Improving appearance and mechanical strength of aluminum-polypropylene/talc composite friction stir joint using a novel tool design

In this research, friction stir joining of aluminum-polypropylene/talc composite was investigated due to the numerous applications aluminum-polymer joints in automotive and aerospace industry. A novel tool design, including a rotary/stationary holder, used improve appearance mechanical performance lap by preventing mixed molten polymer aluminum particles from exiting stirred zone. Effect transverse speed on joint microstructure strength investigated. Using tensile-shear increased (by ~ 45 220% at various speeds). Since during test all failed aluminum/stirred zone interface, affected formation anchor-like pieces substrate as locks, reaction layer large voids near interface. Joining optimum led highest peak load 315 N.