A novel solid-state manufacturing technology called as fed friction-stir (FFS) process was introduced based on the well-established friction-stir welding (FSW) for fabrication of metal–polymer nanocomposite by dissimilar joining, and implemented on a system of AA6082 aluminium alloy and poly-methyl-methacrylate (PMMA) polymer in the T-joint design. FFS technology was found very effective in strengthening the weld nugget and enhancing the dissimilar nanocomposite joining efficiency between aluminium and polymer with respect to FSW without reinforcing agent. Injection of Al2O3 nanoparticles with a high-concentration inside the lower region of weld nugget resulted in decreasing the cooling rate and thickness of interaction layer at the interface as well as a considerable increase in the tensile strength of nanocomposite joint up to ∼20% (60 MPa).
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