Investigation on the microstructure and mechanical property of friction stir lap welded acrylonitrile butadiene styrene/polycarbonate produced by double-pin tool

Friction stir lap welding (FSLW) of dissimilar acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) was conducted using a double-pin tool. The formation process of the weld and the influences of rotational speed on the microstructure and mechanical property were investigated. It was found that the weld was generated accompanying with the closure of old cavities in the front of the pins and the simultaneous regeneration of new cavities in the rear of the pins. Annular material flow on the vertical and horizontal directions occurred during FSLW. With the increase of the rotational speed, the PC anchors resulted from the upflow of plasticized PC layer and the shoulder affected zone both enlarged. Microstructure analysis of the weld nugget showed that PC was fragmented into lamellar, columnar, and spherical particles and their dimensions decreased when rotational speed increased. Lap-shear tensile tests showed that the weld strength increased with higher rotational speed and the maximum strength of the weld produced under 800 r/min reached 19.38 MPa, which was comparable to the ABS/PC welds produced by a tapered pin under the optimal parameters. Through the further optimization of such FSLW process, it was potential to join dissimilar polymeric components in future industrial manufacturing field.