Abstract
Thermal residual stress is an undesirable and unavoidable phenomenon in welding structures. It causes distortion of the weld and reduces the weld’s mechanical properties. In the present study, a new setup of friction stir welding process including cooling of weld nugget was developed to enhance the weld strength and to reduce the angular distortion of the friction stir welded polyethylene sheets. The clamped sheets are firstly welded by FSW process, and then, the traversed weld nugget is cooled by injection of CO2 gas. Here, Taguchi experimental design and response surface methodology were used to analyze effects of tool rotary speed, traverse speed, and cooling gas intake pressure on tensile strength and angular distortion. Also, the nondestructive ultrasonic evaluation was used here to measure residual stress to justify variation of angular distortion. Obtained results revealed that applying cooling causes better consolidation of plasticized material; also, it causes releasing residual stress and decreases the angular distortion.
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