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Metals 2016, 6(5), 101; doi:10.3390/met6050101

Effect of Surface States on Joining Mechanisms and Mechanical Properties of Aluminum Alloy (A5052) and Polyethylene Terephthalate (PET) by Dissimilar Friction Spot Welding

1
Department of Mechanical Engineering, University of Malaya, Kuala Lumpur 50603, Malaysia
2
Centre of Advanced Manufacturing and Material Processing, University of Malaya, Kuala Lumpur 50603, Malaysia
3
Department of System Safety, Nagaoka University of Technology, Nagaoka 940-2188, Japan
*
Author to whom correspondence should be addressed.
Academic Editor: Nong Gao
Received: 10 February 2016 / Revised: 14 March 2016 / Accepted: 18 March 2016 / Published: 28 April 2016
(This article belongs to the Special Issue Aluminum Alloys)
View Full-Text   |   Download PDF [7067 KB, uploaded 28 April 2016]   |  

Abstract

In this research, polyethylene terephthalate (PET), as a high-density thermoplastic sheet, and Aluminum A5052, as a metal with seven distinct surface roughnesses, were joined by friction spot welding (FSW). The effect of A5052’s various surface states on the welding joining mechanism and mechanical properties were investigated. Friction spot welding was successfully applied for the dissimilar joining of PET thermoplastics and aluminum alloy A5052. During FSW, the PET near the joining interface softened, partially melted and adhered to the A5052 joining surface. The melted PET evaporated to form bubbles near the joining interface and cooled, forming hollows. The bubbles have two opposite effects: its presence at the joining interface prevent PET from contacting with A5052, while bubbles or hollows are crack origins that induce crack paths which degrade the joining strength. On the other hand, the bubbles’ flow pushed the softened PET into irregularities on the roughened surface to form mechanical interlocking, which significantly improved the strength. The tensile-shear failure load for an as-received surface (0.31 μ m Ra) specimen was about 0.4–0.8 kN while that for the treated surface (>0.31 μ m Ra) specimen was about 4.8–5.2 kN. View Full-Text
Keywords: friction spot welding; surface roughness; dissimilar welding; polyethylene terephthalate (PET); aluminum alloy; bubble friction spot welding; surface roughness; dissimilar welding; polyethylene terephthalate (PET); aluminum alloy; bubble
This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Yusof, F.; Muhamad, M.R.; Moshwan, R.; Jamaludin, M.F.; Miyashita, Y. Effect of Surface States on Joining Mechanisms and Mechanical Properties of Aluminum Alloy (A5052) and Polyethylene Terephthalate (PET) by Dissimilar Friction Spot Welding. Metals 2016, 6, 101.

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