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A comparative analysis on friction stir welding of similar and dissimilar polymers: acrylonitrile butadiene styrene and polycarbonate plates


In this article, the micro-structural evolution and mechanical performance of similar and dissimilar friction stir welded (FSWed) joints of acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) plates were studied. All the joints (similar ABS-ABS, PC-PC, and dissimilar ABS-PC) were designed under the same process parameters of tool rotational speed (800, 1200, and 1600 rpm), tool traverse speed (0.1, 0.2, and 0.3 mm/s), and tool tilt angle (0°, 1°, and 2°) following an L27 orthogonal array. A joint efficiency of 91.70%, 61.04%, and 64.47% was obtained for similar joints (ABS-ABS, PC-PC) and dissimilar joints (ABS-PC), respectively. The ultimate tensile strength (UTS) and joint efficiency of ABS-PC joints lie in-between the efficiency of ABS-ABS and PC-PC joints for most of the operating parameters which indicate successful joining in contrast to the application of similar welded joints. The UTS, fracture locations, microstructures, and Shore D hardness have been analyzed extensively to evaluate the effects of processing parameters.

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Availability of data and materials

The data analyzed during this study are available with the corresponding author.



Acrylonitrile butadiene styrene


Polycarbonate plate


Friction stir welding


Advancing side


Retreading side


Tool rotational speed


Tool traverse speed


Tool tilt angle


Design of experiment


Base material


Weld nugget


Thermo-mechanically affected zone


Heat affected zone


Ultimate tensile strength


Joint efficiency


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The authors would like to thank the Advanced Centre for Materials Science, IIT Kanpur for testing (Mechanical Testing Lab).

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All authors participated in the conceptualization, interpretation of the data, and drafting of the paper. All authors read and approved the final manuscript.

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Correspondence to Sudhir Kumar.

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Kumar, S., Roy, B.S. A comparative analysis on friction stir welding of similar and dissimilar polymers: acrylonitrile butadiene styrene and polycarbonate plates. Weld World 66, 1141–1153 (2022).

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