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Thermal analysis of revolution pitch effects on friction stir welding of polypropylene

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Abstract

This study explores the relationship between revolution pitch, heat generation, and flow properties in polypropylene friction stir welding joints. Utilizing a modified computational fluid dynamics method, simulations of polypropylene friction stir welding are conducted to elucidate material flow and thermal history in relation to revolution pitch. The study investigates the impact of revolution pitch on internal defects, hardness, and tensile strength of the polypropylene joint. Simulation results reveal that revolution pitch influences polypropylene strain rate and viscosity, leading to variations in internal voids within the stir zone. A higher revolution pitch results in vertical mixing, while a lower revolution pitch causes horizontal lamellar mixing in the stir zone. Controlling revolution pitch is crucial for producing robust joints, as a very low revolution pitch increases the risk of over-stirring and air tapping, while a very high revolution pitch hinders proper joint formation. The optimal heat range for robust joint formation is identified between ~175 (revolution pitch = 0.0410) and ~210 °C. (at revolution pitch = 0.0107). The study demonstrates that consistent polypropylene joint properties can be achieved with similar revolution pitch, even at different friction stir welding tool velocities.

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Abbreviations

P :

Pressure

cv :

Volumetric density

C p :

Specific heat

T :

Temperature

k :

Thermal conductivity

O Total :

Total heat input produced by friction and plastic deformation

𝜓:

Internal mixing factor

R s :

Tool shoulder radius

R p :

Pin body radius

R b :

Pin beneath radius

O w :

Conducted heat into the weld material

τ0:

Plastic tangential adhesion

μf :

Friction coefficient

M :

Welding velocity

ω :

Rotational velocity of the FSW tool

F :

Axial force

F z :

Normal force

F x :

Shear force

ε ij :

Activation strain

ΔU :

Activation energy

V*:

Activation volume

R :

Gas constant

T g,dry :

Glass transition temperature at the dry state

T g,wet :

Glass transition temperature after FSW

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Authors and Affiliations

  1. Department of Mechanics, Design and Industrial Management, University of Deusto, Avda Universidades 24, 48007, Bilbao, Spain

    Hamed Aghajani Derazkola

  2. Department of Manufacturing and Production Engineering, Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, Al. Powst. Warszawy 8, 35-959, Rzeszów, Poland

    Andrzej Kubit

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Derazkola, H.A., Kubit, A. Thermal analysis of revolution pitch effects on friction stir welding of polypropylene. Int J Adv Manuf Technol 130, 1421–1437 (2024). https://doi.org/10.1007/s00170-023-12831-x

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