Investigation of friction stir spot welding of high density polyethylene and polypropylene sheets

2021 ◽  
pp. 009524432110015
Author(s):  
Mustafa Kemal Bilici
Keyword(s):  
High Density Polyethylene ◽  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
Polymer Materials ◽  
Weld Strength ◽  
Tool Rotational Speed ◽  
Friction Stir ◽  
Welding Operation ◽  
Stirring Time ◽  
Welding Materials

In this study, two different polymer materials were used. In the joints made with friction stir spot welding, firstly (PP/PP and HDPE/HDPE) and then different materials (PP/HDPE, HDPE/PP) joining processes were carried. The influence of the tool rotational speed and the stirring time on joint formation and weld strength were determined. The temperature of the liquid welding materials varies according to the materials to be combined. High weld strengths were obtained at the friction stir spot welding of similar plastic sheets. The highest weld strengths were obtained in PP-PP welds. Low weld strengths were obtained at the friction stir spot welding of dissimilar plastic sheets because of immiscible and incompatible blends formed during the welding operation. The lowest weld strengths were obtained in PP-HDPE welds. The chemical composition and the phase morphology of the blends, the mechanical scission occurrence and the welding residual stresses determine the strength of the welds.

scholarly journals Parametric Study Of Friction Stir Spot Welding (FSSW) For Polymer Materials Case Of High Density Polyethylene Sheets: Experimental And Numerical Study

2020 ◽  
Vol 15 (55) ◽  
Author(s):  
Djilali Benyerou ◽  
El Bahri Ould Chikh ◽  
Habib Khellafi ◽  
Hadj Miloud Meddah ◽  
Ali Benhamena ◽  
...  
Keyword(s):  
Finite Element ◽  
Numerical Modeling ◽  
High Density Polyethylene ◽  
Spot Welding ◽  
Welding Process ◽  
Friction Stir Spot Welding ◽  
High Density ◽  
Polymer Materials ◽  
Friction Stir ◽  
Welding Processes

Friction stir spot welding (FSSW) is a very important part of conventional friction stir welding (FSW) which can be a replacement for riveted assemblies and resistance spot welding. This technique provides high quality joints compared to conventional welding processes. Friction stir spot welding (FSSW) is a new technology adopted to join various types of metals such as titanium, aluminum, magnesium. It is also used for welding polymer materials which are difficult to weld by the conventional welding process. In various industrial applications, high density polyethylene (HDPE) becomes the most used material. The parameters and mechanical properties of the welds are the major problems in the welding processes. In this paper, we have presented a contribution in finite element modeling of the friction stir spot welding process (FSSW) using Abaqus as a finite element solver. The objective of this paper is to study the HDPE plates resistance of stir spot welding joints (FSSW). First, we show the experimental tests results of high-density polyethylene (HDPE) plates assembled by friction stir spot welding (FSSW). Three-dimensional numerical modeling by the finite element method makes it possible to determine the best representation of the weld joint for a good prediction of its behavior. Comparison of the results shows that there is a good agreement between the numerical modeling predictions and the experimental results.

Experimental Study and Numerical Modeling of Friction Stir Spot Welding of Pure Copper Lap Joint

2014 ◽  
Author(s):  
Ahmed Kamal Mahgoub ◽  
Abdelaziz Bazoune ◽  
Fadi A. A. Al-Badour ◽  
Abdelrahman Shuaib ◽  
Gihad Mohamed Karrar
Keyword(s):  
Experimental Study ◽  
Spot Welding ◽  
Dwell Time ◽  
Pure Copper ◽  
Friction Stir Spot Welding ◽  
Fusion Welding ◽  
Weld Strength ◽  
Tool Rotational Speed ◽  
Lap Joint ◽  
Friction Stir

Friction stir spot welding (FSSW) is an appropriate process to join materials that are difficult to weld using fusion welding, such as copper. In this paper, an experimental study to weld lap joint of pure copper plates having a dimensions of 100 × 30 × 2 mm is performed, successful spot weld is obtained at tool rotational speed of 1200 rpm, feed rate of 20 mm/min for dwell time of 2 seconds. The tool used in the FSSW has a threaded pin of 5 mm diameter, length of 3.7 mm, and a scrolled shoulder of 11.52 mm diameter. Tensile test and microhardness were performed for the joint and it showed reasonable weld strength. In addition, a numerical model was developed, and the estimated temperatures as well as weld macrostructure matched very well with experimental results.

