Induction heated tool assisted friction-stir welding (i-FSW): A novel hybrid process for joining of thermoplastics

This paper presents a hybrid friction-stir welding process, i-FSW, for the joining of thermoplastics. In this process, the friction-stir tool during welding is heated by induction and the temperature is precisely maintained though feedback control. The paper conveys new observations on friction-stir welding of thermoplastics through a case study on the welding of high-density polyethylene plates. The mechanical behavior and weld microstructure were studied over a wide range of tool rotational speeds and tool-pin temperatures. A narrow transition zone between the weld and base materials without any defect ensures joints with a similar strength to the base material, vis-a-vis better than previously reported results with the same material. A drop in hardness at the weld zone, for all the parameters, and a transition from brittle to ductile nature of the joints at higher tool-pin temperatures were observed. The material flow and weld formation mechanism in i-FSW is discussed.

[1]  Amir Mostafapour,et al.  Experimental investigation on flexural behavior of friction stir welded high density polyethylene sheets , 2014 .

[2]  William J. Arbegast,et al.  A flow-partitioned deformation zone model for defect formation during friction stir welding , 2008 .

[3]  Dulce Maria Rodrigues,et al.  Material flow and thermo-mechanical conditions during Friction Stir Welding of polymers: Literature review, experimental results and empirical analysis , 2014 .

[4]  Ali Doniavi,et al.  An experimental study on mechanical properties of friction stir welded ABS sheets , 2013 .

[5]  Seth R. Strand,et al.  Effects of Friction Stir Welding on Polymer Microstructure , 2004 .

[6]  Pedro Neto,et al.  Morphology and strength of acrylonitrile butadiene styrene welds performed by robotic friction stir welding , 2014 .

[7]  V. Jaiganesh,et al.  Optimization of Process Parameters on Friction Stir Welding of High Density Polypropylene Plate , 2014 .

[8]  Tibor Czigány,et al.  Microscopic analysis of the morphology of seams in friction stir welded polypropylene , 2012 .

[9]  A. Armagan Arici,et al.  Effects of double passes of the tool on friction stir welding of polyethylene , 2005 .

[10]  A. Arici,et al.  Effects of tool tilt angle on tensile strength and fracture locations of friction stir welding of polyethylene , 2007 .

[11]  K. Panneerselvam,et al.  Joining of Nylon 6 plate by friction stir welding process using threaded pin profile , 2014 .

[12]  Amir Mostafapour,et al.  A study on the role of processing parameters in joining polyethylene sheets via heat assisted friction stir welding: Investigating microstructure, tensile and flexural properties , 2012 .

[13]  Samrand Rash Ahmadi,et al.  Friction stir welding of thermoplastics using a newly designed tool , 2014 .

[14]  M. B. Givi,et al.  Investigation of the effects of critical process parameters of friction stir welding of polyethylene , 2011 .

[15]  M. B. Givi,et al.  Influences of welding parameters on the quality and creep properties of friction stir welded polyethylene plates , 2015 .

[16]  Pedro Neto,et al.  Effect of friction stir welding parameters on morphology and strength of acrylonitrile butadiene styrene plate welds , 2014 .

[17]  H. Bhadeshia,et al.  Recent advances in friction-stir welding : Process, weldment structure and properties , 2008 .

[18]  Satish V. Kailas,et al.  The role of friction stir welding tool on material flow and weld formation , 2008 .

[19]  M. B. Givi,et al.  Experimental optimization of the mechanical properties of friction stir welded Acrylonitrile Butadiene Styrene sheets , 2015 .