{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,2,19]],"date-time":"2026-02-19T03:42:48Z","timestamp":1771472568180,"version":"3.50.1"},"reference-count":26,"publisher":"MDPI AG","issue":"3","license":[{"start":{"date-parts":[[2023,6,1]],"date-time":"2023-06-01T00:00:00Z","timestamp":1685577600000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["JMMP"],"abstract":"<jats:p>An engineering grade polymer\u2014glass fiber-reinforced polyphenylene ether blended with polystyrene\u2014and an aluminum alloy\u2014AA6082-T6\u2014were joined by friction stir welding in an overlap configuration. A comprehensive analysis was conducted of the effects of the tool penetration by adjusting the pin length and the process control on the joints\u2019 mechanical performance. To this end, a series of welds with a fixed 3\u00b0 tilt angle, a travel speed of 120 mm\/min, and 600 RPM of rotational speed was carried out. The analysis encompassed the mechanical strength of the fabricated joints and the mechanical energy input throughout the joining processes, the resulting cross-sectional interfaces, both on macro and micro scales, and the observed defects. The quasi-static shear tensile tests resulted in average tensile strengths varying between 5.5 and 26.1 MPa, representing joint efficiencies ranging from 10.1% to 47.4%, respectively. The joints that exhibited the lowest mechanical performance were fabricated with the highest level of tool penetration (higher pin length) with the process being position-controlled, while the best performance was recorded in joints welded with the lowest tool penetration and a force-controlled process. Nonetheless, the joint welded with a 2 mm long pin and position-controlled process exhibited a mechanical strength comparable with the highest one with a significantly lower standard deviation, a promising attribute for technological industrialization. In this way, it was found that the tool penetration, controlled by adjusting the pin length, played a significant role in the development of the joints\u2019 morphology and, consequently, mechanical performance, whereas the process control exhibited a minor influence on the mechanical performance of the joints, but a considerable effect on process repeatability.<\/jats:p>","DOI":"10.3390\/jmmp7030106","type":"journal-article","created":{"date-parts":[[2023,6,1]],"date-time":"2023-06-01T01:40:56Z","timestamp":1685583656000},"page":"106","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":9,"title":["Effects of Friction Stir Welding Process Control and Tool Penetration on Mechanical Strength and Morphology of Dissimilar Aluminum-to-Polymer Joints"],"prefix":"10.3390","volume":"7","author":[{"ORCID":"https:\/\/orcid.org\/0000-0001-8165-5946","authenticated-orcid":false,"given":"Arm\u00e9nio N.","family":"Correia","sequence":"first","affiliation":[{"name":"Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0009-0003-9110-0911","authenticated-orcid":false,"given":"Paulo A. M.","family":"Santos","sequence":"additional","affiliation":[{"name":"Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-0587-3041","authenticated-orcid":false,"given":"Daniel F. O.","family":"Braga","sequence":"additional","affiliation":[{"name":"Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), 4200-465 Porto, Portugal"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-5955-8418","authenticated-orcid":false,"given":"Ricardo","family":"Baptista","sequence":"additional","affiliation":[{"name":"Escola Superior de Tecnologia de Set\u00fabal, Instituto Polit\u00e9cnico de Set\u00fabal, 2970-508 Set\u00fabal, Portugal"}]},{"given":"Virg\u00ednia","family":"Infante","sequence":"additional","affiliation":[{"name":"LAETA, IDMEC, Instituto Superior T\u00e9cnico, Universidade de Lisboa, 1049-001 Lisboa, Portugal"}]}],"member":"1968","published-online":{"date-parts":[[2023,6,1]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","unstructured":"Dias, F., Cipriano, G., Correia, A.N., Braga, D.F.O., Moreira, P., and Infante, V. (2023). Joining of Aluminum Alloy AA7075 and Titanium Alloy Ti-6Al-4V through a Friction Stir Welding-Based Process. Metals, 13.","DOI":"10.3390\/met13020249"},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"105652","DOI":"10.1016\/j.engfailanal.2021.105652","article-title":"Review on dissimilar structures joints failure","volume":"129","author":"Correia","year":"2021","journal-title":"Eng. Fail. Anal."