DISSIMILAR MATERIALS (ALUMINUM-POLYMER) JOINING USING A HYBRID ADHESIVE-FRICTION SPOT WELDING

Abstract

This thesis investigates the difficulties in integrating hybrid aluminium-polymer structures, which are due to their low weight and excellent strength-to-weight ratio. Significant limitations of the present mechanical joining and adhesive bonding techniques include high-stress concentration, protracted curing time, and unstable connections. Consequently, a new joining method that is economical and productive in production is required. The study looks into the possibility of bonding polycarbonate to aluminium using hybrid joining techniques. Experimental studies, including the use of several joining methods, are used to extensively study the impact of welding and curing conditions on the performance of hybrid joints. Covalent bonds formed between the adhesive and aluminium. The analysis of joints is comprehensively covered, and the bonding processes of various joints, such as frictional spot welding (FSW), adhesive bonding, and hybrid joining, are reviewed. According to the study's findings, adhesive bonding is a potential method for joining aluminium polymer hybrid structures since it produces connections with minimum air gap, good material mixing at the interface, and a maximum shear tensile load of 2980 N. However, there is significant scope for further work to improve the load carrying capacity of such joints