Composite Structures 174 (2017) 59–69

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Composite Structures
journal homepage: www.elsev ier.com/locate/compstruc t

A new refill friction spot welding process for

aluminum/polymer composite hybrid structures
Proses pengelasan spot refill friksi baru untuk struktur hybrid aluminium / polimer
komposit

Hossein Karami Pabandi, Mojtaba Movahedi ⇑, Amir Hossein Kokabi

Department of Materials Science and Engineering, Sharif University of Technology, P.O. Box 11365-9466, Azadi Avenue, 14588 Tehran, Iran

a r t i c l e i n f o a b s t r a c t

Article history: A new refill friction spot welding process called Threaded Hole Friction Spot Welding (THFSW) was intro-
Received 16 February 2017 duced to join AA5052 aluminum to short-carbon-fiber-reinforced polypropylene (PP-SCF) composite
Revised 28 March 2017 sheets. The process was based on filling of the pre-threaded hole by melted and re-solidified polymer.
Accepted 20 April 2017
The results showed that THFSW was successful to join aluminum to polymer sheets and the hole was
Available online 22 April 2017
completely filled with melted polymer. Formation of a reaction layer composed mostly of Al, C and O
as well as interlocking between the threaded hole and the re-solidified polymer were recognized as main
Keywords:
bonding mechanisms. Maximum shear-tensile strength of the joints reached to 80 percent of the com-
Friction spot welding
posite base strength. Moreover, Mechanical strength and fracture energy of the joints increased with
Refill Polymer
Aluminum enhancement of tool rotational speed. Variation of the joint strength was explored in light of the fracture
Joint strength surface features as well as crystallinity percent of the re-solidified polymer inside the hole.
Fracture energy 2017 Elsevier Ltd. All rights reserved.

1. Introduction
Successful joint between polymers and metallic alloys is a
necessity for the production of light weight polymer/metal hybrid
structures in various industries such as automotive, aeronautics
and shipbuilding industries [1–3]. Together with traditional meth-
ods such as adhesive bonding [4,5] and mechanical fastening [6],
new joining techniques have been patented and developed in
recent years for ‘‘spot” joining of polymers to metallic alloys. Ultra-
sonic staking [7] and Injection Clinching Joining (ICJ) [1,8] are two
methods with relatively the same principles used for spot joining
of polymers and metals. Abibe et al. [1] compared ultrasonic stak-
ing and ICJ methods for joining polyetherimide and AA6082 alu-
minum alloy. Their results indicated that both processes show
similar mechanical properties. However, ICJ had a higher
strength-to-weight ratio due to the presence of hole formed in
the stake. Moreover, ICJ showed longer joining time in comparison
to ultrasonic staking. Abibe et al. [8] also employed ICJ process to
join short-glass-fiber-reinforced polyamide and AA2024 aluminum
alloy. They reported that volume of the rivet head in contact with
the tool system and efficiency of cavity filling are key factors con-
trolling the strength of the joints.
Welding processes have also been used for spot joining of poly-
mers to metals. Friction Stir Spot Welding (FSSW) is a solid state
⇑ Corresponding author.
E-mail address: m_movahedi@sharif.edu (M. Movahedi).
process with high potential for these types of joints. However,
because of leaving an exit-hole at the center of the nugget, the Fric-
tion Spot Joining (FSpJ) process was developed by GKSS of Ger-
many in order to refill the formed exit-hole [9]. FSpJ has been
used successfully for joining of metals to glass and carbon-fiber-
reinforced composites [3,10–13]. Goushegir et al. [3] utilized FSpJ
process for joining AA2024 aluminum and reinforced poly (pheny-
lene sulfide) with 50 vol% carbon fibers (CF-PPS). They concluded
that by enhancement of the tool plunge depth, the shear fracture
load of the joint as well as the extension to fracture improved
due to increase in the joint area at the sheets interface. Esteves
et al. [11] employed FSpJ process for joining AA6181-T4 aluminum
and carbon-fiber-reinforced poly (phenylene sulfide) composite.
Their results showed that tool rotational speed was the most effec-
tive parameter on the joint strength. In addition, they reported that
at high tool rotational speed (1600 rpm), reduction of the metal
viscosity led to decrease in the heat generated during the process.
Therefore, joint area between the aluminum and polymer sheets at
the interface was reduced.
In the present work, a new friction spot welding process called
‘‘Threaded Hole Friction Spot Welding (THFSW)” was used to join
AA5052 aluminum alloy and short-carbon-fiber-reinforced
polypropylene composite sheets. In this joining process, a pre-
threaded hole in the aluminum sheet is filled by the melted and
re-solidified polymer during the process. Thus, no hole remains
at the joint area after completing the process. In comparison to
ultrasonic staking and ICJ, THFSW does not require an initial

