Friction Stir Joining of Structural Polymers and Aluminum Alloys—A Direct Comparison of Mechanical Behavior and Rheological Effects on Dissimilar Metal–Polymer Joints

The continuous joining of aluminum alloys to engineering thermoplastics has emerged as a promising manufacturing path for lightweight hybrid structures, yet the influence of polymers’ mechanical behavior on friction stir joining remains poorly understood. This work investigates the role of melt rheology on the morphology, joining interface, and mechanical strength of dissimilar joints that combine AA6082-T6 with two engineering-grade thermoplastics, Noryl® GFN2 and SustaPEEK®. Two joining strategies were assessed under identical processing conditions: conventional friction stir joining (FSJ) and through-slot friction stir joining (TS-FSJ), the latter incorporating thin titanium strips intended to reduce heat transfer to the polymer. Joint morphology was assessed by optical and scanning electron microscopy, mechanical performance was evaluated through quasi-static tensile-shear testing, and the rheological behavior of both polymers was characterized by steady shear and oscillatory measurements. Conventional FSJ produced defect-free aluminum–Noryl joints, with a mechanical strength of 111.3 ± 8.4 kN/m, whereas aluminum–PEEK joints exhibited localized polymer overflow, poor surface finish and scattered strength performance of 116.7 ± 77.2 kN/m. Rheological measurements showed that PEEK exhibited higher melt viscosity and viscoelastic moduli, restricting polymer flow and promoting unstable interface formation. Although titanium inserts reduced heat transfer in TS-FSJ, their deformation reduced the effective joining area, resulting in lower tensile strength. Polymer rheology was identified as one of the key factors governing material flow, defect formation, process stability, and the joints’ mechanical performance, emphasizing the importance of tailoring the processing parameters reflecting the rheological characteristics of each polymeric base material.