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Monitoring of Weld Bead Profile in Friction Stir Lap Welding for Polycarbonate Sheets Using Wavelet Packets of Power Signal

  • Research Article-Mechanical Engineering
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Abstract

The solid-state friction stir welding is found to be popular for the joining of thermoplastic materials in different configurations. However, the process variables have to be precisely adjusted with proper selection of tool pin profile to achieve uniform longitudinal weld along the tool traversing direction. The axial thrust and tool stirring torque signals are often used for the process monitoring and associated weld quality prediction. The present work addresses the effect of swept ratio of tool pin contour on the degree of non-uniformity in lap weld profile and index of symmetries in weld bead shape with associated mechanical behavior in tensile–shear loading for polycarbonate sheets. The hexagonal tool pin was found to be the best in terms of stability in weld contour, flawless symmetric weld bead shape with the highest strength efficiency (75.4%) and improved joint ductility particularly at high tool revolving speed (2400 rpm). The input power signal along with thrust–torque signals have also been acquired during welding procedure that was found to be chief indicator of weld quality. The electrical power loss was significantly less at higher tool rotational speed by using this hexagonal tool pin. Thus, this time field power signal has been further analyzed in time–frequency wavelet domain to completely characterize the process variations with corresponding deviations in weld profile. The high-frequency power wavelets were found to be highly sensitive on the deviations in weld quality features though low-frequency power information mainly dictated the variations in weld bead profile.

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Abbreviations

PC-PC:

Polycarbonate to polycarbonate lap

CY, HX, SQ:

Cylindrical, hexagonal, and square pin profile

S-ratio(r) :

Swept ratio

N :

Tool rotational speed, rpm

V :

Traverse speed, mm/min

T :

Spindle torque, Nm

F RMS :

Root mean square axial force, N

T RMS :

Root mean square stirring torque, Nm

P RMS :

Root mean square power, watt (W)

σ ut :

Ultimate tensile strength, MPa

ε f :

Elongation at fracture point, mm

η joint :

Joint efficiency

A ex :

Expelled area, mm2

A SZ :

Stir zone area, mm2

HAZ:

Heat-affected zone

SZ:

Stir zone

UZ:

Undercut zone

P Mech :

Mechanical power, watt (W)

F traverse :

Traverse force, N

η Plunging :

Plunging efficiency, %

η Welding :

Welding efficiency, %

[AUZ]AS :

Undercut area in advancing side, mm2

[AUZ]RS :

Undercut area in retracting side, mm2

[ASZ]AS :

Stir zone area in advancing side, mm2

[ASZ]RS :

Stir zone area in retracting side, mm2

SIVSZ :

Symmetric index value for stir zone

SIVUZ :

Symmetric index value undercut zone

DWT:

Discrete wavelet transform

CWT:

Continuous wavelet transform

Db:

Daubechies

w :

Wavelet function

W :

Weld quality features

S :

Sensor-based features

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Acknowledgements

The authors extend their sincere thanks and heartfelt appreciation to the "Friction Stir Welding Laboratory" at the Department of Mechanical Engineering, IIT Kharagpur, and the Department of Production Engineering at Veer Surendra Sai University of Technology, Burla, for their invaluable contributions in conducting the welding experiment, as well as for their assistance in post-weld sample preparations and testing.

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Authors and Affiliations

  1. Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, Sambalpur, Odisha, 768018, India

    Nisith K. Goswami & Raj K. Bisoyi

  2. Department of Production and Industrial Engineering, National Institute of Technology Jamshedpur, Jamshedpur, Jharkhand, 831014, India

    Kamal Pal

  3. Advanced Technology Development Centre, Indian Institute of Technology, Kharagpur, Kharagpur, West Bengal, 721302, India

    Soumya S. Nayak

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Correspondence to Kamal Pal.

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Goswami, N.K., Pal, K., Bisoyi, R.K. et al. Monitoring of Weld Bead Profile in Friction Stir Lap Welding for Polycarbonate Sheets Using Wavelet Packets of Power Signal. Arab J Sci Eng (2024). https://doi.org/10.1007/s13369-024-09057-8

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