Flat friction spot joining of aluminum alloy to carbon fiber reinforced polymer sheets: Experiment and simulation

• AA6061-T6 alloy and CFRP hybrid structure was successfully joined by the flat friction spot joining (FSJ). • A 3D finite element simulation model was established to simulate the flat FSJ process. • The role of thermal energy generation and conduction during the process was elucidated. • Rotational velocity became a prioritized optimized factor to improve thermal environment affecting joint strength. The Al alloy and carbon fiber reinforced polymer (CFRP) hybrid structures, incorporating the performance advantages of the two materials, have been attracting more attention in high-end manufacturing fields. In the current investigation, the flat friction spot joining (FSJ) was employed in joining the AA6061-T6 alloy and CFRP sheets. The significance of temperature distribution in influencing joint quality was highlighted through analyzing interface microstructural features, weld defect formation as well as fractography. To understand the role of thermal energy generation and conduction in the process comprehensively, a 3D thermal-mechanical coupling finite element model was established. The interfacial temperature was characterized by an uneven distribution behavior due to the inhomogeneous heat distribution. The peak temperatures on the top surface and Al alloy to CFRP interface at 1500 rpm rotational speed with 0.1 mm/s plunging speed were 498 °C and 489 °C, respectively. The peak interface temperature was reduced to 286 °C at 250 rpm, which produced an extremely small melted area. Compared with the plunging speed, rotational speed was found to be the predominant parameter for determining the joint property, which could be optimized to simultaneously realize the avoidance of thermal decomposition of CFRP, the sufficient melting duration time, and the wide enough melted area. Simulated thermal histories and melted area profiles were in agreement with experimental ones. The findings could be utilized to provide some feasible guidance for process optimization of dissimilar FSJ of metals and composites.