Induction heated tool assisted friction-stir welding (i-FSW): A novel hybrid process for joining of thermoplastics

Bandari, Vijendra; Sharma, Abhay

doi:10.1016/j.jmapro.2015.07.005

Cited by 95 publications

(44 citation statements)

References 19 publications

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“…The welding attributes of thermoplastics aids to the cost-effectiveness of the composite part to be manufactured in an industrial environment from forming until the finishing steps [20][21][22][23]. The most feasible welding techniques available for the fusion bonding of thermoplastic composites are resistance [24][25][26], induction [25,[27][28][29][30][31][32] and ultrasonic welding [16,23,. They behave differently in a way in which the heat is generated at the welding interface.…”

Section: Introductionmentioning

confidence: 99%

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

et al. 2020

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The ultrasonic welding (UW) technique is an ultra-fast joining process, and it is used to join thermoplastic composite structures, and provides an excellent bonding strength. It is more cost-efficient as opposed to the conventional adhesive, mechanical and other joining methods. This review paper presents the detailed progress made by the scientific and research community to date in the direction of the UW of thermoplastic composites. The focus of this paper is to review the recent development of the ultrasonic welding technique for thermoplastic composites to thermoplastic composites, and to dissimilar materials. Different ultrasonic welding modes and their processing parameters, namely, weld time, weld pressure, amplitude, type of energy directors (EDs) affecting the welding quality and the advantages and disadvantages of UW over other bonding techniques, are summarized. The current state of the ultrasonic welding of thermoplastic composites and their future perspectives are also deliberated.

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Section: Introductionmentioning

confidence: 99%

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

et al. 2020

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“…Welding attributes of thermoplastics aids in the cost-effectiveness of the composite part to be manufactured in an industrial environment from forming until the finishing steps [3][4][5][6]. The most feasible welding techniques available for fusion bonding of thermoplastic composites are resistance [7][8][9], induction [8,[10][11][12][13][14][15] and ultrasonic welding [6,[16][17][18][19][20][21][22][23][24][25][26][27][28][29][30][31][32][33][34][35]. These behave differently in the way the heat is generated at the welding interface.…”

Section: Introductionmentioning

confidence: 99%

Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

et al. 2020

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Joining large and complex polymer-matrix composite structures is becoming increasingly important in industries such as automobiles, aerospace, sports, wind turbines, and others. Ultrasonic welding is an ultra-fast joining process and also provides excellent joint quality as a cost-effective alternative to other joining processes. This research aims at investigating the welding characteristics of novel methyl methacrylate Elium ® , a liquid thermoplastic resin. Elium ® is the first of its kind of thermoplastic resin, which is curable at room temperature and is suitable for mass production processes. The welding characteristics of Elium ® composites were investigated by optimizing the welding parameters with specially designed integrated energy directors (ED) and manufactured using the Resin transfer molding process. The results showed a 23% higher lap shear strength for ultrasonically welded composite joints when compared to the adhesively bonded joints. The optimized welding time for the ultrasonic welded joint was found to be 1.5 s whereas it was 10 min for the adhesively bonded joint. Fractographic analysis showed the significant plastic deformation and shear cusps formation on the fractured surface, which are typical characteristics for strong interfacial bonding.

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“…Many researchers have been working to enhance the mechanical properties by applying, hybrid processes and various backing plate with different thermal diffusivity and improved tool design. In hybrid FSW, post weld heat treatment, underwater FSW, in process cooling FSW, and heat-assisted FSW such as laser-assisted FSW, electrical current assisted FSW, electric arc, tungsten arc, induction assisted FSW weld were used to enhance mechanical properties of FSW [3][4][5][6][7][8][9][10]. Santos et al [11] utilized electrical heat source in the tool probe tip as the additional heat and observed that the additional heat helps in reducing the lack of penetration in root side.…”

Section: Introductionmentioning

confidence: 99%

Experimental and numerical analysis of the effect of preheating in friction stir welding

Alam¹,

Sinha²

2019

IJITEE

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Friction stir welding has been frequently used for fabrication of low melting point materials. Nevertheless, it is capable to join thin sheet of high melting point materials such as stainless steel, titanium etc. but tool wear rate is high. A Heat-assisted backing plate (HABP) was developed to preheating the welded specimen. In this paper, a modified 3D FE model was established to simulate the heat-assisted backing plate of friction stir welding by using ANSYS APDL to study of the temperature distribution of workpiece. Numerical simulation was defined by six different load steps for preheating, plunge, dwell, traverse, pull out of tool and cooling stage. Observations of preheated friction stir welding were compared with traditional friction stir welding results. It was found that the preheated friction stir welding increased 7.39 % and 7.55 % of peak temperature as compared to traditional friction stir welding in FEA and experimental respectively. In addition, preheating improve the uniform temperature distribution along the thickness of welded joint.

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Induction heated tool assisted friction-stir welding (i-FSW): A novel hybrid process for joining of thermoplastics

Cited by 95 publications

References 19 publications

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

Advances in Ultrasonic Welding of Thermoplastic Composites: A Review

Investigation on Ultrasonic Welding Attributes of Novel Carbon/Elium® Composites

Experimental and numerical analysis of the effect of preheating in friction stir welding

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