Polyethylene FSSW/Adhesive hybrid single strap joints: Parametric optimization and FE simulation

Abstract In this paper, the mechanical behavior of single strap joints was investigated under tensile loading. Four sets of specimens were fabricated e.g., adhesively bonded, friction stir spot welded (FSSW), adhesively bonded-FSSW (AB-FSSW), and hybrid joints. The failure load of specimens subjected to lap shear tests was employed to compare the load carrying capacity of the samples. L9 Taguchi design of experiment was used and the effects of FSSW parameters e.g. tool rotational speed (RS), plunge rate (PR), and dwell time (DT) on the failure load of the specimens were investigated. It was found that the welding parameters of RS = 1600 rpm, PR = 8 mm/min, and DT = 30 s leads to the highest failure load (FL) of FSSW joints, and applying the adhesive increased the joints failure load capacity up to 80%. By comparing the Scanning Electron Micrographs (SEM) images of the FSSW joints, it was revealed that a specimen with the maximum failure load has a homogeneous microstructure. The finite element method was developed to estimate the failure load of different joint types. It was observed that the numerical results are in good agreement with the experimental data with errors of less than 6%.