},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Ahmed, M.M.Z., Seleman, M.M.E.-S., Fydrych, D., and \u00c7am, G. (2023). Friction Stir Welding of Aluminum in the Aerospace Industry: The Current Progress and State-of-the-Art Review. Materials, 16.","DOI":"10.3390\/ma16082971"},{"key":"ref_4","doi-asserted-by":"crossref","first-page":"94","DOI":"10.1515\/ipp-2020-3991","article-title":"The Effect of Top Surface Lubrication on the Friction Stir Welding of Polycarbonate Sheets","volume":"36","author":"Ahmed","year":"2021","journal-title":"Int. Polym. Process."},{"key":"ref_5","doi-asserted-by":"crossref","first-page":"116706","DOI":"10.1016\/j.jmatprotec.2020.116706","article-title":"A review of microstructural changes occurring during FSW in aluminium alloys and their modelling","volume":"288","author":"Jacquin","year":"2020","journal-title":"J. Mater. Process. Technol."},{"key":"ref_6","doi-asserted-by":"crossref","first-page":"7684","DOI":"10.15282\/jmes.15.1.2021.06.0606","article-title":"Effect of friction stir welding parameters on the residual stress distribution of Al-2024-T6 alloy","volume":"15","author":"Farhang","year":"2021","journal-title":"J. Mech. Eng. Sci."},{"key":"ref_7","doi-asserted-by":"crossref","unstructured":"Sambasivam, S., Gupta, N., Jassim, A.S., Singh, D.P., Kumar, S., Giri, J.M., and Gupta, M. (2023). A review paper of FSW on dissimilar materials using aluminum. Mater. Today Proc., in press.","DOI":"10.1016\/j.matpr.2023.03.304"},{"key":"ref_8","doi-asserted-by":"crossref","unstructured":"Kumar, N., Yuan, W., and Mishra, R.S. (2015). Friction Stir Welding of Dissimilar Alloys and Materials, Butterworth-Heinemann.","DOI":"10.1016\/B978-0-12-802418-8.00004-7"},{"key":"ref_9","doi-asserted-by":"crossref","first-page":"107155","DOI":"10.1016\/j.engfailanal.2023.107155","article-title":"Effects of processing temperature on failure mechanisms of dissimilar aluminum-to-polymer joints produced by friction stir welding","volume":"146","author":"Correia","year":"2023","journal-title":"Eng. Fail. Anal."},{"key":"ref_10","doi-asserted-by":"crossref","first-page":"1461","DOI":"10.1002\/pen.21424","article-title":"Joining of polymers and polymer\u2013metal hybrid structures: Recent developments and trends","volume":"49","year":"2009","journal-title":"Polym. Eng. Sci."},{"key":"ref_11","doi-asserted-by":"crossref","first-page":"391","DOI":"10.1080\/13621718.2020.1719304","article-title":"Direct joining of thermoplastic ABS to aluminium alloy 6061-T6 using friction lap welding","volume":"25","author":"Xu","year":"2020","journal-title":"Sci. Technol. Weld. Join."},{"key":"ref_12","doi-asserted-by":"crossref","first-page":"73","DOI":"10.1016\/j.matchar.2014.10.013","article-title":"Microstructure-property characterization of a friction-stir welded joint between AA5059 aluminum alloy and high density polyethylene","volume":"98","author":"Khodabakhshi","year":"2014","journal-title":"Mater. Charact."},{"key":"ref_13","doi-asserted-by":"crossref","first-page":"120","DOI":"10.1080\/13621718.2016.1204171","article-title":"Friction stir lap joining of aluminium alloy to polypropylene sheets","volume":"22","author":"Shahmiri","year":"2016","journal-title":"Sci. Technol. Weld. Join."},{"key":"ref_14","doi-asserted-by":"crossref","first-page":"117","DOI":"10.1007\/s40194-017-0517-y","article-title":"Effects of processing parameters on the characteristics of dissimilar friction-stir-welded joints between AA5058 aluminum alloy and PMMA polymer","volume":"62","author":"Derazkola","year":"2017","journal-title":"Weld. World"},{"key":"ref_15","doi-asserted-by":"crossref","first-page":"88","DOI":"10.1016\/j.jmapro.2018.07.021","article-title":"The influence of process parameters in friction stir welding of Al-Mg alloy and polycarbonate","volume":"35","author":"Derazkola","year":"2018","journal-title":"J. Manuf. Process."