Light Weight Materials

3Recent Trends in Welding Polymers and Polymer–Metal Hybrid Structures

Polymers used for industrial applications are categorized as thermoplastic and thermosetting plastic polymers. Joining of thermosetting polymers is not possible mainly because thermosets have a high cross-linked molecular chain. In most of the thermosets, polymerization is permanent and irreversible. The joining of thermoplastic polymers only facilitates a fusion welding process. This chapter presents a detailed description of various reinforcing materials, performance analysis, processing and characterization of various methods of polymer welding, i.e. laser welding, infrared welding, spin welding, stir welding and vibration welding. It also covers the advantages of aluminum alloys such as Al1XXX, 2024, 3003, 4043, 5182, 6061, 7075 and 8510 and magnesium alloys such as AZ91D, AM60, AM50 and AM20 for lightweight applications and the current status of polymer composite applications in industries and future prospects. This chapter highlights the complications related to fusion, heat transfer and joint strength, as well as their solutions with future prospects of polymer welding for empowering polymers to be an absolute substitute for metal, which can be achieved by understanding the concept of dissimilar welding for joining polymer composites with metals (aluminum and magnesium and its alloys) and their controlling factors, and by selecting an appropriate welding process for various types of polymers.

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