Abstract
Friction stir spot welding (FSSW) is one of the solid state welding techniques commonly used for joining of similar and dissimilar metals, alloys and thermoplastics. In last two decades most of studies reported the approaches of FSSW with varying its input process parameters. But hitherto very less has been reported for the use of a consumable tool for joining of thermoplastic composites sheets. In this study a framework of FSSW with the use of consumable pin as rapid tooling has been explored to be potentially applied it in maintenance and repair applications. The study demonstrates detailed methodology for use of twin screw extrusion (TSE), fused deposition modeling (FDM) for melt flow compatible thermoplastic composite preparations and vertical milling setup for joining of Al reinforced acrylonitrile butadiene styrene (ABS) sheets with pin of Al reinforced polyamide 6 (PA6) as a case study.
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