},{"key":"ref_16","doi-asserted-by":"crossref","first-page":"148","DOI":"10.1016\/j.jmatprotec.2018.02.043","article-title":"Joining of aluminum alloy and polymer via friction stir lap welding","volume":"257","author":"Huang","year":"2018","journal-title":"J. Mater. Process. Technol."},{"key":"ref_17","doi-asserted-by":"crossref","first-page":"4242","DOI":"10.1016\/j.matpr.2017.11.688","article-title":"Investigation of Mechanical Properties for Hybrid Joint of Aluminium to Polymer using Friction Stir Welding (FSW)","volume":"5","author":"Patel","year":"2018","journal-title":"Mater. Today Proc."},{"key":"ref_18","doi-asserted-by":"crossref","first-page":"109305","DOI":"10.1016\/j.matdes.2020.109305","article-title":"Mechanical and microstructural characterization of AZ31 magnesium-carbon fiber reinforced polymer joint obtained by friction stir interlocking technique","volume":"198","author":"Wang","year":"2021","journal-title":"Mater. Des."},{"key":"ref_19","doi-asserted-by":"crossref","first-page":"376","DOI":"10.1016\/j.tws.2018.11.027","article-title":"An investigation on the dissimilar friction stir welding of T-joints between AA5754 aluminum alloy and poly(methyl methacrylate)","volume":"135","author":"Derazkola","year":"2019","journal-title":"Thin-Walled Struct."},{"key":"ref_20","doi-asserted-by":"crossref","first-page":"235","DOI":"10.1016\/j.compositesa.2017.12.005","article-title":"Friction stir welding\/processing of polymers and polymer matrix composites","volume":"105","author":"Huang","year":"2018","journal-title":"Compos. Part A Appl. Sci. Manuf."},{"key":"ref_21","doi-asserted-by":"crossref","first-page":"258","DOI":"10.3139\/146.111172","article-title":"Dissimilar friction stir welding between polycarbonate and AA 7075 aluminum alloy","volume":"106","author":"Moshwan","year":"2015","journal-title":"Int. J. Mater. Res."},{"key":"ref_22","doi-asserted-by":"crossref","first-page":"182","DOI":"10.1080\/13621718.2016.1211583","article-title":"Bonding mechanism and interface characterisation during dissimilar friction stir welding of an aluminium\/polymer bi-material joint","volume":"22","author":"Khodabakhshi","year":"2016","journal-title":"Sci. Technol. Weld. Join."},{"key":"ref_23","doi-asserted-by":"crossref","first-page":"222","DOI":"10.1179\/1362171814Y.0000000276","article-title":"Dissimilar joining between aluminium alloy (AA 6111) and thermoplastics using friction stir welding","volume":"20","author":"Ratanathavorn","year":"2015","journal-title":"Sci. Technol. Weld. Join."},{"key":"ref_24","doi-asserted-by":"crossref","first-page":"108941","DOI":"10.1016\/j.compositesb.2021.108941","article-title":"Achieving high-quality metal to polymer-matrix composites joint via top-thermic solid-state lap joining","volume":"219","author":"Li","year":"2021","journal-title":"Compos. Part B Eng."},{"key":"ref_25","doi-asserted-by":"crossref","first-page":"195","DOI":"10.1016\/j.compositesb.2004.09.001","article-title":"Secondary bending in multi fastener, composite-to-aluminium single shear lap joints","volume":"36","author":"Ekh","year":"2005","journal-title":"Compos. Part B: Eng."},{"key":"ref_26","doi-asserted-by":"crossref","first-page":"1","DOI":"10.1016\/j.ijfatigue.2014.10.008","article-title":"Observations and analyses of secondary bending for riveted lap joints","volume":"72","author":"Skorupa","year":"2015","journal-title":"Int. J. Fatigue"}],"container-title":["Journal of Manufacturing and Materials Processing"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/2504-4494\/7\/3\/106\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2025,10,10]],"date-time":"2025-10-10T19:46:43Z","timestamp":1760125603000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/2504-4494\/7\/3\/106"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2023,6,1]]},"references-count":26,"journal-issue":{"issue":"3","published-online":{"date-parts":[[2023,6]]}},"alternative-id":["jmmp7030106"],"URL":"https:\/\/doi.org\/10.3390\/jmmp7030106","relation":{},"ISSN":["2504-4494"],"issn-type":[{"value":"2504-4494","type":"electronic"}],"subject":[],"published":{"date-parts":[[2023,6,1]]}}}