The effect of surface condition, dwell time and plunge rate on the mechanical properties of dissimilar joints between polyethylene and aluminum were investigated. The scratches made by the mandrels on the aluminum surface acted as mechanical locks and hence the strength of the dissimilar joint was increased. An increased dwell time and a decreased plunge rate exhibited a positive effect on the bond strength values. The major joining mechanisms were mechanical interlocking between the sheets and wetting of the aluminum surface by the molten polyethylene. The increase in the actual contact area due to the increased surface roughness, improved the shear-tensile load of the joint (up to 56%).

Keywords