http://dx.doi.org/10.1016/j.compstruct.2017.04.053
0263-8223/ 2017 Elsevier Ltd. All rights reserved.
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polymeric stud on the polymer sheet; however, the stud is formed Table 2
in the hole by molten polymer during the process. On the other Chemical composition and mechanical properties of PP-SCF used in this
research.
hand, the same as the ultrasonic staking and ICJ, a hole must be Composition of PP-SCF Mechanical properties of PP-SCF
created in the aluminum sheet before joining process. Further- (wt%)

more, in FSSW a keyhole remains at the joint center due to pin pen- PP-Z30S 92 Hardness, Shore D 72
etration, while the suggested joining process is able to refill the PP-g-MA 5 UTS, MPa 35
threaded hole SCF 3
mechanical andduring the system
electronic process.
is In FSpJ, aforrelatively
required complex
joining. Although,
in THFSW, the joint is produced using a simple cylindrical tool
without pin. After joining process, mechanisms of bonding, as well Table 3
Physical propert ies of polypropylene Z30S [15]
as the effects of the tool rotational speed on the mechanical behav-
ior of the joints, were studied. Properties Unit Amount

Density g/cm3 0.9

2. Materials and experimental procedures Melt flow index (MFI) Dg/min 25
Coefficient of thermal expansion (CTE) 10 6/K 100–150
Thermal conductivity (solid) W/m.K 0.17–0.22
2.1. Materials Thermal conductivity (molten) W/m.K 0.16
Softening point C 165
As-received AA5052 aluminum alloy with a thickness of 2 mm
was used as the metallic part of the joint. Chemical composition,
mechanical and physical properties of AA5052 aluminum alloy
used in this study are presented in Table 1. Polymeric sheets used
in this research were short-carbon-fiber-reinforced polypropylene
Z30S composite (PP-SCF) with 2 mm thickness. Dimensions of car-
bon fibers were 3 mm in length and 17 mm in diameter. Chem-
ical composition and mechanical properties of PP-SCF composite
and physical properties of polypropylene Z30S are listed in Tables
2 and 3, respectively. Fig. 1 shows distribution of carbon fibers in
Z30S polypropylene matrix.

