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

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Abstract

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.

Abbreviations

ABS:

Acrylonitrile butadiene styrene

PC:

Polycarbonate plate

FSW:

Friction stir welding

AS:

Advancing side

RS:

Retreading side

TRS:

Tool rotational speed

TTS:

Tool traverse speed

TTA:

Tool tilt angle

DOE:

Design of experiment

BM:

Base material

WN:

Weld nugget

TMAZ:

Thermo-mechanically affected zone

HAZ:

Heat affected zone

UTS:

Ultimate tensile strength

JE:

Joint efficiency

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Acknowledgements

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

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Authors and Affiliations

  1. Department of Mechanical Engineering, National Institute of Technology, Agartala, Tripura-799 046, India

    Sudhir Kumar & Barnik Saha Roy

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  1. Sudhir Kumar
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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). https://doi.org/10.1007/s40194-022-01294-5

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