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Polyethylene friction stir welding parameter optimization and temperature characterization

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Abstract

The use of friction stir welding (FSW) to join thermoplastics has proven to produce strong welds with good surface quality when compared to conventional welding methods. In this study, a Teflon stationary shoulder was developed to weld 3-mm-thick plates of high molecular weight polyethylene in butt-joint configuration. Different sets of welding parameters were chosen and tested to evaluate their effect on the weld strength. Also, in order to increase joint performance, the temperature generated during welding was measured. For that purpose, thermocouples were located underneath of the weld nugget surface to measure the generated frictional heat for different tool diameters and parameters. Tool diameter and rotational and welding speeds are the most influential parameters regarding the welding temperature; however, all the input parameters had statistically significant effect on the weld quality. Unlike FSW in metals, using this tool, the heat is generated mainly by surface contact of the rotating probe and copper sleeve than the base material. The strongest welded joint was able to withstand 97% of the force that is necessary to fracture the base material, without using an external heating source.

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Funding

Dr. Moreira acknowledges POPH – QREN-Tipologia 4.2 – Promotion of scientific employment funded by the ESF and MCTES. Authors gratefully acknowledge the funding of Project NORTE-01-0145-FEDER-000022 - SciTech - Science and Technology for Competitive and Sustainable Industries, cofinanced by Programa Operacional Regional do Norte (NORTE2020), through Fundo Europeu de Desenvolvimento Regional (FEDER). The funding provided by project Sold&Maq - Equipamento integrado de soldadura em estado sólido multimateriais e maquinagem NORTE-01-0247-FEDER-023694 is acknowledged.

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Authors and Affiliations

  1. INEGI – Institute of Science and Innovation in Mechanical and Industrial Engineering, 4200-465, Porto, Portugal

    Shayan Eslami, Paulo J. Tavares & P. M. G. P. Moreira

  2. Departamento de Engenharia Mecânica, Faculdade de Engenharia da Universidade do Porto, Rua Dr. Roberto Frias, 4200-465, Porto, Portugal

    Shayan Eslami & J. Francisco Miranda

  3. ISEP, Instituto Superior de Engenharia do Porto, Rua Dr. António Bernardino de Almeida, 431, 4200-072, Porto, Portugal

    Luis Mourão

Authors
  1. Shayan Eslami
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  2. J. Francisco Miranda
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  3. Luis Mourão
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  4. Paulo J. Tavares
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  5. P. M. G. P. Moreira
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Correspondence to Shayan Eslami.

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Eslami, S., Francisco Miranda, J., Mourão, L. et al. Polyethylene friction stir welding parameter optimization and temperature characterization. Int J Adv Manuf Technol 99, 127–136 (2018). https://doi.org/10.1007/s00170-018-2504-x

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  • DOI: https://doi.org/10.1007/s00170-018-2504-x

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