Friction spot joining is an alternative technique for joining metals with polymers and composites. This study investigated the fatigue performance of aluminum alloy 2024/carbon-fiber-reinforced poly(phenylene sulfide) joints that were produced with friction spot joining. The surface of the aluminum was pre-treated using various surface treatment methods. The joined specimens were tested under dynamic loading using a load ratio of R = 0.1 and a frequency of 5 Hz. The tests were performed at different percentages of the lap shear strength of the joint. Three models-exponential, power law, and wear-out-were used to statistically analyze the fatigue life of the joints and to draw the stress-life (S-N) curves. The joints showed an infinite life of 25-35% of their quasi-static strength at 106 cycles. The joints surpassing 106 cycles were subsequently tested under quasi-static loading, showing no considerable reduction compared to their initial lap shear strength.
Keywords: aluminum and alloys; composite materials; fatigue life; friction spot joining; mechanical properties; surface preparation.