Skip to main content
SpringerLink
Log in

Analysis of forces and temperatures in friction spot stir welding of thermoplastic polymers

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The present investigation analyses the force and torque developing during friction stir spot welding (FSSW) of thermoplastic sheets varying the main process parameters. In addition, measurements of the tool temperature and those of the material close to the welding region were carried out to better understand the variation of the forces during FSSW and quality of the joints. Experimental tests involving an instrumented drilling machine were performed on polycarbonate sheets. The study involved the variation of dwell time, tool plunge rate and rotational speed. Mechanical characterization and dimensional analysis of the joints were performed in order to assess the influence of the process parameters on the joint quality under considered processing conditions. According to the achieved results, using low values of the plunging speed has beneficial effects on both the process (reduction in the force and torque) and the mechanical behaviour of the joints. Increasing the tool rotational speed results in reduced processing forces and higher material mixing and temperature. The dwell time has a negligible effect on developing forces while it highly influences the material temperature, dimension of the welded region and consequently the mechanical behaviour of the joint.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Lambiase F ((in Press)) Joinability of different thermoplastic polymers with aluminium AA6082 sheets by mechanical clinching. Int J Adv Manuf Technol

  2. Lambiase F, Di Ilio A (2015) Mechanical clinching of metal–polymer joints. J Mater Process Technol 215:12–19

    Article  Google Scholar 

  3. Settineri L, Atzeni E, Ippolito R (2010) Self piercing riveting for metal-polymer joints. Int J Mater Form 3(S1):995–998

    Article  Google Scholar 

  4. Hussein FI, Akman E, Genc Oztoprak B, Gunes M, Gundogdu O, Kacar E, Hajim KI, Demir A (2013) Evaluation of PMMA joining to stainless steel 304 using pulsed Nd:YAG laser. Optics Laser Technol 49:143–152

    Article  Google Scholar 

  5. Wirth FX, Zaeh MF, Krutzlinger M, Silvanus J (2014) Analysis of the bonding behavior and joining mechanism during friction press joining of aluminum alloys with thermoplastics. Procedia CIRP 18:215–220

    Article  Google Scholar 

  6. Blaga L, Bancilă R, dos Santos JF, Amancio-Filho ST (2013) Friction riveting of glass–fibre-reinforced polyetherimide composite and titanium grade 2 hybrid joints. Mater Des 50:825–829

    Article  Google Scholar 

  7. Liu FC, Liao J, Nakata K (2014) Joining of metal to plastic using friction lap welding. Mater Des 54:236–244

    Article  Google Scholar 

  8. He X, Gu F, Ball A (2014) A review of numerical analysis of friction stir welding. Prog Mater Sci 65:1–66

    Article  Google Scholar 

  9. Shi L, Wu CS, Liu HJ (2014) Numerical analysis of heat generation and temperature field in reverse dual-rotation friction stir welding. Int J Adv Manuf Technol 74(1-4):319–334

    Article  Google Scholar 

  10. Al-Roubaiy AO, Nabat SM, Batako ADL (2014) Experimental and theoretical analysis of friction stir welding of Al–Cu joints. Int J Adv Manuf Technol 71(9-12):1631–1642

    Article  Google Scholar 

  11. Al-Badour F, Merah N, Shuaib A, Bazoune A (2014) Thermo-mechanical finite element model of friction stir welding of dissimilar alloys. Int J Adv Manuf Technol 72(5-8):607–617

    Article  Google Scholar 

  12. Song X, Ke L, Xing L, Liu F, Huang C (2014) Effect of plunge speeds on hook geometries and mechanical properties in friction stir spot welding of A6061-T6 sheets. Int J Adv Manuf Technol 71(9-12):2003–2010

    Article  Google Scholar 

  13. Papahn H, Bahemmat P, Haghpanahi M, Sommitsch C (2014) Study on governing parameters of thermal history during underwater friction stir welding. Int J Adv Manuf Technol 78(5-8):1101–1111

    Article  Google Scholar 

  14. Ramulu PJ, Narayanan RG, Kailas SV (2013) Forming limit investigation of friction stir welded sheets: influence of shoulder diameter and plunge depth. Int J Adv Manuf Technol 69(9-12):2757–2772

    Article  Google Scholar 

  15. Simões F, Rodrigues DM (2014) Material flow and thermo-mechanical conditions during Friction stir welding of polymers: literature review, experimental results and empirical analysis. Mater Des 59:344–351

    Article  Google Scholar 

  16. Mostafapour A, Azarsa E (2012) A study on the role of processing parameters in joining polyethylene sheets via heat assisted friction stir welding: Investigating microstructure, tensile and flexural properties. Int J Phys Sci 7 (4)

  17. Arora HS, Singh H, Dhindaw BK (2011) Composite fabrication using friction stir processing—a review. Int J Adv Manuf Technol 61(9-12):1043–1055

    Article  Google Scholar 

  18. Oliveira PHF, Amancio-Filho ST, dos Santos JF, Hage E (2010) Preliminary study on the feasibility of friction spot welding in PMMA. Mater Lett 64(19):2098–2101

