A review of friction stir lap welding of polymer to metal

Ghiya, Rutvik; Badheka, Vishvesh J.

doi:10.1080/25740881.2021.1937646

Cited by 9 publications

(9 citation statements)

References 34 publications

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“…However, the root mean square (RMS) of the axial thrust and the circumferential torque in dwelling period has been considered for each friction stir spot welding experiment. The 'RMS' that is, the quadratic mean that specifies the total summation of square root of discrete data in an observation, may be stated by Y rms as per equation (1).…”

Section: Measurements Of Sensors' Based Featuresmentioning

confidence: 99%

“…Weld strength was considered as highly important (0.75) followed by its elongation capability (0.15) while relatively lower weightage for routine tool affected defects (0.1) as per their relative importance in dissimilar metal to polymer spot welds for different engineering applications. 1,19 However, as the index of weld quality (W i ) increases with higher weld strength and elongation whereas it degrades with an increase with oversize tool assisted keyhole, positive and negative mark has been considered, respectively for the calculation of weld quality index in the present case as indicated in equation (2).…”

Section: Measurements Of Weld Quality Characteristicsmentioning

confidence: 99%

“…In contrary, the dissimilar metal to thermoplastic joining is a highly thought-provoking job because of drastic changes in mechanical and thermal properties whose applications are enormous in recent engineering applications. 1 Various experimental efforts have been made in the latest years to achieve the desired weld quality by using solid state high frequency ultrasonic and frictional heat assisted approaches to join these materials alignment. 5 Friction stir spot welding (FSSW) is a variant of friction stir welding (FSW) where sequence of solid-state friction stir spot welds are made to join the over-lapped sheets using a non-consumable rotating tool without much material loss, reduced weld distortion and residual stresses along with fine and uniform weld microstructure.…”

Section: Introductionmentioning

confidence: 99%

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Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Pattanaik,

Nayak,

Bisoyi

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Friction stir processing procedures are often found to be an alternative choice for the joining of thermoplastic polymers without melting the base materials. In recent years, dissimilar metallic to thermoplastic assemblies are highly used in aerospace and automotive industries as mechanical fastener or fusion welding techniques are rather inadequate for extreme discrepancy in thermal properties. The present work addresses the feasibility of friction stirred spot welding for non-ferrous aluminium (Al 6061) to polycarbonate using taper cylindrical tool of hardened H13 steel along with machine integrated axial thrust and stirring torque signals. The real-time positional and axial velocity of the rotating tool has been acquired to distinguish between plunging and dwelling stage. The process stability that is, the deviation of thrust-torque in respective phases was processed. The interaction of plunge depth and dwell time on tool pin assisted keyhole with associated material expulsion for different tool revolving speed was established. The weld mechanical behaviour has been scanned using load versus elongation diagram with associated weld pair interface. Lastly, sensors’ based process monitoring extended to weld quality prediction have been made using various significant features of thrust-torque-velocity based approaches. The tool spinning speed followed by dwell time was found to be important on weld quality index. The joint efficiency was significantly upgraded (more than 60%) at intermediate dwell time (40 s) with low tool plunging (0.3 mm) or reversed parametric setting at high tool revolving speed (2500 rpm) due to substantial reduction in axial thrust with higher stirring torque. The local deviation in thrust-torque during plunging was equally responsible with global mean thrust-torque in dwelling to dictate the joint strength and the weld ductility. The material stirring torque was better indicator of weld shear strength while pin assisted slot size highly correlated with tool thrust though tool plunging speed was highly crucial.

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Section: Measurements Of Sensors' Based Featuresmentioning

confidence: 99%

Section: Measurements Of Weld Quality Characteristicsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Pattanaik,

Nayak,

Bisoyi

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

show abstract

“…Problem occur during the forming process of such hybrids, because both materials exhibit completely different mechanical properties [44,45]. The formation of such joints is based mainly on the mechanical "hooking" of metal elements in polymers; however, a method based on the formation of adhesive joints using increased temperature and pressure is also used [46][47][48][49][50]. There are proposals to use 3D FDM printing to create metal-polymer joints, although they are based on 3D printing by applying polymers to polymers, thereby creating a rivet that holds the metal part [51].…”

Section: Introductionmentioning

confidence: 99%

Deposition of Biocompatible Polymers by 3D Printing (FDM) on Titanium Alloy

2022

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Nowadays, the replacement of a hip joint is a standard surgical procedure. However, researchers have continuingly been trying to upgrade endoprostheses and make them more similar to natural joints. The use of 3D printing could be helpful in such cases, since 3D-printed elements could mimic the natural lubrication mechanism of the meniscus. In this paper, we propose a method to deposit plastics directly on titanium alloy using 3D printing (FDM). This procedure allows one to obtain endoprostheses that are more similar to natural joints, easier to manufacture and have fewer components. During the research, biocompatible polymers suitable for 3D FDM printing were used, namely polylactide (PLA) and polyamide (PA). The research included tensile and shear tests of metal–polymer bonds, friction coefficient measurements and microscopic observations. The friction coefficient measurements revealed that only PA was promising for endoprostheses (the friction coefficient for PLA was too high). The strength tests and microscopic observations showed that PLA and PA deposition by 3D FDM printing directly on Ti6Al4V titanium alloy is possible; however, the achieved bonding strength and repeatability of the process were unsatisfactory. Nevertheless, the benefits arising from application of this method mean that it is worthwhile to continue working on this issue.

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“…Joining different polymers with FSW has been investigated for various polymers, for example, PMMA welded with acrylonitrile butadiene styrene (ABS) [20]. Additionally, polymers have been welded with other materials as well, such as wood-plastic composites [21], aluminum [22], or metals [23,24], with the FSW process. The welding tools' performance has also been investigated, as their effect on the result of the process is critical [25].…”

Section: Introductionmentioning

confidence: 99%

Friction Stir Welding Optimization of 3D-Printed Acrylonitrile Butadiene Styrene in Hybrid Additive Manufacturing

et al. 2022

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The feasibility of joining material extrusion (MEX) 3D-printed acrylonitrile butadiene styrene (ABS) plates with the friction stir welding (FSW) process was investigated herein as a promising topic of hybrid additive manufacturing (HAM). The influence of three process parameters on the mechanical strength of the joints was thoroughly examined and analyzed with a full factorial experimental design and statistical modeling. Hereto, the welding tool pin geometry, travel speed, and rotational speed were investigated. The joint’s efficiency and quality are evaluated through tensile tests and morphological characterization. More specifically, specimens’ areas of particular interest were investigated with stereoscopic, optical, and scanning electron microscopy. Throughout the FSW experimental course, the welding temperature was monitored to evaluate the state of the ABS material during the process. The majority of the welded specimens exhibited increased mechanical strength compared with the respective ones of non-welded 3D printed specimens of the same geometry. Statistical modeling proved that all processing parameters were significant. The feasibility of the FSW process in 3D printed ABS workpieces was confirmed, making the FSW a cost-effective process for joining 3D printing parts, further expanding the industrial merit of the approach.

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A review of friction stir lap welding of polymer to metal

Cited by 9 publications

References 34 publications

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Monitoring of friction stirred spot weld quality for dissimilar Al6061 to polycarbonate using tool assisted thrust-torque signatures

Deposition of Biocompatible Polymers by 3D Printing (FDM) on Titanium Alloy

Friction Stir Welding Optimization of 3D-Printed Acrylonitrile Butadiene Styrene in Hybrid Additive Manufacturing

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