2.2. Joining process

Aluminum sheet with a threaded hole and composite sheet,

both with demotions of 70 30 mm2 were used for joining pro-
cess. To produce the threaded hole, aluminum sheet was drilled
with 4 mm diameter and then threaded by M4 reamer (with the
aim of increasing the joint strength through formation of mechan-
ical interlocks). A cylindrical tool from heat treated H13 steel com-
posed of a shoulder with a diameter of 20 mm was employed as
the welding tool. Joining process was performed in lap configura-
tion with an overlap of 30 mm, while aluminum (as the upper Fig. 1. Distribution of carbon fibers in PP-Z30S matrix.
sheet) was in contact with the tool shoulder. Tool rotational speeds
of 500, 1000, 1500 and 2000 rpm and dwell time of 5 s were
selected for joining. However, since the polymer is a heat insulation material, melting
Schematic of different steps of new joining process introduced of the polymer is limited to the surface of the composite sheet at
in this research (THFSW) is illustrated in Fig. 2. At the first step the interface. Then, by the downward axial pressure of the tool,
of the process, rotating tool is located coaxially with threaded hole melted polymer flows towards the periphery of the joint location
on top of the aluminum sheet surface as shown in Fig. 2-a. In the at the interface. The molten polymer around the hole in aluminum
next step, the rotating tool is moved downward and the shoulder sheet fills the hole and mechanical interlocks are formed between
penetrates 0.3 mm in the aluminum surface (Fig. 2-b). As a result polymer and aluminum due to the existence of threads inside the
of contact between the rotating tool and aluminum sheet, frictional hole (Fig. 2-c and d). After 5 s dwell time, the tool is retracted
heat is generated. This heat reaches to the aluminum/polymer upward (Fig. 2-e), and the joint is completed with the solidification
interface via conduction and melts the polymer at the interface. of the molten polymer inside the hole (Fig. 2-f). It should be noted
that by enhancement of the hole diameter, the required volume of
the molten polymer for filling the hole increases. On the other
hand, raising the shoulder plunging depth leads to increase in
the volume of the molten polymer flowed from the interface of
Table 1
Chemical composition, mechanical and physical properties of AA5052 used in this
the base sheets toward the threaded hole. Therefore, larger diam-
research. eter of the threaded hole needs higher shoulder plunging depth.
Composition Mechanical and physical properties
(wt%)
2.3. Temperature measurement
Al Base Yield Strength, MPa 214
In order to measure temperature variations during the joining
Mg 2.34 UTS, MPa 265
Cr 0.20 Elongation,% 13.5 process, K-type thermocouples with 0.5 mm diameter were
Fe 0.23 Thermal conductivity, W/m.K 138 [14] embedded into the interface of sheets at a distance of 10, 20 and
Si 0.06 Melting point, C 644 [14] 30 mm from the joint center. The maximum temperature obtained
6
/K 23.8 [14]
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Fig. 2. Schematic of the different steps for the joining process.

2.4. Microscopic observations

The stereomicroscope was used for observation of cross-section

and fracture surface of the joints. Moreover, for investigation of the
joints microstructure and the fracture surfaces, Field Emission
Scanning Electron Microscope (FE-SEM) equipped with Energy Dis-
persive Spectroscopy (EDS) was used. For increasing the quality of
SEM images, a gold layer was coated on the samples surfaces.

2.5. Differential scanning calorimetry analysis

The crystallinity of PP-SCF composite and re-solidified polymer

inside the hole was evaluated by differential scanning calorimetry
(DSC) analysis at the temperature of 250 C for 5 min. The mea-
surements were performed on a 8 mg sample under N2 atmo-
sphere. The specimens were heated and cooled at a constant rate
of 10 C/min. The exothermic crystallization peak was recorded
as a function of temperature.

