Comparative Evaluation of Weld Quality, Mechanical Performance, and Feasibility in Dissimilar Friction Stir Welded AA 8090–CFRP and AA 8090-PP Joints

Abstract

Friction stir welding (FSW) joins materials without melting them during the process. It is often used for aluminum because it is more effective than conventional welding methods.

Friction Stir Welding (FSW) can be utilized in the fabrication of thermoplastic polymers and dissimilar hybrid structures, resulting in joints with significant mechanical strength. Nevertheless, the process may occasionally lead to defects, such as voids or incomplete bonding, which could potentially compromise the overall strength and reliability of the joint.

This study presents an experimental investigation into the dissimilar joining of AA 8090 aluminum alloy with carbon fiber reinforced (CFR) polymer and polypropylene (PP) under comparable friction stir welding (FSW) conditions. This study evaluated the joint feasibility, tensile performance, and weld defect characteristics of both material combinations.