1. JOINING OF METALAND PLASTIC
Joints of metal and plastic offer a great potential for
lightweight design and construction.
The synergistic use of metals and plastics in combination
is the likely line of approach in current manufacturing
applications.
Metals and plastics are used in combination in many
industries such as aerospace, automobiles and even in
construction industries.
This has led to high demands in industry and research
interests in joining dissimilar materials involving plastics
and metallic materials.
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2. FRICTION STIR WELDING
Friction Stir Welding (FSW) is typically used to join
aluminium and some lightweight alloys such as magnesium
and titanium.
Welding through friction as the major technique.
No filler material involved.
Welds created by Frictional heating and Mechanical
deformation.
Rotating probe provides friction heat and pressure which
joins the material.
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3. NYLON
Nylon is an engineering thermoplastics possess high
strength, high toughness, flame retardant characteristics,
good rigidity and durability with Tg of 500c .
Excellent insulating properties, corrosion resistance and
light weight make them very useful materials in
automobile, aerospace, and structural parts
Tensile strength of nylon is comparable to aluminium..
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4. ALUMINIUM ALLOYS
Aluminium is the most widely used non-ferrous metal it is
relatively soft, durable, lightweight and ductile metal.
The ALUMINIUM 6061 alloys are heat treatable and high
strength coupled with excellent corrosion resistance.
A unique feature is their extrudability, making them the first
choice for architectural and structural members.
ALUMINIUM 6061 alloy finds broad use in welded
structural members such as truck, marine frames and
pipelines.
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5. AIM OF RESEARCH
To join Nylon-6 plastic to Aluminum alloy 6061 by using
friction lap welding.
To understand the metal-plastics welding, the effects of
welding parameters on the quality of joints in terms of the
maximum tensile shear strength, bending strength and
torsional strength will be investigated.
To increase the weld joint strength by producing
interlocking geometries with various cross cut indentations
in the joining portion of metal.
To examine the fractured surfaces by using scanning
electron microscopy and image processing.
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6. OBJECTIVES
Enhance knowledge of FSW on hybrid-welding
processes of Nylon-6 plastic to aluminum alloy AA6061.
Understand the effects of welding parameters on weld
joint.
Determine, if the interlocking geometries with various
cross cut indentations in the joining portion of metal has an
influence on Mechanical properties of FSW Nylon-6 and
aluminum alloy AA6061.
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7. •Parameters that have an influence on the
weld quality as well as determining the best
setup in terms of tool dimension, rotation rate,
weld speed and plunge depth.
PRELIMINARY
WELDING,
PROCESS
PARAMETERS
AND TRIAL TENSILE
TESTS
• Interlocking geometries with various cross
cut indentations are made on the joining
portion of metal.
INTERLOCKING
GEOMETRIES
• Tensile, Bending and Torsional strength
MECHANICAL
PROPERTIES
• SEM & Image Processing
STRUCTURAL
CHARACTERIZATIO
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11. REFERENCE
F.C. Liu , J. Liao , K. Nakata “Joining of metal to plastic using friction lap welding”
Materials and Design 54 (2014) 236–244 .
A. B. ABIBE, S. T. AMANCIO-FILHO et al “Development and Analysis of a New Joining
Method for Polymer–Metal Hybrid Structures” Journal of Thermoplastic Composite
Materials (2010)
S.T. Amancio-Filho, J.F. dos Santos “Joining of Polymers and Polymer–Metal Hybrid
Structures: Recent Developments and Trends” POLYMER ENGINEERING AND
SCIENCE (2009).
K. Panneerselvam , K. Lenin “Joining of Nylon 6 plate by friction stir welding process
using threaded pin profile” Materials and Design 53 (2014) 302–307.
Mehdi Pirizadeh, Taher Azdast et al “Friction stir welding of thermoplastics using a
newly designed tool” Materials and Design 54 (2014) 342–347.
A.B. Abibe , S.T. Amancio-Filho et al “Mechanical and failure behavior of hybrid
polymer–metal staked joints” Materials and Design 46 (2013) 338–347.
G. RAMARATHNAM, M. LIBERTUCCI et al “Joining of Polymers to Metal” Welding
Research supplement (1991)
McKenna, L., Wohl, M., and Woodbrey, J., "New Light-Weight Materials for Vehicle Body
Panels –Aluminum/Nylon Laminates," SAE Technical Paper 800079, 1980,.
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