Abstract
Aluminum alloys and high density polyethylene are utilized in a wide variety of industrial applications. In the present work the feasibility of friction stir butt welding between AA5059 alloy and high density polyethylene sheets is examined. The bonding mechanism, joint strength, and microhardness are considered in this study. Various welding parameters and tool alignment were investigated until sound joints were achieved by positioning approximately 85% of the rotating tool in the aluminum material on the advancing side (1.4mm offset) at constant spindle speed and traverse speed of 710rpm and 63mm/min, respectively. The results indicate that AA5059 aluminum and high density polyethylene sheets can be successfully joined with a combination of secondary bonding and mechanical interlocking of the materials, which provides a potential alternative to adhesive bonding or mechanical fastening.
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