2.6. Mechanical properties

For evaluation of the mechanical behavior of the joints, shear-
tensile and cross-tension tests were carried out with the cross head
speed of 0.5 mm/min. Dimensions of the sheets and the overlap
area were selected as 70 30 mm2 and 30 30 mm2, respectively
(Fig. 3). The threaded hole was located at the center of the overlap
area. At each set of joining parameters, three samples were tested
for tensile tests and the average of maximum forces were reported.
The hardness of the composite sheet and re-solidified polymer Fig. 3. Schematic of tensile test specimens and their dimensions: a) Shear-Tensile
inside the hole was measured in Shore D scale to investigate the specimen and b) Cross-Tension specimen.
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effect of temperature changes during the joining process on the
hardness and joint strength.
3. Results and discussion
3.1. Macro-profile of joints
The surface appearance of the joints for different rotational
speeds is presented in Fig. 4. The re-solidified polymer in the hole
and the surface of aluminum affected by the rotating tool are
shown in the figure. As can be seen, surface appearance of the
joints is smooth especially at higher rotational speeds due to more
heat generation and improved flow of the aluminum under the tool
shoulder. Fig. 5 shows the cross-section of the joints and various
macro-structural zones including base materials, threaded hole
and re-solidified polymer inside the threaded hole. It can be seen
that the rotational speed of the tool affected filling behavior of
the threaded hole by the molten polymer. The higher was the rota-
tional speed, the more was the frictional heat generated during
welding. The maximum temperature experienced at different dis-
tances from the joint center (R) are shown in Fig. 6. It was observed
that by enhancement of the tool rotational speed, the maximum
temperature produced during the process increased. Moreover,
the area experiencing temperatures higher than the melting point
of the polymer was broader. Therefore, the temperature and vol-
ume of the molten polymer at the interface of the base sheets
increased.
At the rotational speed of 500 rpm, the volume of the molten
polymer is not enough to fill completely the hole. Fig. 5-a shows
porosity and unfilled zone at the joint center and separation
occurred at the interface of sheets due to lack of adhesion force
in this area. By enhancement of the tool rotational speed, more
heat was generated and as a result, more polymers melted and
entered into the hole. In the cross-section of the joints produced
at 1000, 1500 and 2000 rpm, all areas of the hole were filled com-
pletely with molten polymer and mechanical interlocks were
formed between the threads of the hole and re-solidified polymer.
Furthermore, due to the melting of polymer at the interface of the
aluminum and composite sheets, an adhesion force was also
Fig. 4. Joint surface appearance at different rotational speeds: a) 500 rpm, b)
1000 rpm, c) 1500 rpm, d) 2000 rpm.
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formed at the periphery of the hole [11]. Referring to Fig. 5-d, as
a result of high frictional heat at a rotational speed of 2000 rpm,
the excess melted polymer re-solidified as a convex surface on
the threaded hole. This convexity was formed in effect of the pres-
sure of holding clamps after retracting of the welding tool.
3.2. Reaction layer formation and joining mechanisms
Fig. 7-a shows SEM image from a typical cross-section of the
joint. Magnified SEM image of the interface between aluminum
and re-solidified polymer inside the hole (area ‘‘A” in Fig. 7-a) is
given in Fig. 7-b. It is obvious that a reaction layer was formed with
a thickness of approximately 15 lm at the interface. The term of
‘‘reaction layer” refers to a layer formed between the aluminum
and the molten polymer and atoms of both materials exist in this
layer. It seems that this layer has been formed by erosion mecha-
nism (a well-known phenomenon in the brazing and soldering)
[16] in which due to the collision between molten polymer and
the hole wall at high temperatures, aluminum atoms were sepa-
rated from the aluminum surface and entered into the molten
polymer and formed the reaction layer.
Comparison between Fig. 7-b and c indicate that the thickness
of the reaction layer did not change significantly by variation of
the tool rotational speed. However, the chemical composition of
the layer was affected by the tool rotation speed. Table 4 shows
EDS analysis of the reaction layer for samples welded at the tool
rotational speed of 500 rpm (minimum heat input) and 2000 rpm
(maximum heat input). Enhancement of the tool rotational speed
led to increase in weight percent of Al and slightly decrease in
weight percent of C. In the explanation of this phenomenon, it
can be mentioned that the higher was the temperature of the mol-
