Abstract
Abstract Friction lap welding technology was adopted to join glass fiber reinforced (GFR) nylon 6 and AA6061-T6. Grooves were fabricated on the lap surface of aluminum plate and rectangular GFR nylon fillers were inserted into the grooves before welding operation. Influences of the welding parameters and the number and geometry of the grooves on weld morphology and mechanical performance were investigated. The microscopic analysis showed that the aluminum alloy and the filler incompletely connected with the lower GFR nylon sheet at large welding speed. Increased rotational speed and plunge depth caused the extrusion of GFR nylon material and the generation of a porous solidification layer underneath the lap interface. Three fracture morphologies were observed in the lap-shear tensile tests, including the pure shear fracture, the tearing of the porous solidification layer and the shear fracture accompanied by partial filler pulling out. Through the fabrication of grooves, the joint lap-shear tensile load and fracture displacement were greatly promoted compared with that without grooves. The grooves with the interior angle of 45° were better than that of 90° in promoting the joint performance. Furthermore, the joint fracture load and displacement enhanced with the proper increase of the number of grooves.
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