Effect of process temperatures on material flow and weld quality in the friction stir welding of high density polyethylene

Sheikh-Ahmad, Jamal; Deveci, Süleyman; Almaskari, Fahad; Rehman, Razi Ur

doi:10.1016/j.jmrt.2022.03.082

Cited by 15 publications

(21 citation statements)

References 18 publications

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“…Weld PEH_1500_60, Figure 5 d, presented the largest SZ (47 mm 2 ) and the smallest root defect (350 µm). Similar observations were reported by Rehman et al [ 27 ] and Sheikh-Ahmad et al [ 28 ].…”

Section: Resultssupporting

confidence: 91%

“…Furthermore, all specimens failed outside of the weld nugget, in the interface between the SZ and HAZ of the RS. The literature review confirms that the drop in elongation at break is a typical observation on PE joints by FSW, as well as brittle fracture on the RS [ 2 , 12 , 27 , 28 , 34 ]. In the current work, the elongation at break was generally greater for higher rotational speeds, lower welding speed and heated shoe.…”

Section: Resultssupporting

confidence: 71%

“…However, since conventional welding tools were used, a poor surface finish was generally obtained in the aforementioned studies. Rehman et al [ 27 ] and Sheikh-Ahmad et al [ 28 ] managed to produce welds with an ultimate tensile strength that was greater than the yield strength of the parent material for the joining of 6 mm-thick HDPE with a conventional tool and a PTFE shoulder.…”

Section: Introductionmentioning

confidence: 99%

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Joining of Polyethylene Using a Non-Conventional Friction Stir Welding Tool

et al. 2022

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The objective of the current study was to butt-weld 6 mm-thick polyethylene (PE) plates by friction stir welding (FSW) using a non-conventional stationary shoulder tool. The welds were performed with an unheated shoulder and with a shoulder temperature of 85 °C. Additionally, rotational speeds of 870, 1140 and 1500 rpm; welding speeds of 60 and 120 mm/min; and plunge depths of 5.5 and 5.7 mm were used. The influence of these parameters on morphology, hardness, ultimate tensile strength, elongation at break and fracture modes was evaluated. Shoulder heating proved to be crucial for the optimization of PE joints by FSW, as it clearly improved joint efficiency. Furthermore, shoulder heating promoted the reduction in internal and external defects, such as porosity and surface burning. Defect-free weld seams were obtained with higher rotational speeds and a lower welding speed. A maximum joint efficiency of about 97% was achieved with a shoulder temperature of 85 °C, a rotational speed of 1500 rpm, a welding speed of 60 mm/min and a plunge depth of 5.7 mm. A weld with the average joint efficiency of 92% was produced at 120 mm/min, which based on the literature found is the highest welding speed reported that achieved a joint efficiency above 90%.

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Section: Resultssupporting

confidence: 91%

Section: Resultssupporting

confidence: 71%

Section: Introductionmentioning

confidence: 99%

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Joining of Polyethylene Using a Non-Conventional Friction Stir Welding Tool

et al. 2022

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“…They used CFD to find the optimum heat generation that maximizes tensile strength during the FSJ process. Sheikh-Ahmad et al [28,29] simulated a similar FSJ of HDPE. Shete and Yarasu [30] used the finite element method (FEM) to simulate a high-density polyethylene joint's friction stir spot welding (FSSW).…”

Section: Introductionmentioning

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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“…Sheikh-Ahmad et al [12] examined the material flow patterns during FSW of HDPE sheets (one sheet has a white color whereas the second sheet has a black color) were also investigated. It was found that most of the welding defects are concentrated at the bottom area of the welding nugget where the heat is not sufficient to fuse the two parts together.…”

Section: Introductionmentioning

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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Effect of process temperatures on material flow and weld quality in the friction stir welding of high density polyethylene

Cited by 15 publications

References 18 publications

Joining of Polyethylene Using a Non-Conventional Friction Stir Welding Tool

Joining of Polyethylene Using a Non-Conventional Friction Stir Welding Tool

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

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

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