ten polymer entered into the hole, the more was the aluminum
surface erosion inside the hole and consequently the presence of
aluminum atoms in the reaction layer. Moreover, the presence of
oxygen in the reaction layer was probably attributed to degrada-
tion of the molten polymer in effect of reaction with oxygen [2].
Formation of a reaction layer with 8 wt% of Al was also mentioned
by Shahmiri et al. [16] in FSW of Polypropylene C30S to AA5052
aluminum alloy.
In addition to the reaction layer, there was also a gap between
the reaction layer and re-solidified polymer some regions inside
the hole (Fig. 7-b and c). It seems that this gap was formed during
the cooling process of the joint due to the large difference between
the coefficients of thermal expansion (CTE) of the base materials
[1]. The CTE of aluminum and polypropylene are 23.8 10 6 K 1
and 100-150 10 6 K 1, respectively [1,15]. Compared to alu-
minum, higher CTE of polypropylene resulted in more shrinkage
of the molten polymer during the cooling cycle of the weld and
thus, a gap was formed between the polymer and the reaction
layer. On the other hand, shrinkage of the molten polymer during
solidification depended on the melt temperature. The higher was
the temperature of the molten polymer, the more was its shrinkage
during cooling. Since the temperature of the molten polymer at the
rotational speed of 2000 rpm was higher (Fig. 6), a wider gap was
expected in this tool rotational speed. As can be seen in Fig. 7-c, the
wide gap was filled with epoxy resin (cold mounting material) in
the preparation stage of the sample for microstructural studies.
From what mentioned above, the obtained joint between alu-
minum and composite sheets using THFSW process is the result
of two phenomena:
i) Mechanical interlocks between re-solidified polymer and
threads inside the hole,
ii) Formation of reaction layer between aluminum and
polymer.
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Fig. 5. Stereograph images from cross-section of the joints at the rotational speed of: a) 500 rpm, b) 1000 rpm, c) 1500 rpm and d) 2000 rpm.
Fig. 6. The effect of tool rotational speed on the maximum temperature obtained at
different distances from the joint center.
It is crucial of importance that the results of a research carried
out by Khodabakhshi et al. [17] on FSW of aluminum to polymer
sheets proved the formation of Van der Waal’s bonds between
the atoms of aluminum oxide layer on the surface and polymer.
However, formation of a gap between the reaction layer and the
re-solidified polymer inside the hole reduces the effectiveness of
Van der Waal’s bonds and reaction layer for the joint strength. This
mechanism can be helpful for joint strength at the interface of the
base sheets and periphery of the hole (a region with adhesion force
in Fig. 5).
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3.3. Distribution of carbon fibers
Fig. 8 presents the carbon fibers distribution in the re-solidified
polymer matrix inside the hole. As can be seen, variation of the tool
rotational speed had no effect on the fibers distribution in the re-
solidified polymer matrix. However, comparison between Fig. 1
(base composite sheet) and Fig. 8 shows that in general, the carbon
fibers in the re-solidified polymer were shorter than those in the
base composite sheet. This may be due to the fragmentation of
the carbon fibers within the molten polymer in the effect of their
flowing from the interface of the base sheets toward the threaded
hole during the welding process. On the other hand, the carbon
fibers in the base composite sheet had a relatively preferred orien-
tation which is a well-known phenomenon in the injected polymer
matrix composites [18,19]. However, carbon fibers in the re-
solidified polymer show a random orientation.
3.4. Fracture surface analysis
Fig. 9 shows the fracture surfaces of the samples after cross-
tension and shear-tensile tests. In the samples welded at the tool
rotational speeds of 500, 1000 and 1500 rpm, fracture occurred
at the interface of the composite sheet and re-solidified polymer
inside the hole. Indeed, fracture surface of the joint on the compos-
ite sheet was a circle in which unmelted polymer surface at the
center of this circle was surrounded by the melted polymer sur-
face. The melted surface was formed due to entry of the melted
polymer from the sheets interface toward inside the hole resulting
in surface melting of the primary polymer at the periphery of the
hole and combination of the two mentioned melts with each other.
In other words, the surface of the composite sheet that is at the
base of the hole had no direct contact with the aluminum sheet.
Therefore, an increase in the temperature of the aluminum sheet
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Fig. 7. a) SEM image from a typical cross-section of the joint, b) Reaction layer and the gap formed between aluminum and re-solidified composite in the threaded hole at the