    Article  Google Scholar 

  19. Bilici MK, Yükler Aİ, Kurtulmuş M (2011) The optimization of welding parameters for friction stir spot welding of high density polyethylene sheets. Mater Des 32(7):4074–4079

    Article  Google Scholar 

  20. Bilici MK, Yükler Aİ (2012) Influence of tool geometry and process parameters on macrostructure and static strength in friction stir spot welded polyethylene sheets. Mater Des 33:145–152

    Article  Google Scholar 

  21. Memduh K (2012) Friction stir spot welding parameters for polypropylene sheets. Sci Res Essays 7 (8)

  22. Hoseinlaghab S, Mirjavadi SS, Sadeghian N, Jalili I, Azarbarmas M, Besharati Givi MK (2015) Influences of welding parameters on the quality and creep properties of friction stir welded polyethylene plates. Mater Des 67:369–378

    Article  Google Scholar 

  23. Pirizadeh M, Azdast T, Rash Ahmadi S, Mamaghani Shishavan S, Bagheri A (2014) Friction stir welding of thermoplastics using a newly designed tool. Mater Des 54:342–347

    Article  Google Scholar 

  24. Panneerselvam K, Lenin K (2014) Joining of Nylon 6 plate by friction stir welding process using threaded pin profile. Mater Des 53:302–307

    Article  Google Scholar 

  25. Mendes N, Loureiro A, Martins C, Neto P, Pires JN (2014) Morphology and strength of acrylonitrile butadiene styrene welds performed by robotic friction stir welding. Mater Des 64:81–90

    Article  Google Scholar 

  26. Mendes N, Neto P, Simão MA, Loureiro A, Pires JN (2014) A novel friction stir welding robotic platform: welding polymeric materials. Int J Adv Manuf Technol

  27. Lambiase F, Di Ilio A, Paoletti A (2014) Optimization of friction stir welding of thermoplastics. In: Teti P (ed) 9th CIRP Conference on Intelligent Computation in Manufacturing Engineering - CIRP ICME '14, Ischia (Na). Italy

  28. Junior WS, Emmler T, Abetz C, Handge UA, dos Santos JF, Amancio-Filho ST, Abetz V (2014) Friction spot welding of PMMA with PMMA/silica and PMMA/silica-g-PMMA nanocomposites functionalized via ATRP. Polymer 55(20):5146–5159

    Article  Google Scholar 

  29. Junior WS, Handge UA, dos Santos JF, Abetz V, Amancio-Filho ST (2014) Feasibility study of friction spot welding of dissimilar single-lap joint between poly(methyl methacrylate) and poly(methyl methacrylate)-SiO2 nanocomposite. Mater Des 64:246–250

    Article  Google Scholar 

  30. Goushegir SM, dos Santos JF, Amancio-Filho ST (2014) Friction spot joining of aluminum AA2024/carbon-fiber reinforced poly(phenylene sulfide) composite single lap joints: microstructure and mechanical performance. Mater Des 54:196–206

    Article  Google Scholar 

  31. Dashatan SH, Azdast T, Ahmadi SR, Bagheri A (2013) Friction stir spot welding of dissimilar polymethyl methacrylate and acrylonitrile butadiene styrene sheets. Mater Des 45:135–141

    Article  Google Scholar 

  32. Lambiase F, Paoletti A, Di Ilio A (2015) Mechanical behaviour of friction stir spot welds of polycarbonate sheets. Int J Adv Manuf Technol:in Press

  33. Hamilton C, Dymek S, Sommers A (2008) A thermal model of friction stir welding in aluminum alloys. Int J Mach Tools Manuf 48(10):1120–1130

    Article  Google Scholar 

  34. Prasanna P, Rao BS, Rao GKM (2010) Finite element modeling for maximum temperature in friction stir welding and its validation. Int J Adv Manuf Technol 51(9-12):925–933

    Article  Google Scholar 

  35. Luo J, Li S, Chen W, Xiang J, Wang H (2015) Simulation of aluminum alloy flowing in friction stir welding with a multiphysics field model. Int J Adv Manuf Technol

  36. Nandan R, Roy GG, Debroy T (2006) Numerical simulation of three-dimensional heat transfer and plastic flow during friction stir welding. Metall Mater Trans A 37(4):1247–1259

    Article  Google Scholar 

  37. Neto DM, Neto P (2012) Numerical modeling of friction stir welding process: a literature review. Int J Adv Manuf Technol

Download references

Author information

Authors and Affiliations

  1. Department of Industrial and Information Engineering and Economics, University of L’Aquila, Monteluco di Roio, 67040, Italy

    A. Paoletti, F. Lambiase & A. Di Ilio

Authors
  1. A. Paoletti
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. F. Lambiase
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Di Ilio
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to A. Paoletti.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Paoletti, A., Lambiase, F. & Di Ilio, A. Analysis of forces and temperatures in friction spot stir welding of thermoplastic polymers. Int J Adv Manuf Technol 83, 1395–1407 (2016). https://doi.org/10.1007/s00170-015-7669-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7669-y

Keywords

Search

Navigation