Session: 03-06-01: Advanced Material Forming – Mechanism, Characterization, Novel Processes, and Control

Paper Number: 144137

144137 - Investigation of Friction Stir Welding (Fsw) of Dissimilar Polymeric Materials 

Friction Stir Welding (FSW) has emerged as a novel technique for joining polymers. Unlike traditional welding methods that involve melting and solidification, FSW operates in the solid-state, mitigating issues associated with thermal degradation, distortion, and residual stresses. This approach utilizes a non-consumable rotating tool to generate frictional heat and mechanically stir the polymer material, effectively creating a solid-state bond between the joined surfaces without reaching their melting point.

The versatility of FSW in polymer welding is one of its most notable features, as it allows for the joining of dissimilar materials with different melting points. The process produces high-quality joints that exhibit enhanced mechanical properties and structural integrity. This capability is particularly valuable in applications where materials with contrasting properties need to be seamlessly integrated, such as in the aerospace and automotive industries.

One of the key advantages of FSW is its ability to accommodate a wide range of polymer materials, including thermoplastics and thermosets. This versatility makes FSW suitable for various applications across diverse industries, from manufacturing lightweight components for aircraft and automobiles to assembling intricate structures for renewable energy systems.

Research efforts in the field of polymer FSW have been gaining interest in recent years, with a focus on optimizing process parameters, tool design, and material properties to improve joint quality and reliability. Studies investigating the effects of factors such as tool rotation speed, welding temperature, and material composition have yielded valuable insights into the underlying mechanisms of the FSW process, leading to advancements in performance and efficiency.

In recent years, the application of FSW in polymer welding has expanded to include emerging fields such as additive manufacturing and biomedical engineering. Additive manufacturing processes, such as 3D printing, can benefit from FSW's ability to produce strong and reliable bonds between polymer layers, enabling the fabrication of complex and functional parts with improved mechanical properties. In the biomedical field, FSW has been used to join biocompatible polymers for the fabrication of medical devices and implants, offering a safe and effective means of assembly that minimizes the risk of contamination and infection.

Overall, friction stir welding offers a promising solution for joining polymers, providing a combination of technical, practical, and environmental benefits. With ongoing research and development efforts aimed at optimizing process parameters, tool design, and material properties, FSW is poised to become a widely adopted joining technique in various industries, ranging from automotive and aerospace to renewable energy and electronics.

The work presented herein investigates the effects of process parameters on the friction stir welded joints through various tests including tension, hardness, and microstructure analyses.  The joining process involved defined parameters such as feed rate, spindle speed, and plunge depth. The materials investigated here in are polypropylene and polycarbonate. Baseline testing included joining similar material. The study is expanded to cover joining the two materials together. Hardness tests are expected to reveal the hardness distribution around the joint, and tension tests will be conducted to examine the joint quality across the weld width. Microstructure evaluations will focus on material mixing and depth of welds. The findings of the study are expected to contribute to understanding the impact of process parameters on joint quality and material properties of similar and dissimilar polymeric materials.

Presenting Author: Ihab Ragai Penn State University, Erie

Presenting Author Biography: Dr. Ragai is a professor at Penn State University in Erie, PA. His research focus is on advanced manufacturing processes and systems.

Authors:

Ihab Ragai Penn State University, Erie
Mark Rubeo Penn State University, Erie
William Emblom University of Louisiana at Lafayette