Abstract
The effect of plunge speed on the friction stir spot welding of AA5052-H32/HDPE/AA5052-H32 sandwich sheets is studied in the range of 2 mm/min. to 12 mm/min. The joint performance is assessed through hook geometry, grain size, hardness distribution, and temperature distribution. The hook geometry and hardness significantly affect the joint performance. The performance of sandwich sheet are best at plunge speed of 8 mm/min. and 6 mm/min. in lap shear and cross-tension tests respectively while in peel test, it persistently enhanced with increasing plunge speed. The failure modes and locations predicted with finite element simulation match with experimental results.
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