Navigating Joining Challenges in Friction Stir Welding of Hybrid Composite Structures

Abstract

Joining hybrid composites is challenges due to the combination of different materials with varying physical, chemical and thermal properties, and their compatibility with FSW process. However, the components of a successful FSW joint must be selected based on their thermal properties. The heat input through increasing the tool rotational speed, tilt angle and plunge depth, and decreasing the traverse speed influences the FSW joint strength. A large shoulder tool diameter and concave profile along with short pins generates a high strength joint. The suitable tool material is selected based on the mechanical properties of the welded materials. Voids, bubbles, pores, and contact layer between the metal and polymer are the main internal defects in the FSW joints. Mechanical interlocking is the main bonding mechanism throughout the joining process. By addressing the challenges associated with joining hybrid composite structures using FSW techniques, engineers are eager to formulate a comprehensive procedure that makes FSW process possible for this newly developed class of materials.