The Effect of Top Surface Lubrication on the Friction Stir Welding of Polycarbonate Sheets

M. M. Z. Ahmed; A. Elnaml; M. Shazly; M. M. El-Sayed Seleman

doi:10.1515/ipp-2020-3991

Article

The Effect of Top Surface Lubrication on the Friction Stir Welding of Polycarbonate Sheets

M. M. Z. Ahmed , A. Elnaml , M. Shazly and M. M. El-Sayed Seleman

Published/Copyright: March 9, 2021

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From the journal International Polymer Processing Volume 36 Issue 1

Abstract

In this work, top surface lubrication during friction stir welding of polycarbonate sheets was applied. A homogenous layer of Paraffin wax has been placed on the top surface of the joint area with a width that ensures to cover the shoulder diameter. Then FSW was applied using conventional FSW tool with rotating pin and shoulder at different FSW parameters (Rotation speeds of 1 000, 1500, 2 000 min^–1 and welding speeds of 25, 50, 75,100 mm/min). The main objective of using the wax is to act as a lubricant that reduces the friction between the shoulder and the polycarbonate surface. The joints produced were investigated in terms of surface quality, internal defects, and mechanical properties. During FSW the wax is melted and played as lubricant between the tool shoulder and the polycarbonate surface and resulted in defect-free surface with no thickness reduction of the original plate. The transverse cross-section showed defect-free joints for the majority of the FSW parameters investigated. Tensile testing results showed a reduction of the tensile strength after FSW, and an enhancement in the tensile strength with the increase of welding speed or rotation speed. The fracture occurs at the joint zone and the fracture surface investigation using SEM showed the existence of spherulitic structure in the weld joint.

Mohamed Mohamed Zaky Ahmed, Mechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 11942, Saudi Arabia

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Acknowledgements

The authors acknowledge the financial support rendered by the Science and Technology Development fund (STDF), Egyptian State Ministry of Higher Education and Scientific Research (Project IDs: 3926 and 5304).

Received: 2020-05-29

Accepted: 2020-08-13

Published Online: 2021-03-09

Published in Print: 2021-03-26

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https://doi.org/10.1515/ipp-2020-3991