transfer and visco-elastic flow in friction stir welding [Phd thesis]. The Pennsylvania State University; 2008.
   Google Scholar
• Zhang Z, Wu Q. Numerical studies of tool diameter on strain rates, temperature rises and grain sizes in friction stir welding. J Mater Sci Technol. 2015;29:4121–4128.
   Google Scholar
• Zhang Z, Zhang HW. Solid mechanics-based Eulerian model of friction stir welding. Int J Adv Manuf Technol. 2014;72:1647–1653. doi: 10.1007/s00170-014-5789-4
   Web of Science ®Google Scholar
• Khodabakhshi F, Simchi A, Kokabi AH, et al. Reactive friction stir processing of AA 5052–TiO2 nanocomposite: process–microstructure–mechanical characteristics. Mater Sci Technol. 2015;31:426–435. doi: 10.1179/1743284714Y.0000000573
   Web of Science ®Google Scholar
• Kumar AP, Raj R, Kailas SV. A novel in-situ polymer derived nano ceramic MMC by friction stir processing. Mater Des. 2015;85:626–634. doi: 10.1016/j.matdes.2015.07.054
   Web of Science ®Google Scholar
• Khodabakhshi F, Simchi A, Kokabi AH, et al. Effects of nanometric inclusions on the microstructural characteristics and strengthening of a friction-stir processed aluminum–magnesium alloy. Mater Sci Eng A. 2015;642:215–229. doi: 10.1016/j.msea.2015.06.081
   Web of Science ®Google Scholar
• Simões F, Rodrigues DM. Material flow and thermo-mechanical conditions during friction stir welding of polymers: literature review, experimental results and empirical analysis. Mater Des. 2014;59:344–351. doi: 10.1016/j.matdes.2013.12.038
   Web of Science ®Google Scholar
• De Leon M, Shin HS. Material flow behaviours during friction stir spot welding of lightweight alloys using pin and pinless tools. Sci Technol Weld Join. 2016;21:140–146. doi: 10.1179/1362171815Y.0000000075
   Web of Science ®Google Scholar
• Derazkola HA, Aval HJ, Elyasi M. Analysis of process parameters effects on dissimilar friction stir welding of AA1100 and A441 AISI steel. Sci Technol Weld Join. 2015;20:553–562. doi: 10.1179/1362171815Y.0000000038
   Web of Science ®Google Scholar
• Elyasi M, Derazkola HA, Hosseinzadeh M. Investigations of tool tilt angle on properties friction stir welding of A441 AISI to AA1100 aluminium. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture; 2016. DOI:10.1177/0954405416645986
   Google Scholar
• Eskandari H, Taheri R, Khodabakhshi F. Friction-stir processing of an AA8026-TiB2-Al2O3 hybrid nanocomposite: microstructural developments and mechanical properties. Mater Sci Eng A. 2016;660:84–96. doi: 10.1016/j.msea.2016.02.081
   Web of Science ®Google Scholar
• Khodabakhshi F, Simchi A, Kokabi AH, et al. Effects of stored strain energy on restoration mechanisms and texture components in an aluminum–magnesium alloy prepared by friction stir processing. Mater Sci Eng A. 2015;642:204–214. doi: 10.1016/j.msea.2015.07.001
   Web of Science ®Google Scholar
• Galvão I, Oliveira JC, Loureiro A, et al. Formation and distribution of brittle structures in friction stir welding of aluminium and copper: influence of process parameters. Sci Technol Weld Join. 2011;16:681–689. doi: 10.1179/1362171811Y.0000000057
   Web of Science ®Google Scholar
• Nishida T, Ogura T, Nishida H, et al. Formation of interfacial microstructure in a friction stir welded lap joint between aluminium alloy and stainless steel. Sci Technol Weld Join. 2014;19:609–616. doi: 10.1179/1362171814Y.0000000232
   Web of Science ®Google Scholar
• Vigueras DJ, de Renero CT, Inal OT. Explosive and impact welding: technical review. Mater Technol. 2007;22:200–204. doi: 10.1179/175355507X236740
   Web of Science ®Google Scholar