tool rotational speed of 500 rpm (magnified of area ‘‘A”) and c) Reaction layer and the gap refilled by epoxy resin at the tool rotational speed of 2000 rpm.
Table 4
Effect of tool rotational speed on the composition of the reaction layer.
Elements Tool rotational speed (rpm)
500
Al 21
C 37
O 33
as a result of the frictional heat did not directly melt the polymer
surface at this region. The existence of the unmelted surface in
the center of the circular base of the threaded hole at the interface
of the sheets means that re-solidified polymer in the hole was not
joined to the primary polymer at this region. Therefore, if the re-
solidified polymer inside the hole is considered as a small cylinder
with a diameter of 4 mm and a height equal to the thickness of alu-
minum sheet (2 mm), there was a crack in the base of this cylinder
(interface of the composite sheet and re-solidified polymer) due to
lack of melting of the composite sheet. Huang et al. [20] utilized
self-riveting friction stir lap welding for joining of AA6082 to steel
with filing the prefabricated holes in the bottom steel sheet by
plasticized aluminum. They reported that downward flow of the
plasticized aluminum occurred because of two origins: i) with pro-
gress of the welding tool, aluminum alloy ahead of the pin is plas-
ticized and then, threads of the rotating pin pushes the plasticized
metal downwards; ii) imposed pressure by the pin bottom
extrudes the plasticized aluminum alloy into the prefabricated
hole. Since the tool used for welding in the present work is pin-
less, there is no flow of the molten polymer by the threads of the
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tool pin. Therefore, the molten polymer formed at the interface
of the base sheets flows upward with back extrusion into the
threaded hole just in the effect of the downward pressure of the
tool. It should be mentioned that the molten polymer has high flu-
2000
idity and can easily flow and fill the threads of the hole with the
38
pressure applied by the welding tool. High fluidity of the molten
35
22 polymer is caused by the elevated temperature experienced by it
during the welding process. Fig. 6 confirms that the temperature
of the molten polymer at the distance of 10 mm from the joint cen-
ter is significantly higher than the melting point of polypropylene
(from 30 C above the melting point at 500 rpm to 175 C above
the melting point at 2000 rpm). Fig. 10 shows the flow model of the
molten polymer inside the threaded hole. The molten polymer
moves upward after entering into the threaded hole from the
periphery of the hole. However, upward movement of the molten
polymer is restricted by the shoulder surface. As a result, the mol-
ten polymer moves horizontally and then continues its path down-
ward. Therefore, a vortex structure is formed in the re-solidified
polymer inside the hole center.
By comparing Fig. 9-a to c, it is evident that enhancement of the
tool rotational speed reduced the area of the unmelted surface of
the polymer. The higher was the temperature of the molten poly-
mer, the more was the melting of the polymer surface. Fig. 9-d
and e show the fracture surfaces of the samples welded at
2000 rpm after cross-tension and shear-tensile tests, respectively.
It is observed in fracture surface of the shear-tensile sample
(Fig. 9-e) that there is no unmelted surface at the rotational speed
of 2000 rpm. Therefore, the obtained joint failed in cross-tension
test with the exit of the re-solidified polymer from the threaded
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Fig. 8. Carbon fibers distribution in the re-solidified polymer matrix at different rotational speed of: a) 500 rpm, b) 1000 rpm, c) 1500 rpm and d) 2000 rpm.
hole rather than fracture from the interface of the composite sheet
and re-solidified polymer inside the hole (Fig. 9-d).
SEM images of the fracture surface of the joint processed at
500 rpm rotational speed clearly indicate the difference between
the internal and marginal regions of the fracture surface at the hole
base (Fig. 11). The internal region of the joint surface (area ‘‘A” in
Fig. 11-a) showed a rough structure, while the structure of the
marginal region was relatively smooth (area ‘‘B” in Fig. 11-a). The
rough structure formed in area ‘‘A” may be the result of partial
plastic deformation during tensile test [21]. In other words, the
region in which the re-solidified polymer and the initial polymer
were combined and joined to each other during welding undergoes
plastic deformation before fracture. However, there was no evi-
dence of plastic deformation in area ‘‘B”. It seems that this area
with brittle fracture characteristics was formed as a result of crack
rapid growth before final fracture. Fig. 11-d to f show the SEM
images from the fracture surface of the sample welded at
2000 rpm after shear-tensile test. As can be seen, the surface
