Feasibility of Joining Aluminum to Nylon Using Friction Stir Welding (FSW)

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.