Improved performance of a heterogeneous weld joint of copper-steel AISI 1045 obtained by rotary friction using a metal powder insert

Bouarroudj, El-oualid; Abdi, Saîd; Miroud, Djamel

doi:10.1007/s00170-022-10326-9

Cited by 5 publications

(4 citation statements)

References 28 publications

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“…In this study, a conventional turning machine was used to carry out the RFW of polymer rods. In future studies, a high-speed lathe or computer numerical control lathe [40,41] are recommended to carry out RFW [42][43][44][45]. These topics are currently being investigated, and the results will be presented in future work.…”

Section: Resultsmentioning

confidence: 99%

Mechanical Performance and Microstructural Evolution of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Rods

et al. 2023

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Rotary friction welding (RFW) is a green manufacturing technology with environmental pollution in the field of joining methods. In practice, the welding quality of the friction-welded parts was affected by the peak temperature in the weld joint during the RFW of dissimilar plastic rods. In industry, polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) are two commonly used plastics in consumer products. In this study, the COMSOL multiphysics software was employed to estimate the peak temperature in the weld joint during the RFW of PC and ABS rods. After RFW, the mechanical performance and microstructural evolution of friction-welded parts were investigated experimentally. The average Shore A surface hardness, flexural strength, and impact energy are directly proportional to the rotation speed of the RFW. The quality of RFW is excellent, since the welding strength in the weld joint is better than that of the ABS base materials. The fracture occurs in the ABS rods since their brittleness is higher than that of the PC rods. The average percentage error of predicting the peak temperature using COMSOL software using a mesh element count of 875,688 for five different rotation speeds is about 16.6%. The differential scanning calorimetry curve for the friction-welded parts welded at a rotation speed of 1350 rpm shows an endothermic peak between 400 to 440 °C and an exothermic peak between 600 to 700 °C, showing that the friction-welded parts have better mechanical properties.

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Section: Resultsmentioning

confidence: 99%

Mechanical Performance and Microstructural Evolution of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Rods

et al. 2023

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“…In future investigations, the computer numerical control turning machine [46] is recommended to perform RFW of ABS and PC rods since the feed rate of RFW can be precisely controlled to replace human error. In addition, the rotational speed [47][48][49][50][51][52] can be changed during the whole process of RFW. These topics are interesting research topics and are currently being investigated, and the results will be presented in later works.…”

Section: Resultsmentioning

confidence: 99%

Experimentation and Numerical Modeling of Peak Temperature in the Weld Joint during Rotary Friction Welding of Dissimilar Plastic Rods

et al. 2023

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Rotary friction welding (RFW) could result in lower welding temperature, energy consumption, or environmental effects as compared with fusion welding processes. RFW is a green manufacturing technology with little environmental pollution in the field of joining methods. Thus, RFW is widely employed to manufacture green products. In general, the welding quality of welded parts, such as tensile strength, bending strength, and surface hardness is affected by the peak temperature in the weld joint during the RFW of dissimilar plastic rods. However, hitherto little is known about the domain knowledge of RFW of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) polymer rods. To prevent random efforts and energy consumption, a green method to predict the peak temperature in the weld joint of dissimilar RFW of ABS and PC rods was proposed. The main objective of this work is to investigate the peak temperature in the weld joint during the RFW using COMSOL multiphysics software for establishing an empirical technical database of RFW of dissimilar polymer rods under different rotational speeds. The main findings include that the peak temperature affecting the mechanical properties of RFW of PC and ABS can be determined by the simulation model proposed in this work. The average error of predicting the peak temperature using COMSOL software for five different rotational speeds is about 15 °C. The mesh element count of 875,688 is the optimal number of meshes for predicting peak temperature in the weld joint. The bending strength of the welded part (y) using peak welding temperature (x) can be predicted by the equation of y = −0.019 x2 + 5.081x − 200.75 with a correlation coefficient of 0.8857. The average shore A surface hardness, impact energy, and bending strength of the welded parts were found to be increased with increasing the rotational speed of RFW.

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“…This study employed a conventional turning machine to perform RFW of ABS/PC. A computer numerically controlled turning machine [43] was suggested to perform the RFW of ABS/PC to reduce the human error in the RFW using a conventional turning machine because the rotational speed can be changed during RFW ABS/PC [44]. Predicting the cracks of fracture structure using the COMSOL Multiphysics software is also an important research issue [45].…”

Section: Resultsmentioning

confidence: 99%

Effects of Ambient Temperature on the Mechanical Properties of Frictionally Welded Components of Polycarbonate and Acrylonitrile Butadiene Styrene Dissimilar Polymer Rods

Kuo,

Gurumurthy,

Huang

2023

Polymers

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Rotary friction welding (RFW) has no electric arc and the energy consumption during welding can be reduced as compared with conventional arc welding since it is a solid-phase welding process. The RFW is a sustainable manufacturing process because it provides low environmental pollution and energy consumption. However, few works focus on the reliability of dissimilar polymer rods fabricated via RFW. The reliability of the frictionally welded components is also related to the ambient temperatures. This work aims to investigate the effects of ambient temperature on the mechanical properties of frictionally welded components of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS) dissimilar polymer rods. It was found that the heat-affected zone width increases with increasing rotational speeds due to peak welding temperature. The Shore A surface hardness of ABS/PC weld joint does not change with the increased rotational speeds. The Shore A surface hardness in the weld joint of RFW of the ABS/PC is about Shore A 70. The bending strength was increased by about 53% when the welded parts were placed at 60–70 °C compared with bending strength at room temperature. The remarkable finding is that the bending fracture position of the weldment occurs on the ABS side. It should be pointed out that the bending strength can be determined by the placed ambient temperature according to the proposed prediction equation. The impact energy was decreased by about 33% when the welded parts were placed at 65–70 °C compared with the impact energy at room temperature. The impact energy (y) can be determined by the placed ambient temperature according to the proposed prediction equation. The peak temperature in the weld interface can be predicted by the rotational speed based on the proposed equation.

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Improved performance of a heterogeneous weld joint of copper-steel AISI 1045 obtained by rotary friction using a metal powder insert

Cited by 5 publications

References 28 publications

Mechanical Performance and Microstructural Evolution of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Rods

Mechanical Performance and Microstructural Evolution of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Rods

Experimentation and Numerical Modeling of Peak Temperature in the Weld Joint during Rotary Friction Welding of Dissimilar Plastic Rods

Effects of Ambient Temperature on the Mechanical Properties of Frictionally Welded Components of Polycarbonate and Acrylonitrile Butadiene Styrene Dissimilar Polymer Rods

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