Mechanical and microstructural aspects of the hybrid joint of PP-C30S and 2219 aluminum alloy

Abstract In this work, 2219 aluminum alloy and PP-C30S sheets are welded using Threaded-hole Friction Stir Spot Welding (THFSSW) and Probeless Friction Stir Spot Welding (PFSSW). The results revealed that the reaction layers were produced between the aluminum and polymer, irrespective of the process type. However, a larger reaction layer was formed in the THFSSW joint (37µm) as compared to that of the PFSSW joint (24µm), and this consequently in conjunction with the induced mechanical interlocking resulted in the increment of the weld strength from 290 N to 436 N. This implies that various frictional heat and adhesion force was generated during processes.