Friction plug welding acrylonitrile butadiene styrene sheets: the investigation of welding process, joint morphology and mechanical property

Abstract

In this paper, friction plug welding technology was employed to join Acrylonitrile Butadiene Styrene sheets. Proper welding process was investigated and determined first, and the influence of plug diameter and length, blind hole profile and depth on joint morphology and mechanical performance was investigated subsequently. Results showed that incomplete connection was generated at the weld boundary when no chuck was utilized, and excellent bonding was produced with the employment of a chuck. Joints produced with blind holes that characterized by perpendicular base angle showed incomplete fusion at the bottom corner of the weld while defect-free joints were obtained with rounded hole base angle. Plug size and blind hole depth significantly affected the joint morphology and strength. Cavities were formed under small plug diameter, excessive plug length or large blind hole depth, and weak connection occurred when plug length was small. Joint shear strength increased with the plug diameter but decreased with the plug length. Proper increase of the hole depth slightly influenced the joint quality, but extreme hole depth caused reduced joint strength. Only joints fabricated with insufficient plug length failed with lower nugget pulling out and other spot welds failed with shear fracture.