Feasibility of FSJ of thermoplastics and Carbon Fiber reinforced thermosetting laminates

The feasibility of Friction Stir Joining (FSJ) process applied to join amorphous thermoplastic sheets and CFRP (Carbon Fiber Reinforced Polymers) with thermosetting matrix is investigated, experimentally. A preliminary experimental plan involving the variation the welding speed and tool rotation was conducted. IR thermal analysis is performed along with the analysis of the material flow to determine the influence of the process parameters on the developing processing conditions. Mechanical characterization of the welds was performed to understand the influence of the processing conditions on the weld quality, defects, and strength. Fracture surface analysis and optical microscopy analysis were carried out to investigate the interface between the substrates and the penetration of the carbon fibers within the polycarbonate (PC). The results indicate relatively high mechanical strength of the joints that suggests the possibility to adopt FSJ to produce such hybrid structures.