A review on friction stir welding of thermoplastic materials: recent advances and progress

Omer, M. A.; Rashad, Mona M.; Elsheikh, Ammar H.; Showaib, Ezzat A.

doi:10.1007/s40194-021-01178-0

Cited by 14 publications

(4 citation statements)

References 117 publications

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“…the welding procedure was performed in a single pass along x-axis using a customized 3-axis FSW machine (Fig. 2), this machine was described elsewhere [13].…”

Section: Methodsmentioning

confidence: 99%

Defect formation in Friction Stir Welding of Polycarbonate Sheets: Their Types, Causes and Treatment

Omer

Showaib

Rashad

2022

Journal of Engineering Research

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Friction stir welding (FSW) was initially developed for welding aluminium alloys which were difficult to weld using conventional welding techniques. With the remarkable success accomplished with these alloys, materials manufacturers were passionate about using FSW with other materials. In the case of polymeric materials, the application of conventional FSW was not satisfactory due to the differences between the characteristics of metals and polymeric materials. Consequently, many modifications were developed to overcome the drawbacks of conventional FSW technique. For instance, heating the tool with an external heating source is one of the major modifications. The aim of this work is to clarify the quality of friction stir welding of polycarbonate (PC) in square butt configuration as a function of tool temperature, rotational speed and welding speed. This material was selected due to its transparency as well as its good photoelastic properties. Therefore, the defects can be easily detected and the residual stresses can be revealed under a polarized optical microscope. Four values of suggested welding parameters (pin temperature, rotational speed and welding speed) were investigated. Both the mechanical properties and the defect formation were studied in order to achieve a better welding joint. The investigation of samples macrostructure showed that several defects such as islands of melted and nonmelted material, discontinuous bonding line, macro-cracks, tunnels, flash formation, surface grooves, voids and root defects were formed as a response to the different interactions between the welding parameters. These defects can be minimized when the welding process is performed at a rotational speed of 1800 rpm, welding speed of 30 mm/min and tool temperature of 50 • C. In this situation, the joint efficiency of the welded joint reached 92.2% relative to the base material flexural strength.

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“…the welding procedure was performed in a single pass along x-axis using a customized 3-axis FSW machine (Fig. 2), this machine was described elsewhere [13].…”

Section: Methodsmentioning

confidence: 99%

Defect formation in Friction Stir Welding of Polycarbonate Sheets: Their Types, Causes and Treatment

Omer

Showaib

Rashad

2022

Journal of Engineering Research

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“…The maximum heat and internal temperature gradient are shown in Figure 6. In regular FSJ of polymers, the tool shoulder directly contacts the raw materials [47]. The shoulder has more of a contact area with the polymer; for this reason, during rotational movement of the FSJ tool, the stirring action in the upper area of SZ is more intense than in other areas.…”

Section: Heat Generationmentioning

confidence: 99%

Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)

et al. 2022

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In this study, the effects of the traverse and rotational velocities of the noncontact shoulder tool on the heat generation and heated flux during the friction stir joining of high-density polyamide 6 (PA6) polymer were investigated. The computational fluid dynamics (CFD) method was employed to simulate the thermomechanical phenomena during the friction stir joining (FSJ) process of PA6. A developed model was used to consider the void formation and thermochemical properties of PA6. The surface and internal heat flow, material flow, and geometry of the joint were simulated, and an experimental study evaluated the simulation results. The simulation results indicated that the stir zone formed was smaller than regular joints with a noncontact shoulder tool. Despite the polymer’s traditional FSJ, heat generation and material flow do not differ significantly between advancing and retreating sides. On the other hand, the surface flow is not formed, and the surface temperature gradient is in a narrow line behind the tool. The material velocity increased at higher rotational speed and lower transverse velocity and in the stir zone with more giant geometry forms. The maximum generated heat was 204 °C, and the maximum material velocity was predicted at 0.44 m/s in the stir zone, achieved at 440 rpm and 40 mm/min tool velocities.

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“…Joining polymeric materials is a critical industrial issue to obtain high-quality products that fit a range of industrial and daily-life applications [ 6 , 7 , 8 ]. Many joining techniques of polymeric materials have been developed in literature such as hot plate welding [ 9 ], hot gas implant welding [ 10 ], hot gas butt welding [ 11 ], friction stir welding [ 12 , 13 ], electromagnetic pulse welding [ 14 ], vibration welding [ 15 ], and ultrasonic welding [ 16 , 17 ]. Laser welding has shown promising applications in the welding of polymeric materials due to its flexibility, versatility, and speed, producing narrow and deep welds, non-continuous nature, and non-contact nature [ 18 , 19 ].…”

Section: Introductionmentioning

confidence: 99%

Predicting Characteristics of Dissimilar Laser Welded Polymeric Joints Using a Multi-Layer Perceptrons Model Coupled with Archimedes Optimizer

Moustafa

Elsheikh

2023

Polymers

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This study investigates the application of a coupled multi-layer perceptrons (MLP) model with Archimedes optimizer (AO) to predict characteristics of dissimilar lap joints made of polymethyl methacrylate (PMMA) and polycarbonate (PC). The joints were welded using the laser transmission welding (LTW) technique equipped with a beam wobbling feature. The inputs of the models were laser power, welding speed, pulse frequency, wobble frequency, and wobble width; whereas, the outputs were seam width and shear strength of the joint. The Archimedes optimizer was employed to obtain the optimal internal parameters of the multi-layer perceptrons. In addition to the Archimedes optimizer, the conventional gradient descent technique, as well as the particle swarm optimizer (PSO), was employed as internal optimizers of the multi-layer perceptrons model. The prediction accuracy of the three models was compared using different error measures. The AO-MLP outperformed the other two models. The computed root mean square errors of the MLP, PSO-MLP, and AO-MLP models are (39.798, 19.909, and 2.283) and (0.153, 0.084, and 0.0321) for shear strength and seam width, respectively.

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A review on friction stir welding of thermoplastic materials: recent advances and progress

Cited by 14 publications

References 117 publications

Defect formation in Friction Stir Welding of Polycarbonate Sheets: Their Types, Causes and Treatment

Defect formation in Friction Stir Welding of Polycarbonate Sheets: Their Types, Causes and Treatment

Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6)

Predicting Characteristics of Dissimilar Laser Welded Polymeric Joints Using a Multi-Layer Perceptrons Model Coupled with Archimedes Optimizer

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