In this research, a new fed friction-stir (FFS) technology was implemented for dissimilar nanocomposite joining between AA2024 aluminum alloy and polycarbonate (PC) polymer with a T-joint design. Alumina (Al₂O₃) nanoparticles in the form of paste were injected through the stir zone (SZ) during dissimilar mixing of aluminum and polymer using the FFS system to strengthen the polymer side. The effects of processing parameters on the soundness and characteristics of dissimilar weldments were examined in terms of rotational tool speed (w = 1400−2100 r/min), traverse velocity (v = 25−55 mm/min), and reinforcement powder feeding. Stiff competition was found between w and v on controlling the weld nugget formation and its property. Increasing w and heat input ratio showed a beneficial influence on the materials flow and intermixing. Meanwhile, increasing v revealed detrimental impact by affecting the alumina powder feeding rate into the SZ. According to experiments, to attain a sound and defect-free dissimilar nanocomposite joint with superior mechanical property, the central processing parameters were optimized in the moderate range as w = 1750 r/min and v = 35 mm/min. A maximum tensile strength of ∼36 MPa and maximum flexural strength of ∼74 MPa were noted. Hence, the maximum joining efficiency was determined by ∼53 % and 93 % ratios of PC as the weakest part of dissimilar weldment during tensile and bending tests, respectively, with a failure behavior across the SZ.

在这项研究中，采用T型接头设计，将新的喂入摩擦搅拌（FFS）技术用于AA2024铝合金与聚碳酸酯（PC）聚合物之间的异种纳米复合材料连接。使用FFS系统在铝和聚合物的异种混合过程中，将糊状的氧化铝（Al ₂ O ₃）纳米颗粒通过搅拌区（SZ）注入，以增强聚合物侧面。通过旋转工具速度（w = 1400-2100 r / min），横向速度（v = 25-55 mm / min）和补强粉末进料，检查了加工参数对异种焊件的健全性和特性的影响。w和v之间发现激烈竞争控制焊点熔核的形成及其性能。w和热输入比的增加显示出对材料流动和混合的有益影响。同时，增加v显示出通过影响进入SZ的氧化铝粉进料速率的有害影响。根据实验，为了获得具有良好机械性能的无缺陷且无缺陷的异种纳米复合材料接头，在w = 1750 r / min和v的中等范围内优化了中央加工参数= 35毫米/分钟。注意到最大拉伸强度为〜36 MPa，最大弯曲强度为〜74 MPa。因此，最大的连接效率是由PC的53％和93％的比率确定的，这是在拉伸和弯曲测试过程中不同焊接件的最薄弱部分，并且在整个SZ上都有失效行为。