Friction stir welding is a solid-state method of joining thermoplastic materials. This paper studied the effect that varying process parameters (rotational speed, welding speed, and attack angle) had on the weld quality of polyethylene sheets. Experiments were performed at rotational speeds of 1000, 1200, 1400, 1600, and 1800 r/min, welding speeds of 12, 16, and 20 mm/min, and attack angles of 1° and 2°. A strength value of 75 per cent of that of the base material was achieved at the isolated optimum welding condition. Changes in the weld zone microstructure were investigated using differential scanning calorimetry and scanning electron microscopy. The observed microstructures were used to explain the reduced value of the strength.
Abbasi GharachehMKokabiA. HDaneshiG. HShalchiBSarrafiR. The influence of the ratio of ‘rotational speed/traverse speed’ on mechanical properties of AZ31 friction stir welds, Int. J. Mach. Tools Mf., 2006, 46, 1983–1987.
2.
BahemmatPBesharatiM. KHaghpanahiMRahbariASalekrostamR. Mechanical, micro, and macrostructural analysis of AA7075–T6 fabricated by friction stir butt welding with different rotational speeds and tool pin profiles, Proc. IMechE, Part B: J. Engng Mf., 2009, 224, 419–433. DOI: 10.1243/09544054JEM1554.
3.
MishraR. SMabZ. Y. Friction stir welding and processing, Mater. Sci. Engng, Part R:Rep., 2005, 50, 1–78.
4.
RecordJ. HStatistical investigations of friction stir processing parameter relationships, 2005 (Department of Mechanical Engineering, Brigham Young University), MSc Thesis.
5.
CovingtonJ. LExperimental and numerical investigations of tool heating during friction stir welding, 2005 (Department of Mechanical Engineering, Brigham Young University), MSc Thesis.
6.
ZadpoorA. ASinkeJBenedictusRPietersR. Mechanical properties and microstructure of friction stir welded tailor-made blanks, Mater. Sci. Engng, Part A: Struct. Mater. Prop. Microstuct. Process., 2008, 494, 281–290.
7.
PeelMSteuwerAPreussMWithersP. J. Microstructure, mechanical properties and residual stresses as a function of welding speed in aluminum AA5083 friction stir welds, Acta Mater., 2003, 51, 4791–4801.
8.
KumarKKailasS. V. The role of friction stir welding tool on material flow and weld formation, Mater. Sci. Engng, Part A: Struct. Mater. Prop. Microstuct. Process., 2008, 485, 367–374.
9.
AriciASinmazT. Effects of double passes of the tool on friction stir welding of polyethylene, J. Mater. Sci., 2005, 40, 3313–3316.
10.
PeacockA. JHandbook of polyethylene structures, properties and applications, 2000 (Marcel Dekker, New York, NY), p. 67 and p. 149.
11.
BironMThermoplastics and thermoplastic composites – technical information for plastics users, 2007LondonButterworth Heinemannp. 223.
12.
WiseR. JThermal welding of polymers, 1999 (Woodhead, Abington, Cambridge), p. 45.
13.
TroughtonM. JHandbook of plastics joining: a practical guide, 2008, second edition. (William Andrew, New York), p. 5 and p. 323.
14.
MillsN. JPlastics: microstructure and engineering applications, 2005LondonButterworth Heinemannpp. 94, 268, and 62.
15.
AssidiMFourmentLGuerdouxSNelsonT. Friction model for friction stir welding process simulation: calibrations from welding experiments, Int. J. Mach. Tools Mf, 2009, 50, 143–155.
