Friction welding joint analysis of dissimilar nanocomposites: PEEK/aluminum to PEEK/titanium

Abstract Welding of dissimilar materials is extremely challenging to the researchers. In present work, for the first time, poly(ether ether ketone) (PEEK) based aluminum (Al), titanium (Ti) reinforced nanocomposites with varying reinforcements of 10, 20, 30, and 40 vol% were developed using powder metallurgy technology. Additionally, for the first time, the two dissimilar nanocomposites of PEEK/Al and PEEK/Ti were successfully welded by friction welding (FW) process to produce FW PEEK/Al‐PEEK/Ti nanocomposites with equal metallic reinforcements (viz., 10–40 vol% Ti or Al). The nanocomposites were characterized precisely and correlated by physical, microstructural, structural, thermal, and micromechanical tests. Crystallinity being a factor of melting temperature affects significantly the micromechanical characteristics influenced by reinforced particle‐concentrations. The FW PEEK/30Al‐PEEK/30Ti was found as best material since it showed highest nanohardness (0.652 GPa) and elastic modulus (15.902 GPa) in FW Joint at 40 mN compared to other FW nanocomposites. At the FW joint section, it was discovered that the reinforced particles were being transferred through an interdiffusion mechanism. Mobility of the nanoparticles was influenced by the concentration of the reinforced particles, which further modified the matrix's crystallization behavior and consequently influenced the FW nanocomposites' micromechanical properties. Therefore, the present work has suggested a feasible route for applying thermoplastic nanocomposites in the biomedical and aerospace industries.