Relation between Friction Stir Spot Welding Parameters and Mechanical Properties of High Density Polyethylene/Glass Spheres Polymer Composites

2016 ◽  
Vol 860 ◽  
pp. 49-52 ◽  
Author(s):  
Munir Tasdemir ◽  
Mustafa Kemal Bilici ◽  
Mehmet Kurt
Keyword(s):  
Mechanical Properties ◽  
Polymer Composites ◽  
High Density Polyethylene ◽  
Spot Welding ◽  
Friction Stir Spot Welding ◽  
High Density ◽  
Welding Parameters ◽  
Friction Stir ◽  
Glass Spheres ◽  
Welding Properties

In the present study, we attempt to use powder of glass spheres filler and reinforce material in HDPE to produce composite structure and then evaluate its mechanical properties to study the effect of welding parameters and filler content on mechanical properties of HDPE. The effect of welding parameters (tool rotational speed, the plunge depth and the dwell time) on friction stir spot welding properties of high density polyethylene/glass spheres (hollow) polymer composites sheets was studied.

Friction Stir Spot Welding of AA2024-T3 with Modified Refill Technique

2020 ◽  
Vol 835 ◽  
pp. 274-287
Author(s):  
Mahmoud Hussin Fahmy ◽  
Hamed A. Abdel-Aleem ◽  
Nahid Ahmed Abdel-Elraheem ◽  
M.R. El-Kousy
Keyword(s):  
Spot Welding ◽  
Metal Flow ◽  
Vertical Direction ◽  
Friction Stir Spot Welding ◽  
Weld Strength ◽  
Al Alloy ◽  
Exit Hole ◽  
Two Stage ◽  
Friction Stir ◽  
Second Stage

The quality of welded joints of FSSW is mainly dependent on the processing parameters while the main disadvantage of this process is the creation of an exit hole. Process parameters, namely tool dimensions, tool rotational speed, and stir time were changed and their impact on bond dimensions and weld strength was investigated using 2024-T3 Al Alloy. Macro- and microstructures of the welded samples were examined; shear fracture loads were measured and the optimum set of operation variables was determined. To decrease the exit hole of the first stage the present paper proposes a modified two-stage weld-refill process employing the same welding machine. In this work, this two-stage process was referred to as reversed friction stir spot welding (ReFSSW). In the second stage, a smaller pin was used and the shoulder diameter was designed such that to force the metal of the upper plate to flow towards the exit hole of the first stage decreasing its dimensions. The metal flow in the second stage was evaluated by examining the microstructure of the metal that filled the exit hole of the first stage. Thin stir zone was found around the pin of the second stage followed by thermomechanically affected zone consisting of grains elongated in the vertical direction. The proposed process resulted in smaller exit hole dimensions and consequently higher mechanical properties compared with the conventional single-stage FSSW.

Friction Stir Spot Welding of AZ31B Magnesium Alloy

2017 ◽  
Vol 867 ◽  
pp. 105-111
Author(s):  
S. Ramesh Babu ◽  
M. Nithin ◽  
S. Pavithran ◽  
B Parameshwaran
Keyword(s):  
Shear Strength ◽  
Magnesium Alloy ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Resistance Welding ◽  
Hardness Distribution ◽  
Tool Rotational Speed ◽  
Friction Stir

The Electrical Resistance Welding (ERW) of Magnesium and Aluminium is more difficult than steel because the welding machines must provide high currents and exact pressures in order to provide the heat necessary to melt the magnesium for proper fusion at the interface in order to produce a sound weld. Further, resistance welding of magnesium requires a backup plate made of steel to conduct the heat to the workpiece material. To overcome this problem, Friction Stir Spot Welding (FSSW) has been developed. In this study, the hardness distribution and the tensile shear strength of FSSW welds in the AZ31B Magnesium alloy has been investigated and it has been found that tool rotational speed and dwell time plays a major role in determining the weld strength. From the experimental study, a tool rotational speed of 1100 rpm and dwell time of 20 s produced good shear strength of 2824 N and the corresponding grain size was 4.54 μm. This result is very well supported by microstructural examinations and hardness distribution studies.

scholarly journals Investigasi dan Optimasi Parameter Proses Micro Friction Stir Spot Welding Material A1100/Cu1100P Menggunakan Metode Taguchi

2019 ◽  
Vol 3 (2) ◽  
pp. 59
Author(s):  
Pathya Rupajati ◽  
Pathya Rupajati
Keyword(s):  
Friction Stir Welding ◽  
Intermetallic Compound ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Shear Load ◽  
Tool Rotational Speed ◽  
Tensile Shear ◽  
Plunge Depth ◽  
Friction Stir

Abstrak  Salah satu karakteristik sifat mekanis yang penting untuk dianalisis adalah tensile shear load. Penelitian ini bertujuan untuk melakukan optimasi tensile shear load hasil pengelasan micro friction stir welding (µFSSW) pada material AA1100 dan Cu1100P menggunakan metode Taguchi. Rancangan percobaan yang digunakan dalam penelitian ini adalah matriks orthogonal array L8 dengan memvariasikan parameter proses pengelasan yaitu dwell time dan plunge depth yang memiliki masing-masing empat level dan dua level. Sedangkan variabel konstan yang digunakan adalah tool rotational speed sebesar 33.000 rpm. Hasil penelitian menunjukkan bahwa parameter pengelasan yang memiliki kontribusi terbesar dalam meningkatkan tensile shear load hasil pengelasan micro friction stir spot welding adalah dwell time, yang menghasilkan tensile shear load sebesar 265,12 N dengan seting kombinasi dwell time pada 5 s dan plunge depth pada 0,7 mm. Hasil struktur mikro juga menunjukkan terlihat adanya flash dan hook defect, tetapi tidak menujukkan adanya intermetallic compound dan crack. Kata kunci: A1100, µFSSW, Taguchi, Dwell time, Plunge Depth

