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Friction stir lap welding of 3003 aluminum alloy to both polycarbonate and ABS resin are investigated. The welding was implemented using a numerically controlled friction stir welder using a special FSW tool with a sub probe. Friction stir lap welding of 3003 aluminum alloy to both types of resin materials is possible at higher welding speed than metals. The macrostructures of the joints show anchored structure in which the aluminum alloy partly penetrates into the resin. Maximum tensile shear load of the joint under the welding condition of rotational speed of 1400 rpm and welding speed of 10 mm/s with 3003 aluminum alloy to polycarbonate resin shows 1275 N, and that of the joint under the welding condition of rotational speed of 1100 rpm and welding speed of 14 mm/s with 3003 aluminum alloy to ABS resin shows 834 N. They are higher values than those of the adhesive joints with the same combination. (Received March 24, 2015 Accepted July 7, 2015)

Friction stir lap welding of thermoplastic resins to 3003 aluminum alloy