Joining of metal to plastic using friction lap welding

•A new conception of joining method, friction lap welding (FLW), was developed.•The AA6061 Al and MC Nylon-6 were tightly jointed together using FLW.•High quality FLW joints were obtained over a wide range of welding parameters.•Thick nylon films were observed on the fracture surface of AA6061 Al.

Friction lap welding (FLW) is a new conception of joining method developed in Joining and Welding Research Institute (JWRI). The efficiency of joining metal and plastic using FLW was demonstrated through a case study on aluminium alloy AA6061 and MC Nylon-6. The lap joints with high shear strength were obtained over a wide range of welding parameters. A linear relationship was observed between FLW parameters (R/ν)0.5 and the thickness of melted nylon (H). The influences of FLW parameters on bubbles and shear strength were investigated. The morphologies of the fractured surfaces of AA6061 alloy fell into seven types based on the scanning electron microscopy examination. Statistical analysis showed that the contribution to shear strength of these regions followed such an order: region II > region V > region VI > region VII > region IV > region I or III.