Friction stir welding of polypropylene sheet

Sahu, Santosh Kumar; Mishra, Debasish; Mahto, Raju Prasad; Sharma, Vyas Mani; Pal, Surjya K.; Pal, Kamal; Banerjee, Susanta; Dash, P. R.

doi:10.1016/j.jestch.2018.03.002

Cited by 52 publications

(45 citation statements)

References 18 publications

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“…Thermoplastic-thermoset MMCs combine the damage tolerance characteristics, and welding capability of thermoplastics with the strength and stiffness of thermoset composites resulting in more reliable structures with an extended lifetime [ 4 , 5 , 6 ]. However, joining thermoplastics to thermosets remains a challenging step despite the development of various joining technologies for composite structures including (i) mechanical fastening [ 7 , 8 , 9 ], (ii) welding [ 10 , 11 , 12 , 13 ], (iii) adhesive bonding [ 14 , 15 , 16 ], (iv) co-curing (parts are cured at the same time) [ 17 , 18 ], and (v) hybrid joints (combination of two or more of previous methods) [ 19 , 20 , 21 ]. Nevertheless, all these joining methods have disadvantages in terms of being unreliable, labour-intensive, time-consuming and expensive [ 22 ].…”

Section: Introductionmentioning

confidence: 99%

Co-Bonded Hybrid Thermoplastic-Thermoset Composite Interphase: Process-Microstructure-Property Correlation

Zanjani

Baran

2021

Materials

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Co-bonding is an effective joining method for fiber-reinforced composites in which a prefabricated part bonds with a thermoset resin during the curing process. Manufacturing of co-bonded thermoset-thermoplastic hybrid composites is a challenging task due to the complexities of the interdiffusion of reactive thermoset resin and thermoplastic polymer at the interface between two plies. Herein, the interphase properties of co-bonded acrylonitrile butadiene styrene thermoplastic to unsaturated polyester thermoset are investigated for different processing conditions. The effect of processing temperature on the cure kinetics and interdiffusion kinetics are studied experimentally. The interphase thickness and microstructure are linked to the chemo-rheological properties of the materials. The interdiffusion mechanisms are explored and models are developed to predict the interphase thickness and microstructure for various process conditions. The temperature-dependent diffusivities were estimated by incorporating an inverse diffusion model. The mechanical response of interphases was analyzed by the Vickers microhardness test and was correlated to the processing condition and microstructure. It was observed that processing temperature has significant effect on the interdiffusion process and, consequently, on the interphase thickness, its microstructure and mechanical performance.

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Section: Introductionmentioning

confidence: 99%

Co-Bonded Hybrid Thermoplastic-Thermoset Composite Interphase: Process-Microstructure-Property Correlation

Zanjani

Baran

2021

Materials

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“…This might be the reason behind the better performance of a cylindrical pin in comparison to a conical pin. Sahu et al [118] have studied polypropylene sheets, and have shown that the square pin tool provides the maximum tensile strength compared to the cylindrical pin tool. This again might be because of its better mixing ability as the square edges are able to push more molten material than the plain cylindrical shape.…”

Section: Butt-joint Configurationmentioning

confidence: 99%

A Comprehensive Review on Optimal Welding Conditions for Friction Stir Welding of Thermoplastic Polymers and Their Composites

et al. 2021

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Friction stir welding (FSW) and friction stir spot welding (FSSW) techniques are becoming widely popular joining techniques because of their increasing potential applications in automotive, aerospace, and other structural industries. These techniques have not only successfully joined similar and dissimilar metal and polymer parts but have also successfully developed polymer-metallic hybrid joints. This study classifies the literature available on the FSW and FSSW of thermoplastic polymers and polymer composites on the basis of joining materials (similar or dissimilar), joint configurations, tooling conditions, medium conditions, and study types. It provides a state-of-the-art and detailed review of the experimental studies available on the FSW and FSSW between similar thermoplastics. The mechanical properties of FSW (butt- and lap-joint configurations) and FSSW weld joints depend on various factors. These factors include the welding process parameters (tool rotational speed, tool traverse speed, tool tilt angle, etc.), base material, tool geometry (pin and shoulder size, pin profile, etc.) and tool material, and medium conditions (submerged, non-submerged, heat-assisted tooling, cooling-assisted tooling). Because of the dependence on many factors, it is difficult to optimize the welding conditions to obtain a high-quality weld joint with superior mechanical properties. The general guidelines are established by reviewing the available literature. These guidelines, if followed, will help to achieve high-quality weld joints with least defects and superior mechanical properties. Apart from parametric-based studies, the statistical-based studies (e.g., analysis of variance (ANOVA)-based studies) are covered, which helps with the determination of the influential parameters that affect the FSW and FSSW weld joint strength. Also, the optimal ranges of the most influential process parameters for different thermoplastic materials are established. The current work on the development of general guidelines and determination of influential parameters and their operating ranges from published literature can help with designing smart future experimental studies for obtaining the global optimum welding conditions. The gaps in the available literature and recommendations for future studies are also discussed.

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“…They observed that good quality butt joints were developed by FSW in HDPE. Sahu et al [16] used three different tool geometries with varying traverse and rotational speeds while applying FSW on PE sheets. They achieved a maximum of 59.82% weld strength by using square pin tool.…”

Section: Introductionmentioning

confidence: 99%

Parametric Optimization of Butt Welded Polycarbonate using Response Surface Methodology

Imtiaz

Tariq

Janjua

et al. 2021

Mehran Univ. res. j. eng. technol.

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Friction Stir Welding (FSW) is a solid-state joining process for metals, non-metals and polymers. It is carried out with the help of a specially designed, non-consumable tool. The heat required, for creating a softened region at the faying surfaces, is generated by rotation of tool against the work piece material. Being a solid-state welding process, it offers several advantages like inducing minimum effect on the mechanical properties of base material, reduced shrinkage and distortion, no spatter or Ultra Violet (UV) radiations etc. However, developing a sound weld requires an appropriate combination of several process parameters e.g. the design of tool, its rotational and traversing speeds etc. To substantiate this aspect, an approach based on Response Surface Methodology (RSM) is presented during this paper that optimizes the combination of process parameters while investigating their effect on the mechanical properties of a friction stir welded butt joint configuration of Polycarbonate. To minimize the total number of combinations a Central Composite Rotatable Design (CCRD) is used with three factors and two levels. The results have shown that the butt joints fabricated at a traverse speed of 14 mm/min, rotational speed of 1700 RPM and with simple cylindrical conical tool geometry yielded the maximum ultimate tensile strength of 51.299 MPa.

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Friction stir welding of polypropylene sheet

Cited by 52 publications

References 18 publications

Co-Bonded Hybrid Thermoplastic-Thermoset Composite Interphase: Process-Microstructure-Property Correlation

Co-Bonded Hybrid Thermoplastic-Thermoset Composite Interphase: Process-Microstructure-Property Correlation

A Comprehensive Review on Optimal Welding Conditions for Friction Stir Welding of Thermoplastic Polymers and Their Composites

Parametric Optimization of Butt Welded Polycarbonate using Response Surface Methodology

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