Friction stir extrusion of aluminum AA6061 into isostatically molded graphite

This work investigates existing metal-graphite joining methods with friction stir extrusion (FSE) proposed as a viable alternative process. Current for these materials, including adhesives, mechanical fastening, and brazing, all have shortcomings that are desired to be avoided. Aluminum AA6061-T6 is used isostatically molded graphite establish proof-of-concept FSE. Empirically determined operating conditions were established reduced force spikes, vibration, FSE flaws while preventing significant defects in the final product. Successful joints created tested lap shear compression loading. A comparison of joint strength brazed presented. Metal-graphite concluded technique low-load applications. Process optimization future enhancement discussed.