On the friction stir welding, tool design optimization, and strain rate-dependent mechanical properties of HDPE–ceramic composite joints

Abstract

Friction stir welding is a recently developed technique for joining low-melting metals and polymers. In the present work, friction stir welded joints of high-density polyethylene (HDPE) sheets were produced using a newly designed tool with a concave shoulder and a grooved conical pin. The joints were produced with and without the additions of ceramic particulates including silicon carbide (SiC), alumina, graphite, and silica. The effect of strain rate on the tensile properties of base material and plain welded joints was examined. In addition to tensile properties of composite joints, hardness profiles across the weld nugget were analyzed. It was observed that the increasing strain rate improved both the tensile strength and the ductility of the plain welded joints. The tool was able to yield a joint efficiency of around 84% in the plain welded samples. Although, in terms of joint efficiency, the composite joints were less efficient than the plain welded HDPE, SiC additions were found to yield better material properties relative to other reinforcements. Finally, it was concluded that an SiC–HDPE composite joint can be of practical importance in high strain rate applications, provided the optimum tool design and stir welding parameters are available.

Experimental Investigation and Optimization on Friction Stir Welding of Nylon 6A Using Taguchi and ANOVA with Microstructural Analysis

“…ese polymer composites are 20% carbon fiber-reinforced PP composite [9], 30% glasses fiber-reinforced PP composite [10], polyethylene terephthalate (PET) [11], polycaprolactam (nylon 6) [12], polymethyl methacrylate (PMMA) [13], acrylonitrile butadiene styrene (ABS) [14], poly carbonate (PC) [15], poly propylene (PP) [16], and different grades of polyethylene (PE) [17]. Raza et al used a specific developed tool with a grooved conical pin and a concave shoulder based on highdensity polyethylene (HDPE) sheet friction stir welded joints [18]. With and without including the ceramic particulates, the joints were manufactured that included silica, graphite, alumina, and silicon carbide (SiC).…”

Investigation of the effects of welding variables on the welding defects of the friction stir welded high density polyethylene sheets

“…Various welding defects that may occur during the FSW process or when the welding is finished are given in Figure 3. 24 Weld defects occur in friction stir welding of plastics due to three basic factors. When insufficient heat generation occurs in the stir zone, welding defects such as voids, no bond formation in the weld, no joint in the weld bead occured.…”

“…In the literature reviews, there are studies on FSW methods applied to plastic materials. [22][23][24][25][26][27] No studies have been conducted on welding defects in friction stir welding of plastic materials and methods to prevent these defects. In this study, the causes of welding defects (groove formation, discontinuities, material accumulation, insufficient penetration, excessive melt, and weld bead failure) occurring in friction stir welding applied to high density polyethylene sheets were investigated.…”

Experimental and thermal investigation with optimization on friction stir welding of nylon 6A using Taguchi and microstructural analysis

“…These polymer composites are 20% carbon fiber-reinforced PP composite, 9 30% glasses fiber reinforced PP composite, 10 Polyethylene Terephthalate (PET), 11 Polycaprolactam (nylon 6), 12 Polymethyl Methacrylate (PMMA), 13 Acrylonitrile Butadiene Styrene (ABS), 14 Poly Carbonate (PC), 15 Poly Propylene (PP), 16 and different grades of Polyethylene (PE). 17 Raza et al 18 was used a specific developed tool with a grooved conical pin and a concave shoulder based on high-density polyethylene (HDPE) sheet friction stir welded joints. With and without including the ceramic particulates, the joints were manufactured that included silica, graphite, alumina, and silicon carbide (SiC).…”