Novel approach to produce reinforced plastic weld seams using an additive friction stir welding process
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Julian Ehrler
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Dominik Müller
Abstract
Friction stir welding (FSW) is a well-established method for joining metal components in lightweight construction. Despite its excellent joining properties, the process has primarily been used in high-tech applications requiring exceptional joint strength. However, the unresolved challenge of gap bridging limits its wider adoption. Recently, efforts have been made to extend FSW to plastic components. To address some of its limitations, this study presents a hybrid approach for thermoplastic materials, combining FSW with additive manufacturing techniques. In this method, a filament serves as a filler material during the welding process. This approach aims to improve both the mechanical and aesthetic properties of the weld seam by incorporating reinforced plastics, while also addressing the gap-bridging requirements of industrial applications. Newly developed stirring tools enable precise delivery of filler material into the process zone. Their modular design allows for the conveyance of both molten and solid material into the joining zone, with the conveying capacity adjustable through modifications to tool geometry. The results of joints made from various homogeneous plastic types, including ABS, PC, and PA6, are presented. The quality of the weld seams is assessed through mechanical characterization, complemented by microscopic examination to evaluate weld integrity.
Acknowledgments
We would like to thank the project partner, the Materialprüfungsanstalt (MPA) at the University of Stuttgart, as well as Tim Fritschle and Christian Class for conducting parts of the experiments.
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Research ethics: Not applicable.
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Informed consent: Not applicable.
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Author contributions: All authors have accepted responsibility for the entire content of this manuscript and approved its submission.
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Use of Large Language Models, AI and Machine Learning Tools: ChatGPT 4.0: improvement of language. DeepL: Translation German to English.
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Conflict of interest: The authors state no conflict of interest.
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Research funding: This project is co-financed by the EU and the state of Baden-Württemberg as part of the European Regional Development Fund (EFRE).
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Data availability: Shared on request.
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Articles in the same Issue
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Articles in the same Issue
- Frontmatter
- Editorial
- PPS2024 Ferrol: advances and perspectives in polymer processing
- Research Articles
- Applying network theory to the modeling of multilayer flows in slot dies: a use case for symbolic regression-based co-extrusion prediction models
- Multiscale polyethylene fiber – bacterial nanocellulose composites through combined laser fusion and bacterial in situ synthesis
- Novel approach to produce reinforced plastic weld seams using an additive friction stir welding process
- Local thermal activation for a combined thermoforming and 3D-printing process
- A new recycling strategy for airbag waste
- Highly electro-conductive PEDOT based thermoplastic composites: effect of filler form factor on electrical percolation threshold
- Cavity balance improvement for injection molded parts via automated flow leader generation
- Application of artificial intelligence techniques to select the objectives in the multi-objective optimization of injection molding
- Modeling melt conveying and power consumption of conveying elements in co-rotating twin-screw extruders
