Analysing significant process parameters for friction stir welding of polymer composite

Joining of Fibre-Reinforced Thermoplastic Polymer Composites by Friction Stir Welding—A Review

“…The analysis of variance (ANOVA) performed by Ahmadi et al [49] showed that welding speed had the greatest impact on the performance of their welds with a contribution of about 79% and that rotational speed was the second with an influence of about 12%. In contrast, Ahmadi et al [47], Kumar et al [50], Eslami et al [52], and Ishraq et al [54] observed that the rotational speed had a bigger contribution with an influence between 47% and 57%, while the welding speed showed an influence between 12% and 33%. Anyway, the ANOVA performed by the different authors shows that rotational speed and welding speed are the two parameters with most influence on the welding process, with a combined influence between 65% and 91% when compared to other welding parameters such as tilt angle [47,49,50], axial force [52], and tool geometry [54].…”

“…Rezgui et al [85] and Eslami et al [86] confirmed this thesis after verifying that most of the temperatures measured during the welding process of PE were above the melting point. In the case of composite welding, Ishraq et al [54] argued that the process must generate enough temperature to reach the melting of the composite to produce welds with good mechanical properties. On the other hand, excessive temperatures should be avoided as they can lead to the burning and deterioration of the composite materials, resulting in loss of mechanical strength [50,54].…”

“…In the case of composite welding, Ishraq et al [54] argued that the process must generate enough temperature to reach the melting of the composite to produce welds with good mechanical properties. On the other hand, excessive temperatures should be avoided as they can lead to the burning and deterioration of the composite materials, resulting in loss of mechanical strength [50,54]. Thus, it is important to control the welding temperature, since it is proved that the joint strength is reduced when the decomposition point is exceeded [20].…”

“…Since 2011, FSW is also being studied for the joining of FRTP composites reinforced with chopped fibres [45,46]. Most of the publications found are related to PP reinforced with chopped GF [3,5,[45][46][47][48] or chopped CF [3,5,48,49], but matrices of PA6 [50][51][52][53], PC [54] and polyetheretherketone (PEEK) [40] have also been reported. The studies found in the literature are still very much focused on the feasibility of the technology.…”

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

“…Azhiri et al [30] reported that high level of tool rotational speed resulted in sufficient heat input, which improved the stirring action as well as both the tensile and impact strengths of the weld joint. Whereas increasing the rotational speed to 800 rpm generates a sticking condition and hereby prevents proper material mixing [31]. Moreover, with the increase of the rotational speed, residual stress of the joints also increases leading to decrease of the weld strength [32].…”