In the present study, the feasibility of friction stir welding (FSW) of polyamide 6/Nitrile butadiene rubber composite was carried out with and without an additional heating system. By controlling heat input and cooling rate, sound joints were obtained during heat-assisted FSW. Mechanical tests under different rotational speeds were performed to probe the tool design efficiency. Produced welds with a heating system minimised improper fusion and defect formation, which resulted in considerable improvement of mechanical properties. Tensile strength and hardness still have lower values at the presence of NBR phase; introducing halloysite nanotubes into PA6 matrix resolved this issue. The highest tensile strength was 61 MPa with over 91% of base material strength. Results are corroborated by photomicrographs.

In recent decades, extensive research has been performed on the friction stir welding of flat-shaped materials while pipe welding, particularly polymer pipes, still encounters challenging issues. This work presents a feasible route for joining high-density polyethylene (HDPE) pipes using an orbital friction stir welding (OFSW) set-up properly designed with a retractable pin tool. Fully consolidated joints were achieved using a portable heating-assisted OFSW system suited for on-site pipeline welding. The obtained joined pipes were characterized by a high-quality weld surface and a lack of defects arising from the tool-pin hole. The samples welded with the optimum parameters presented comparable properties with the base materials and even a slight increase in the tensile strength. The highest tensile and impact strengths were 14.4 MPa and 2.45 kJ/m2, respectively, which is 105% and 89% of those of the base material. XRD, FTIR, and SEM were also applied to assess the property changes in the HDPE pipes after the FSW process. The morphological analysis evidenced that the crystalline structure of the welded sample was similar to that of the base material, proving the effectiveness of the proposed technology.

The present paper aims to compare the microstructural and mechanical properties of CK45 carbon steel plates, joined by friction stir (FSW) and tungsten inert gas (TIG) welding methods. Besides visual inspection, the welded joints and the base material were subsequently evaluated in respect of optical microstructures, hardness and tensile properties. Sound joints could be accomplished using both the FSW and TIG welding methods through proper selection of process parameters and the filler metal. The influence of a water-cooling system on the FSW and various filler metals on the quality of TIG welding were further assessed. Both the FS welded sample as well as TIG welded samples with two different filler metals ER70S-6 and ER80S-B2 exhibited brittle behavior that could be mitigated through optimized water cooling and use of R60 filler metal. A drastic reduction of brittle martensite phase constituent in the microstructure corroborated significant improvements in mechanical properties of the welded zones for both the FSW sample as well as TIG welded samples with R60 filler metal.

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Polypropylene (PP)/acrylonitrile butadiene rubber (NBR) composite plates reinforced with halloysite nanotubes (HNTs) were manufactured in the presence of dual compatibilizers: PP-grafted maleic anhydride (PP-g-MA) and styrene ethylene butylene styrene-grafted maleic anhydride (SEBS-g-MA). The mechanical characteristics and microstructure of the PP/NBR/HNT nanocomposites were investigated as a function of NBR content (10, 20, and 30 wt.%) and HNTs content (3, 5, and 7 wt.%). The results demonstrated that the rubber particles were well dispersed over the PP matrix and that the HNTs were partly agglomerated at contents above 5%. Friction stir welding (FSW) was used to join the nanocomposite plates. A significant reduction in scattered NBR droplet size was seen in the FS-welded specimens containing 80/20 (wt/wt) PP/NBR composites in the presence of a dual compatibilizer. Considerable improvement in particle dispersion was observed in the case of PP/NBR blends filled 80/20 (wt/wt) with HNTs joined using FSW, leading to enhanced mechanical properties in the joints. This was due to the stirring action of the FSW tool. Suitable agreement between anticipated and confirmed values was observed in experiments.