Abstract Friction stir incremental forming (FSIF) process was applied to join a commercial open-cell type nickel foam with a polymethyl methacrylate (PMMA) sheet for fabrication of porous metal–nonporous resin composite. In this process, a rotating rod-shaped tool was vertically pushed and horizontally fed against the sheet on the foam. The sheet was frictionally heated and incrementally deformed by the rotating tool, while the cellular matrix of the foam was not plastically deformed. The sheet with a thickness of 1.0 mm was joined with the foam under FSIF conditions of rotation rate faster than 2000 rpm and feed rate slower than 60 mm/min. The joining strength between the foam and the sheet was investigated by performing tensile test. The joining strength was obtained over the fracture strength of the foam. The joining mechanism of the foam and the sheet was discussed from the microscopic observation of the foam–sheet interface and the temperature change in the sheet. It is concluded that the sheet was mechanically interlocked (anchored) to the porous structure of the foam by the plastic flow of the heated and softened PMMA into the surface pores of the foam.

中文翻译：

---

通过搅拌摩擦渐进成型对开孔泡沫镍和聚甲基丙烯酸甲酯 (PMMA) 板进行塑料连接

摘要 采用摩擦搅拌渐进成型 (FSIF) 工艺将商用开孔型镍泡沫与聚甲基丙烯酸甲酯 (PMMA) 片材连接起来，以制备多孔金属-无孔树脂复合材料。在这个过程中，一个旋转的棒状工具被垂直推动并水平送入泡沫上的片材。片材被旋转工具摩擦加热并逐渐变形，而泡沫的多孔基质没有塑性变形。在转速高于 2000 rpm 且进料速率低于 60 mm/min 的 FSIF 条件下，将厚度为 1.0 mm 的片材与泡沫接合。通过拉伸试验研究泡沫和片材之间的接合强度。获得的连接强度超过了泡沫的断裂强度。从泡沫-片材界面的显微观察和片材的温度变化讨论了泡沫与片材的接合机制。得出的结论是，通过加热和软化的 PMMA 塑性流动进入泡沫的表面孔隙，该片材机械互锁（锚定）到泡沫的多孔结构上。