46
N. K. Jha et al.
three techniques used for the fabrication of metal and thermoplastic parts (dissimilar
material).
1. Mechanical fastening
2. Adhesive bonding
3. Solid-state welding [5].
But each welding process has some limitation, Mechanical Fastening (Riveting)
such as increment in weight of component and stress rivets holes lead to stress concentration, which debases the strength as well as generates corrosion, an additional limitation of Adhesively bonded joints often fail instantaneously instead of progressively
that is why forecasting can be burdensome (life Span). This limitation restricts the
use of mechanical fastening and adhesive bonding joining techniques that is why
the new technique used is welding [6]. In welding, conventional processes (SMAW,
GTAW, and GMAW) cannot be used due to the high heat input fusion process which
results in metallurgical distortion and also melting temperature of metals is extremely
high compared to the melting temperature of thermoplastic. Hence, polymers tend to
degrade before metals melt so new promising techniques can be used for joining of
dissimilar materials like ultrasonic welding, laser welding, and friction stir welding
and each process amounts to advantages and limitation [7]. Ultrasonic welding is
widely used for overlap joining with a small amount of plate thickness (1–2 mm)
[5]. During laser welding, heat generated is maximum so polymers tend to degrade
before metal; due to this, we acquire to use the joining technique known as friction
stir welding in our research [7].
It is a solid-state joining technique in which non-consumable tools in the absence
of filler wire and pressure may or may not be used to join the components [8, 9]. The
tool used in friction stir welding is having two parts that are pin and shoulder which
is pushed inside the adjoining edges of two different or the same material where the
material is in the form of plates. When shoulders come in contact with the material
to be joined, friction takes place between them and results in heat generation and pin
shows its importance in the movement of material in such a way that material flows
from the front to the back of the pin. This process results in solid-state welding [9].
The schematic of friction stir welding is shown in Fig. 1.
The intension of this experimental work is to assess the feasibility of the FSW
joint between the aluminum alloy and nylon plates in butt joint configuration and
also exhibit the effects of process parameters such as material position, tilt angle,
offset, and tool rotation.
2 Experiment Procedures
The joining experiments were steered on a vertical milling machine (VMC) as shown
in Fig. 2. The fixture used during the welding process is shown in Fig. 3 made of
stainless steel. Commercial aluminum (Al) plates and nylon sheets having a thickness
of 6 mm were joined by friction stir welding. Initially, the specimen was cut into
N. K. Jha et al.
three techniques used for the fabrication of metal and thermoplastic parts (dissimilar
material).
1. Mechanical fastening
2. Adhesive bonding
3. Solid-state welding [5].
But each welding process has some limitation, Mechanical Fastening (Riveting)
such as increment in weight of component and stress rivets holes lead to stress concentration, which debases the strength as well as generates corrosion, an additional limitation of Adhesively bonded joints often fail instantaneously instead of progressively
that is why forecasting can be burdensome (life Span). This limitation restricts the
use of mechanical fastening and adhesive bonding joining techniques that is why
the new technique used is welding [6]. In welding, conventional processes (SMAW,
GTAW, and GMAW) cannot be used due to the high heat input fusion process which
results in metallurgical distortion and also melting temperature of metals is extremely
high compared to the melting temperature of thermoplastic. Hence, polymers tend to
degrade before metals melt so new promising techniques can be used for joining of
dissimilar materials like ultrasonic welding, laser welding, and friction stir welding
and each process amounts to advantages and limitation [7]. Ultrasonic welding is
widely used for overlap joining with a small amount of plate thickness (1–2 mm)
[5]. During laser welding, heat generated is maximum so polymers tend to degrade
before metal; due to this, we acquire to use the joining technique known as friction
stir welding in our research [7].
It is a solid-state joining technique in which non-consumable tools in the absence
of filler wire and pressure may or may not be used to join the components [8, 9]. The
tool used in friction stir welding is having two parts that are pin and shoulder which
is pushed inside the adjoining edges of two different or the same material where the
material is in the form of plates. When shoulders come in contact with the material
to be joined, friction takes place between them and results in heat generation and pin
shows its importance in the movement of material in such a way that material flows
from the front to the back of the pin. This process results in solid-state welding [9].
The schematic of friction stir welding is shown in Fig. 1.
The intension of this experimental work is to assess the feasibility of the FSW
joint between the aluminum alloy and nylon plates in butt joint configuration and
also exhibit the effects of process parameters such as material position, tilt angle,
offset, and tool rotation.
2 Experiment Procedures
The joining experiments were steered on a vertical milling machine (VMC) as shown
in Fig. 2. The fixture used during the welding process is shown in Fig. 3 made of
stainless steel. Commercial aluminum (Al) plates and nylon sheets having a thickness
of 6 mm were joined by friction stir welding. Initially, the specimen was cut into