A novel double-side welding approach for friction stir welding of polypropylene plate

Abstract

In almost every industry, polymer materials are in high demand in recent years due to their lightweight and easy formability. However, eco-friendly, cost-efficient and defect-free joining of polymers is a major concern. In this article, a novel approach is taken for friction stir welding of polypropylene by implementing a double-side welding technique. The effect of tool rotational speed on construction and properties of the welded joints are studied. The torque and forces exerted on the tool during double-side welding are compared with single-side welding. Cross-sectional morphology examination using optical and scanning electron microscope reveals defect-free sound welding by double-side weld with uniform material flow. The molecular bonds of the welded specimens are examined by FTIR analysis. The double-side welding technique yields superior joints in terms of tensile strength and flexural strength than the joints obtained by single-side welding.

The Effect of Tool Rotational Speed and Welding Configuration on the Mechanical Properties of High Density Polyethylene (HDPE) Plate Friction Stir Welded Joint

“…On the other hand, the double-sided pass technique in FSW has been proven to improve joint quality and mechanical performance. It leads to smaller defect-free joints and higher tensile strength, as per previous research (Arici & Sinmaz, 2005;Nath et al, 2021). This technique improves material consolidation and homogenization across the joint interface, forming a defect-free weld zone with enhanced metallurgical bonding and structural integrity.…”

“…Figure 7. bottom, reveals that double-side pass welding successfully eliminates root defects (Nath et al, 2021) and increases joint efficiency but leaves a poor surface finish on the bottom surface. Root defects were observed in every single side weld produced in this study (Figure 7.…”

“…By employing dual passes of the tool on the FSW of PE, they successfully eradicated the root fault, which plays a crucial role in initiating failure in the welding area, and obtained favorable tensile and bending outcomes. Nath et al(2021) presents a novel approach for friction stir welding of PP using a double-side welding technique. It examines the impact of tool rotational speed on joint construction and properties, compares torque and forces during double-side welding with single-side welding, and reveals defect-free sound welding with uniform material flow.…”

Fracture analysis of friction stir spot welded acrylonitrile butadiene styrene sheet in butt configuration

“…The spot weld pattern was varied with 4-3, 4-5, and 7-6 welds in the first and second pass respectively. In double pass FSSW the overlapping region gets heated and stirred twice resulting in least microhardness as shown in [29], however performing a second pass was necessary to increase overall strength of the joint. In the second group spindle speed (2000 rpm), plunge depth (1 mm), and weld pattern (4-5) were constant and dwell time varied from 40 s to 60 s. It was observed that as the number of spot welds increases, the thermally affected regions start to overlap and result in material sticking to the tool pin.…”

Optimization of Friction Stir Welding Parameters in Hybrid Additive Manufacturing: Weldability of 3D-Printed Poly(methyl methacrylate) Plates

“…The feasibility of welding poly(methyl methacrylate) (PMMA) sheets via the FSW process has also been investigated experimentally and theoretically, employing simulation tools [20]. Polypropylene (PP) has also been investigated for FSW [21,22]. The feasibility and the mechanical performance of dissimilar joints of plastics and composites have also been investigated and reported [23][24][25][26].…”