A high-speed metal-to-polymer direct joining technique and underlying bonding mechanisms

[Display omitted] A high-speed friction lap welding (FLW) technique for directly joining of aluminum to polymer is presented in this paper. Experimental results show that a consistent bond quality at the joint interface has been achieved at welding speeds as high as 5 m/min, which can be attributed to the formation of new C-O-Al bonds observed by X-ray photoelectron spectroscopy (XPS), in addition to mechanical interlocking. Lap-shear tests were performed for evaluating joint shear strengths of the welded samples corresponding to different welding conditions. It was found that as long as an interfacial threshold temperature was attained, the actual interface bond strengths are essentially the same regardless of welding temperature and welding speed.