Short carbon fiber reinforced poly-ether-ether-ketone (SCF/PEEK) and 2060-T8 aluminum alloy (AA2060-T8) were joined via friction stir welding with co-controlling shape and performance. The high-quality surface integrity and joint formation were acquired based on a tapered thread pin with the triple facets, a stationary shoulder and a new lap configuration of the SCF/PEEK and the AA2060-T8 at the upper and lower sides. An intimate contact formed at the AA2060-T8 and the SCF/PEEK interface. The macro/micro-mechanical interlocking and the chemical bond attributed to the main bonding mechanisms. Decreasing heat input was beneficial to eliminating the welding defects and improving the load bearing of the joint. The maximum tensile shear strength was 33 MPa. This work indicates that friction stir welding with co-controlling shape and performance has the feasible and potential to join thermoplastic and metal.

短碳纤维增强聚醚醚酮（SCF / PEEK）和2060-T8铝合金（AA2060-T8）通过摩擦搅拌焊连接在一起，共同控制形状和性能。高质量的表面完整性和接头形成是基于带有三重面的锥形螺纹销，固定的肩部以及上侧和下侧的SCF / PEEK和AA2060-T8的新型搭接构造而获得的。在AA2060-T8和SCF / PEEK界面处形成紧密接触。宏观/微观机械联锁和化学键归因于主要的键合机理。减少热量输入有利于消除焊接缺陷并改善接头的承载能力。最大拉伸剪切强度为33MPa。