Feasibility of Joining Aluminum to Nylon
Using Friction Stir Welding (FSW)
Nitesh Kumar Jha, Darshit K. Desai, and Vishvesh J. Badheka
Abstract Friction stir welding has been showing the promising result for joining the
thermoplastic and aluminum over conventional joining because of heat produced by
friction rather than direct flame. In the coming future, the joining of aluminum and
thermoplastic will make innovative manufacturing due to its lightweight and high
strength-to-weight ratio. This experimental work comes up with the feasibility of
joining dissimilar material through numerous process parameters such as changing
position, offset, and tool rotation. The dissimilar joining (butt joint) of aluminum and
nylon with the thickness of 6-mm plate was executed by friction stir welding (FSW).
We started our work by varying the tool rotational speed from 270 to 540 rpm by
fixing the traverse speed. The further experiment was carried by varying the position
of material taking the constant tool speed and under various offsets. It was perceived
that to gain an effective joint process parameter plays a significant role.
Keywords Friction stir welding · Aluminum · Nylon · Dissimilar joining
1 Introduction
In recent days, the use of aluminum and its alloys, and thermoplastic is more due to
their dominant mechanical properties such as high strength-to-weight ratio, relatively
low cost, non-magnetic and corrosion resistance properties. They are used in the
fledgling aeronautical industry, missile, and automobile (supercars) industry [1]. In
the case of aerospace and automobile industry, it reduces the weight [2].
Aluminum and plastic give a high degree of freedom for design as well as manufacturing of products, so fabrication or joining is very important [3, 4]. There are
N. K. Jha (B) · D. K. Desai · V. J. Badheka
Department of Mechanical Engineering, Pandit Deendayal Petroleum University, Gandhinagar
382007, India
e-mail: Nitesh.jmtmm19@sot.pdpu.ac.in
V. J. Badheka
e-mail: vishvesh.badheka@spt.pdpu.ac.in
© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2021
A. K. Parwani et al. (eds.), Recent Advances in Mechanical Infrastructure,
Lecture Notes in Intelligent Transportation and Infrastructure,
https://doi.org/10.1007/978-981-33-4176-0_4
45
Using Friction Stir Welding (FSW)
Nitesh Kumar Jha, Darshit K. Desai, and Vishvesh J. Badheka
Abstract Friction stir welding has been showing the promising result for joining the
thermoplastic and aluminum over conventional joining because of heat produced by
friction rather than direct flame. In the coming future, the joining of aluminum and
thermoplastic will make innovative manufacturing due to its lightweight and high
strength-to-weight ratio. This experimental work comes up with the feasibility of
joining dissimilar material through numerous process parameters such as changing
position, offset, and tool rotation. The dissimilar joining (butt joint) of aluminum and
nylon with the thickness of 6-mm plate was executed by friction stir welding (FSW).
We started our work by varying the tool rotational speed from 270 to 540 rpm by
fixing the traverse speed. The further experiment was carried by varying the position
of material taking the constant tool speed and under various offsets. It was perceived
that to gain an effective joint process parameter plays a significant role.
Keywords Friction stir welding · Aluminum · Nylon · Dissimilar joining
1 Introduction
In recent days, the use of aluminum and its alloys, and thermoplastic is more due to
their dominant mechanical properties such as high strength-to-weight ratio, relatively
low cost, non-magnetic and corrosion resistance properties. They are used in the
fledgling aeronautical industry, missile, and automobile (supercars) industry [1]. In
the case of aerospace and automobile industry, it reduces the weight [2].
Aluminum and plastic give a high degree of freedom for design as well as manufacturing of products, so fabrication or joining is very important [3, 4]. There are
N. K. Jha (B) · D. K. Desai · V. J. Badheka
Department of Mechanical Engineering, Pandit Deendayal Petroleum University, Gandhinagar
382007, India
e-mail: Nitesh.jmtmm19@sot.pdpu.ac.in
V. J. Badheka
e-mail: vishvesh.badheka@spt.pdpu.ac.in
© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2021
A. K. Parwani et al. (eds.), Recent Advances in Mechanical Infrastructure,
Lecture Notes in Intelligent Transportation and Infrastructure,
https://doi.org/10.1007/978-981-33-4176-0_4
45