Joining of Aluminium Alloy AA6061-T6 to PVC Polymer by Friction Stir Lap joining Process

Abstract

Abstract The aim of this research is to join sheets of aluminium alloy AA6061-T6 of 1.5 mm thickness with polymer polyvinyl chloride (PVC) of 4 mm thickness by a friction lap technique. Drill holes of 3, 4 and 5 mm were produced in the AA6061 specimens and a lap joint arrangement was set up with the PVC sheet. Six parameters were used in this technique: hole diameter, tool diameter, number of holes, rotating speed, linear speed, and tool plunging depth. The shear test results at the holes were analyzed by a Minitab program with the aid of the Taguchi method. IR thermometer was used to measure the temperature distribution at the joint. The results indicated that all the samples failed with shearing the PVC at the aluminium hole without dislocation the polymer. The maximum shear force is 1850N. The joint shear force increased by increasing the plunging depth and rotation speed of the tool and decreased by increasing the hole numbers and diameter of the aluminium specimen. The hole diameter beside the rotating and the linear speed exhibited the highest effect on the joint shear strength. The developed temperature during the joining process was an effective parameter on the joints quality. The SEM tests indicated that the joining between the aluminium and polymers occurred by a mechanical interlocking at the common surfaces.