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  Scopus ID: 21100926589

Joining of Dissimilar Thermoplastic Polymers Using Friction Stir Processing: A Review

Nisith Kumar Goswami, Lalita Prasad Nayak and Kamal Pal

Abstract

Nowadays lightweight thermoplastic materials are widely used in numerous fabricated parts such as of wings, fuselage panels in aircraft industries, automobile panel and lighting systems in automobile industries because of its greater strength-to-weight ratio, anti-corrosion and self-insulating properties. Friction stir joining is a solid-state processing that is highly popular for the joining of the various structured amorphous to semi-crystalline thermoplastics as fusion heat assisted welding methodologies are not often found to be beneficial due to improper thermal properties. Thus, the weldability of dissimilar thermoplastic materials particularly metal to polymers is highly challenging task because of drastic variance in chemical and thermal properties. This paper addresses the review on the joining of thermoplastic materials in several joint configurations like end to end and overlap using advanced friction stir techniques. The parametric interaction effects using different rotating tool pin geometry on weld bead profile, its interface microstructure extended to joint mechanical behaviour during tensile, impact, and fatigue loading for various unlike base materials have been summarized. Various modified process technologies like preheating of unlike high-density polyethylene (HDPE) to Polyamide-6 laminate, adjusted tool tilting with high plunging depth for thin polymethyl methacrylate (PMMA) to polycarbonate sheet, and threaded cylindrical or square tool pin for polypropylene to polyethylene are indicated case wise. The friction welding process monitoring using different sensors’-based algorithms in the time-frequency domain has also been reviewed. Thus, the process dynamics in real-time are abridged with acquired force, torque, and acoustic signals. This brief review will have a considerable impact on the industrial and manufacturing sectors.

Published on: March 24, 2023
doi: 10.17756/nwj.2023-s1-015
Citation: Goswami NK, Nayak LP, Pal K. 2023. Joining of Dissimilar Thermoplastic Polymers Using Friction Stir Processing: A Review. NanoWorld J 9(S1): S72-S77.

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