Development of a Self-Heated Friction Stir Welding tool for welding of polypropylene sheets

Abstract

The present investigation is focused on the development of a new FSW tool for polymer welding. The newly developed Self-Heated Friction Stir Welding (FSW) tool as well as a conventional FSW tool was employed to join 3-mm polypropylene sheets at different traverse speeds. The spindle torque and various forces exerted on the tool pin during welding were studied. The weldments obtained from both the tools were tested in order to analyse the weld morphology and tensile strength. SEM analysis of the stir zone revealed that the Self-Heated FSW tool had significant influence on the material flow and consequently resulted in defect-free welded joints. Also, the relationship between weld quality and tool axial and transverse forces on tool pin was established. The Self-Heated FSW tool was able to produce durable weld with superior mechanical property in terms of tensile strength compared to the conventional FSW tool.