included ductile (region C) and brittle (region D) fracture, relatively
similar to the fracture surface of the cross-tension sample welded
at 500 rpm. However, locations of the brittle and ductile fracture
regions in shear-tensile test are different from those in cross-
tension test, maybe due to difference in loading mode between
two types of the tests.
3.5. Hardness variation of re-solidified polymer
Since fracture in the samples welded at the tool rotational
speed of 500–1500 rpm occurred from the melted and re-
solidified polymer at the interface of the base sheets (as mentioned
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in Section 3.3), the hardness of the re-solidified polymer may play
an important role in the mechanical strength of the joints. Fig. 12-a
gives the hardness variation of the re-solidified polymer inside the
hole versus tool rotational speed. The results showed that the
hardness of re-solidified polymer inside the hole decreased slightly
(about 4–6 in Shore D scale) compared to primary composite sheet.
In order to investigate the reasons for this phenomenon, DSC anal-
ysis was carried out on the primary composite and re-solidified
polymer inside the hole. Fig. 12-b presents DSC curve of the pri-
mary composite sheet and the effect of the tool rotational speed
on the crystallinity percent of the re-solidified polymer. Given
Fig. 12, by enhancement of the tool rotational speed, the hardness
and crystallinity percent of the re-solidified polymer decreased.
This may be related to molecular weight reduction of the resolidi-
fied polymer, since the molten polymer was affected by the fric-
tional heat during the process [21,22]. The more was the tool
rotational speed, the higher was the temperature of the molten
polymer.
3.6. Strength and fracture energy of joints
3.6.1. Cross-tension test
Fig. 13 shows the force-extension curves and the effect of tool
rotational speed on the fracture force and fracture energy of the
joints in cross-tension tests. As can be seen, the fracture force
increased by enhancement of the tool rotational speed. In this join-
ing process, two factors compete with each other in order to deter-
mine the fracture force by enhancement of the tool rotational
speed:
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Fig. 9. Fracture surface of the polymeric composite sheet; variation in the area of the unmelted surface and fracture location at different rotational speed of: a) 500 rpm, b)
1000 rpm, c) 1500 rpm, d) 2000 rpm (cross-tension) and e) 2000 rpm (shear-tensile).
Fig. 10. Flow model of the molten polymer inside the hole.
1) Increase in fracture force due to the increase in the load
bearing area caused by the reduction of the unmelted sur-
face of the polymer (as mentioned in Section 3.4).
2) Decrease in the fracture force due to the reduction of the
hardness at the fracture location, i.e. re-solidified polymer
(as mentioned in Section 3.5).
Results of cross-tension tests confirm that increase in the load
bearing area overcomes hardness reduction of the re-solidified
polymer and thus, fracture force improves with enhancement of
the tool rotational speed. During tensile test, the unmelted surface
of the polymer at the base of the hole (which mentioned in Sec-
tion 3.5) not only reduces the load bearing area, but also acts as
a stress concentration location and consequently decreases the
joint strength. As mentioned before, the samples joined at the tool
rotational speed of 500–1500 rpm failed from the interface of re-
solidified polymer and primary composite sheet. By increasing
the tool rotational speed, the polymer surface at the base of the
hole was melted more and the joint strength improved. At the tool
rotational speed of 2000 rpm, there was no unmelted surface or
this surface was very small. Therefore, failure occurred by the exit
of the re-solidified polymer from the threaded hole rather than
fracture from the interface of the composite sheet and re-
solidified polymer and the fracture load increased to higher values.
It is worth mentioning that distribution of carbon fibers in the
threaded hole can also be effective on the joint strength. However,
as discussed in Section 3.3, distribution of carbon fibers did not
change with variation of the tool rotational speed. Therefore, from
this point of view, enhancement of the tool rotational speed has no
effect on the joint strength.
Given the curves in Fig. 13-a, due to a decrease in the crack
length (i.e. unmelted surface) at the interface of the primary
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Fig. 11. SEM image from fracture surfaces: a) two different areas on the fracture surface of the sample welded at 500 rpm, b) ductile fracture surface (area A), c) brittle
fracture surface (area B), d) two different areas on the fracture surface of the sample welded at 2000 rpm, e) ductile fracture surface (area C) and f) brittle fracture surface
(area D).

