Novel Method to Join Aluminum With Nylon

Today, frequently used joining methods for metal and polymer hybrid structures are adhesive bonding and mechanical fastening. These joining processes have several limitations. This project aims to utilized Friction Stir Welding (FSW) to join dissimilar material materials specifically nylon and aluminum. This kind of joining is often very difficult to achieve and the composite’s behaviors are not completely understood. This study aims to develop fundamental understandings towards this technology by investigating the effects of joint configuration and length of tool tip to the welding quality. The scope of study revolves around the parameters of the friction stir welding process, the configuration of the samples and also the length of the tool tip used. This paper will discuss the literature that has been done by previous researcher relevant to this project. The literature aims to provide valuable information that may add to the progress of this project. The material used in this research is Aluminum 6061 and Polyethylene. At the end of the paper, the results of the research was discussed and conclusion were presented. The joint created were weak and some of them detached. The research shows that within the limited scope of time and resources, the FSW cannot be proved as the novel method to join Aluminum and Nylon since no good joint were achieved.