Abstract
Friction stir welding is an environmentally friendly process of joining due to the non-usage of flux, or any shield gas. Therefore, this article proposes an experimental and thermal investigation with optimization technique for studying the process of FSW on nylon 6A or polycaprolactam polymer composite plates. Specifically, the influence of input operating process parameters such as tool rotational speed (TRS), feed rate, and pitch values on the output response parameters like ultimate tensile strength (UTS), and hardness of welded joints is examined. In addition, L27 orthogonal array of Taguchi approach is employed for the optimization of design experiments of FSW parameters. The experimental setup is carried out with various process parameter combinations like 500, 1000, and 1500 rpm as TRS, 30, 40, and 50 mm as feed rate by varying the pitch values as 1, 2, and 3 mm. Further, the analysis of variance (ANOVA) also employed for finding the significant parameters of input process using the regression analysis equations. Finally, microstructural analysis is used to assess the mixing or dispersing uniformity of composites effectively. The experimental and optimum FSW parameters for maximum UTS are obtained at a feed rate of 30 mm/min, tool pitch of 3 mm, and the TRS of 500 rpm.
Highlights
For improving production efficiency and reducing the costs with lower environmental effect in electronic, automobile, and aerospace devices, the benefits of good corrosion resistance, high specific strength, processing ability, and excellent design freedom have the potential in polymers and polymer matrix composites (PMCs).[1,2] The joining technology of welding techniques like adhesive bonding and mechanical fastening are required for the large and complex parts fabrication.[3]
The FSW techniques for aluminum alloy sheets for joining different types of thermoplastics with and without fibers are addressed in Ratanathavorn,[24] where an experimental research work is recommended to get insight into the welding parameters’ effects on the hybrid joints’ efficiency in terms of tensile shear strength
tool rotational speed (TRS), feed rate, and pitch are considered as input process parameters while the ultimate tensile strength (UTS) and hardness are assumed as output parameters, which means the strength of welding is assessed using these UTS, and hardness values
Summary
For improving production efficiency and reducing the costs with lower environmental effect in electronic, automobile, and aerospace devices, the benefits of good corrosion resistance, high specific strength, processing ability, and excellent design freedom have the potential in polymers and polymer matrix composites (PMCs).[1,2] The joining technology of welding techniques like adhesive bonding and mechanical fastening are required for the large and complex parts fabrication.[3]. The welding process is the best joining technique that includes different kinds, such as electric resistance welding, linear vibration welding, hot plate welding, FSW, and ultrasonic welding, etc.[3] Three different processes include in these welding techniques: (a) a layer of molten material formation to be joined on the surfaces, (b) upsetting forms the bonding, and (c) the stage pressure and molten material cools should have to maintain for preventing the forming of voids within the weld zone.[4] Spot welding is performed mainly by ultrasonic welding but need to spend higher costs on tools and machines and more time is required for preparation. FSW has the potential of overcoming the drawbacks of aforementioned welding techniques due to that it has the benefits like high joint quality, severe plastic deformation, low temperature and machine/tool consumable costs, low process time, and no preparation.[5] Figure 1 shows the schematic diagram of FSW. At a high rotational velocity, the frictions with the workpieces producing material flow to mix, generating frictional heat to smoothen the materials, and combining the welded materials for welding
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