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<p>To replace toxic adhesives and construct high-performance hybrid structures, this study proposes an environmentally friendly solid-state joining strategy for AA6061-T6 aluminum alloy and red oak using friction stir spot welding with a polyamide 66 (PA66) interlayer. The thermoplastic interlayer effectively bridged the physicochemical mismatch between the dissimilar materials. Comprehensive characterization revealed that the joint integrity relies on the synergistic effect of mechanical interlocking and chemical bonding: the molten PA66 mechanically interlocks with the aluminum microgrooves and deeply infiltrates the vessel pores of the red oak. Interestingly, it was observed that the PA66 was completely extruded in localized regions, forming a tight direct contact between the metal and the wood substrate. By strictly controlling the rotational speed to mitigate thermal degradation of the wood, a maximum tensile shear load of 1127 N was achieved at an optimal speed of 800 rpm. Furthermore, the joint failure behavior exhibited a hierarchical evolution characteristic, manifested as wood matrix tearing and PA66 pull-out, realizing a transition from brittle fracture to tough fracture behavior. The results indicate that FSSW has the potential to join high-performance adhesive-free wood-metal hybrid structures.</p>

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Joint interface of friction stir spot welded AA6061 aluminum alloy and red oak

  • 期刊论文

  • 发表日期：

    2026年6月29日

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  • Danfeng Du,
  • Guoxu Xu,
  • Chaowei Sun,
  • Xiurong Guo,
  • Yongxian Huang

摘要

To replace toxic adhesives and construct high-performance hybrid structures, this study proposes an environmentally friendly solid-state joining strategy for AA6061-T6 aluminum alloy and red oak using friction stir spot welding with a polyamide 66 (PA66) interlayer. The thermoplastic interlayer effectively bridged the physicochemical mismatch between the dissimilar materials. Comprehensive characterization revealed that the joint integrity relies on the synergistic effect of mechanical interlocking and chemical bonding: the molten PA66 mechanically interlocks with the aluminum microgrooves and deeply infiltrates the vessel pores of the red oak. Interestingly, it was observed that the PA66 was completely extruded in localized regions, forming a tight direct contact between the metal and the wood substrate. By strictly controlling the rotational speed to mitigate thermal degradation of the wood, a maximum tensile shear load of 1127 N was achieved at an optimal speed of 800 rpm. Furthermore, the joint failure behavior exhibited a hierarchical evolution characteristic, manifested as wood matrix tearing and PA66 pull-out, realizing a transition from brittle fracture to tough fracture behavior. The results indicate that FSSW has the potential to join high-performance adhesive-free wood-metal hybrid structures.