composite sheet and re-solidified polymer, the extension of the

joints at the maximum fracture load increased by enhancement
of the tool rotational speed.
Fig. 13-b shows fracture energy of the joints calculated by mea-
suring the area under the load-extension curve until maximum
fracture force obtained from cross-tension test. It is obvious that
enhancement of the tool rotational speed led to increasing the frac-
ture energy due to the simultaneous improvement of the fracture
force and extension of the joints.

3.6.2. Shear-tensile test

Fig. 12. a) Hardness and crystallinity percent of the primary and re-solidified
composite inside the hole versus the tool rotational speed and b) DSC curve of the
primary composite sheet.
The effect of tool rotational speed on the fracture force and
energy in shear-tensile tests is shown in Fig. 14-a. All samples in
this test failed from the interface of the primary composite sheet
and the re-solidified polymer. According to the results, the rela-
tionship between the fracture force and energy with tool rotational
speed in shear-tensile test is similar to that of in cross-tension test,
i.e., by enhancement of the tool rotational speed, both fracture
force and energy increased. This may be explained again by an
increase in the load bearing area in the joints due to a decrease
in the unmelted surface of the polymer at the base of the threaded
hole. The maximum fracture load was 350 N obtained at the tool
rotational speed of 2000 rpm. If the joint area is considered as a cir-
cle with a diameter of 4 mm (base of the threaded hole), the max-
imum shear strength of the joint may be calculated as 28 MPa, i.e.,
80% of the composite sheet strength.
Fig. 14-b shows that the fracture energy in the cross-tension
test was significantly higher than that in shear-tensile test.
Although the fracture loads of the joints in cross-tension test were
relatively lower due to opening-mode of fracture [23], extensions
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Fig. 13. a) Force-extension curves of cross-tension tests related to the specimens
with maximum fracture force at different tool rotational speeds and b) effect of the
tool rotational speed on the average cross-tension force and fracture energy of the
joints.
of the joints at the maximum fracture force in cross-tension tests
(5–7 mm) were noticeably higher than that in shear-tensile test
(less than 1 mm). The higher extension of the joints in cross-
tension test was attributed to the elastic bending and deformation
of the composite base sheet in the tensile direction during cross-
tension test. Since the fracture energy is directly related to the area
under the force-extension curve up to maximum fracture load,
fracture energy in the cross-tension test was obtained higher than
that in shear-tensile test.
4. Conclusion
In this research, a new refill friction spot welding process
named Threaded Hole Friction Spot Welding (THFSW) was used
to join AA5052 aluminum alloy and short-carbon-fiber-reinforced
polypropylene composite sheets. The microstructure and mechan-
ical properties of the joints were investigated and the following
results were obtained:
1) The results indicated that THFSW was used successfully in
order to join aluminum and polymer sheets and the hole
refilled completely by the molten polymer at appropriate
tool rotational speeds (higher than 1000 rpm).
2) A reaction layer composed mostly of Al, C and O was formed
between aluminum and re-solidified polymer inside the
hole. While enhancement of the tool rotational speed did
not affect significantly the reaction layer thickness, the
weight percent of Al in this layer increased.
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Fig. 14. a) Effect of tool rotational speed on the average shear-tensile load and
fracture energy of the joints and b) comparison of fracture energy of the joints in
shear-tensile and cross-tension tests.
3) Mechanical interlocks between threads and re-solidified
polymer inside the hole and formation of the reaction layer
between aluminum and polymer were recognized as two
main bonding mechanisms in this process. Formation of a
gap between the reaction layer and the re-solidified polymer
inside the hole reduced the effectiveness of Van der Waal’s
bonds and reaction layer for the joint strength.
4) The samples joined at the rotational speed of 500, 1000 and
1500 rpm failed from the interface the composite sheet and
the re-solidified polymer inside the hole. However, at the
rotational speed of 2000 rpm, the joint failed by the exit of
the re-solidified polymer from the threaded hole. The frac-
ture surface was composed of two distinct regions of melted
and unmelted polymer. The internal part of the melted
region showed evidence of plastic deformation during a ten-
sile test, while at the marginal region, brittle fracture
occurred due to the rapid growth of the crack.
5) Two factors of load bearing area and the hardness of the
fracture location competed with each other for determina-
tion of the fracture force. The strength and fracture energy
of the joints improved by enhancement of the tool rotational
speed due to a decrease in the unmelted surface of the poly-
mer and increase in load bearing area. The maximum shear-
tensile strength of the joints reached to 80 percent of the
composite base strength at the tool rotational speed of
2000 rpm. Fracture energy in cross-tension test was signifi-
cantly higher than that in shear-tensile test.
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