Abstract
In this study, a new method of forming conductive large area metal/polymer composites called top plate friction stir processing was performed using a thin aluminum plate and HDPE sheet. To form the composite, a rotary tool uses friction to heat and stir lapped aluminum into HDPE. This method differs from other forms of friction stir processing polymers because the base material does not need modification prior to processing, increasing the total manufacturing efficiency. Upon processing, the top plate becomes the composite filler material in addition to controlling surface quality by containing the molten polymer and distributing heat. Optical analysis, electrical and thermal conductivity tests, and tensile tests were performed to determine the material distribution, conductivity, and mechanical properties of processed specimens. These tests revealed that top plate friction stir processing improved the electrical and thermal conductivity over the base HDPE. Electrical resistance across specimens measured just several ohms and thermal conductivity increased up to 108%, but mechanical properties have room for improvement.
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