Investigation of the effects of rotation speed, feed and depth of tool penetration on composite metal bonding by friction welding

Combination of metal and composites are frequently used in manufacturing structures.Therefore it is a great importance to join these mat ends composite and metals strongly. Thisjoint between metals and composites plays a key role in hybrid designs. Hybrid design is anewly appearing process for joining metals and composites, which have special and demandingproperties, such as higher strength, higher resistance to radiation and compatible design, etc. Inthe present study, which is an experimental investigation of joining metals and composites usingfriction lab joining (FLJ) method the composite is made up glass fibers, polymer PA6 asThermoplastic and 20% weighs glass fiber. Aluminum alloy (AL 5052) is used as metal.The goal of this study is to explore the strength of joint between composite and metal, which ismade using FLJ in two different ways (static and dynamic). During the study, progress rate,spinning speed and depth of penetration are parameters to be considered as effective on the jointstrength. The results showed that the joint properties and strength was affected by all 3mentioned Parameters, in which, when the penetration depth decreases and normal spinningspeed and progress rate increases, the most efficient joint properties (strength) has beenobtained. As pressure and temperature increases in the joining area, GFRTP gets thinner andthe joint becomes weaker. Due to porosity and voids in the joining area the joint can be failed.The strength of joints in specimen showed a good result in fatigue test. In 72% of the fatiguetest the failure occurred in composite itself not in joint between AL5052/GFRTP.