Parametric Study Of Friction Stir Spot Welding (FSSW) For Polymer Materials Case Of High Density Polyethylene Sheets: Experimental And Numerical Study

Abstract

Friction stir spot welding (FSSW) is a very important part of conventional friction stir welding (FSW) which can be a replacement for riveted assemblies and resistance spot welding. This technique provides high quality joints compared to conventional welding processes. Friction stir spot welding (FSSW) is a new technology adopted to join various types of metals such as titanium, aluminum, magnesium. It is also used for welding polymer materials which are difficult to weld by the conventional welding process. In various industrial applications, high density polyethylene (HDPE) becomes the most used material. The parameters and mechanical properties of the welds are the major problems in the welding processes. In this paper, we have presented a contribution in finite element modeling of the friction stir spot welding process (FSSW) using Abaqus as a finite element solver. The objective of this paper is to study the HDPE plates resistance of stir spot welding joints (FSSW). First, we show the experimental tests results of high-density polyethylene (HDPE) plates assembled by friction stir spot welding (FSSW). Three-dimensional numerical modeling by the finite element method makes it possible to determine the best representation of the weld joint for a good prediction of its behavior. Comparison of the results shows that there is a good agreement between the numerical modeling predictions and the experimental results.

Fracture analysis of friction stir spot welded acrylonitrile butadiene styrene sheet in butt configuration

“…Furthermore, it has been reported that the rotational speed of the tool along with traverse speed in the second position is the most significant parameter for impact strength [6], elongation percentage [7], and other mechanical properties of the weld [8]. This was positively verified by [9] through experimental and numerical investigation for lap joints of high-density polyethylene (HDPE). Frictional heat decreases with temperature because it depends on the contact pressure between the material and the tool.…”

“…Among the designed experimental layout for the study 1000 rpm spindle speed resulted in strong weld strength by generating sufficient frictional heat for ABS-ABS weld specimens. Excessive spindle speed leads to overheating of the tool, high heat input, higher inertial forces and grain growth in stir zone, thereby resulting in more welding defects, similar observation by [9][10][11][12]. This condition decreases the weld quality and weld strength.…”

Investigations on friction stir spot welding to overcome bed size limits of material extrusion (MEX) 3D printers

“…As reported by various researchers, the strength of the FSSW joints is affected by the temperature distribution in the welding region which in turn depends upon three factors: the quality of stirring, the material mixing and the amount of heat developed (Benyerou et al , 2021; Lambiase et al , 2017). The tool geometry affects the stirring, the dwell time and infill percentage affect the material mixing, while the tool rotational speed, plunge depth and material combination would determine the amount of heat developed.…”

Analysis of Mechanical Properties and Microstructure of Aluminum and Copper Sheet Welding Using Friction Stir Spot Welding Method

“…In the case of FSSW of thermoplastics, the process consists of four phases: plunging, stirring, solidifying, and retracting. The friction between the tool and the plates generates the heat required to weld the plates (Benyerou et al, 2021).…”