Effects of Process Parameters on Friction Stir Spot Welding of Aluminum Alloy to Advanced High-Strength Steel

2017 ◽  
Vol 139 (8) ◽  
Author(s):  
Kai Chen ◽  
Xun Liu ◽  
Jun Ni
Keyword(s):  
Aluminum Alloy ◽  
Process Parameters ◽  
Cross Sections ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Thin Layers ◽  
Weld Strength ◽  
Friction Stir ◽  
Lap Shear

This paper studies a friction stir spot welding (FSSW) process that has been successfully applied to join aluminum alloy 6061-T6 to transformation-induced plasticity steel (TRIP) 780/800 steel. Cross sections of weld specimens show the formation of a hook with a swirling structure. A higher magnified scanning electron microscope (SEM) view of the swirling structure with energy dispersive X-ray spectroscopy (EDS) analysis reveals that it is composed of alternating thin layers of steel and Al–Fe intermetallic compounds (IMCs). To check the effect of different process parameters on the weld strength, the effects of tool plunge speed and dwell time were studied through the design of experiments (DOE) and analysis of variance (ANOVA) method. It shows that dwell time is a more dominant parameter in affecting the weld strength than plunge speed. Furthermore, investigation of failure using a lap shear tests reveals that cross nugget failure is the only failure mode. It also shows that cracks are initiated in the swirling structure at the tensile side of the weld nugget. After failure, a cleavage feature can be observed on the fractured surface.

Microstructure and Mechanical Properties of Refilled Friction Stir Spot Welding of Commercial Pure Aluminium

2013 ◽  
Vol 765 ◽  
pp. 776-780 ◽  
Author(s):  
S. Venukumar ◽  
S. Muthukumaran ◽  
Y. Swaroop
Keyword(s):  
Rotational Speed ◽  
Spot Welding ◽  
High Energy ◽  
Friction Stir Spot Welding ◽  
Pure Aluminium ◽  
Tool Rotational Speed ◽  
Cross Sectional ◽  
Friction Stir ◽  
Lap Shear ◽  
Probe Hole

Aluminium and magnesium alloys are expected to make considerable contributions in reducing the weight of automobiles as they are increasingly used as an alternative to steel; improving fuel economy and vehicle performance while simultaneously reducing emissions. Higher electrical and thermal conductivities of these materials make them difficult to weld using existing resistance spot welding leading to high energy consumption. Friction stir spot welding has proven to be a better alternative to weld these materials. But a probe hole left behind is the main problem in conventional Friction Stir Spot welding (FSSW). In the present work a new method has been developed to refill the probe hole using an additional filler plate known as Refill Friction Stir Spot welding (RFSSW). This new refilling technique and the conventional FSSW process were both used to weld commercially pure aluminium lap shear specimens and the results were compared. The effect of tool rotational speed on mechanical and metallurgical properties were studied in both cases. Static shear strength of RFSSW weld samples was found to be better than conventional FSSW process at higher tool rotational speed. This is explained in terms of effective increase in cross sectional area of weld nugget due addition of more material from the filler plate thereby eliminating the probe hole.

Optimizing the Friction Stir Spot Welding Parameters to Attain Maximum Strength in Dissimilar Joints of Aluminum and Carbon Steel

2016 ◽  
Vol 3 (2) ◽  
pp. 64-76
Author(s):  
Sundaram Manickam ◽  
Visvalingam Balasubramanian
Keyword(s):  
Carbon Steel ◽  
Rotational Speed ◽  
Spot Welding ◽  
Dwell Time ◽  
Friction Stir Spot Welding ◽  
Diameter Ratio ◽  
Tool Rotational Speed ◽  
Dissimilar Joints ◽  
Friction Stir ◽  
Tool Diameter

The present investigation is aimed at optimizing the friction stir spot welding (FSSW) process parameters such as tool rotational speed, plunge rate, dwell time and tool diameter ratio, to attain the maximum strength in dissimilar joints of AA6061 aluminum and carbon steel. Experiments were conducted according to the four factor, five level central composite rotatable design matrix. Strength of the joints was evaluated by means of single lap shear test. Optimization was done by response surface method (RSM). A maximum tensile shear fracture load (TSFL) of 9.46 kN was exhibited by a joint welded using following parameters: tool rotational speed of 1000 rpm, plunge rate of 4 mm/ min, dwell time of 5 sec and tool diameter ratio of 3.0.

Sign in / Sign up

Export Citation Format

Share Document