In this study, two different polymer materials were used. In the joints made with friction stir spot welding, firstly (PP/PP and HDPE/HDPE) and then different materials (PP/HDPE, HDPE/PP) joining processes were carried. The influence of the tool rotational speed and the stirring time on joint formation and weld strength were determined. The temperature of the liquid welding materials varies according to the materials to be combined. High weld strengths were obtained at the friction stir spot welding of similar plastic sheets. The highest weld strengths were obtained in PP-PP welds. Low weld strengths were obtained at the friction stir spot welding of dissimilar plastic sheets because of immiscible and incompatible blends formed during the welding operation. The lowest weld strengths were obtained in PP-HDPE welds. The chemical composition and the phase morphology of the blends, the mechanical scission occurrence and the welding residual stresses determine the strength of the welds.
AotaKIkeuchiK. Development of friction stir spot welding using rotating tool without probe and its application to low carbon steel plates. Weld Inter2009; 23: 572–580.
2.
BiliciMKYuklerAI. Influence of tool geometry and process parameters on macrostructure and static strength in friction stir spot welded polyethylene sheets. Mater Des2012; 33: 145–152.
3.
BiliciMK. Effect of tool geometry on friction stir spot welding of polypropylene sheets. eXPRESS Poly Lett2012; 6: 805–813.
4.
MertSArıcıA. Design of optimal joining for friction stir spot welding of polypropylene sheets. Sci Technol Weld Join2011; 16: 522–527.
5.
OliveriaPHFFilhoSTASantosJF, et al.Preliminary study on the feasibility of friction spot welding in PMMA. Mater Lett2010; 64: 2098–2101.
6.
LambiaseFPaolettiADi IlioA. Mechanical behaviour of friction stir spot welds of polycarbonate sheets. Inter J Adv Manuf and Technol2015; 80: 301–314.
7.
DashatanSAzdastTAhmadiS, et al.Friction stir spot welding of dissimilar polymethyl methacrylate and acrylonitrile butadiene styrene sheets. Mater Des2013; 45: 135–141.
8.
BiliciMKYuklerAIFidanerO. The effect of welding parameters on the friction stir spot welding of thermoplastics high density polyethylene sheets. Turkey: 3rd National Design, Manufacturing and Analysis Congress, 2012, pp. 355–365.
9.
HuangYMengXXieY, et al.Friction stir welding/processing of polymers and polymer matrix composites. Compos Part A: Applied Sci Manuf2018; 105: 235–257.
10.
AndradeDGLeitaoCRodriguesDM. Influence of base material characteristics and process parameters on frictional heat generation during friction stir spot welding of steels. J Manuf Proces2019; 43: 98–104.
11.
BiliciMKYuklerAIKurtulmusM. The optimization of welding parameters for friction stir spot welding of high density polyethylene sheets. Mater Des2011; 32: 4074–4079.
12.
BiliciMKYuklerAIKastanA. Effect of the tool geometry and welding parameters on the macrostructure, fracture mode and weld strength of friction stir spot welded polypropylene sheets. Mater Technol2014; 48: 705–711.
13.
BadarinarayanHShiYLiX, et al.Effect of tool geometry on hook formation and static strength of friction stir spot welded aluminum 5754-O sheets. Inter J Machine Tool Manuf2007; 49: 814–823.
14.
GoncalvesJSantosJFCantoLB, et al.Friction spot welding of carbon fiber-reinforced polyamide66 laminate. Mater Lett2015; 159: 506–509.
15.
MontagaTWulfsbergJHameisterH, et al.Influence of tool wear on quality criteria for refill friction stir spot welding process. Procedia CIRP2014; 24: 108–111.
16.
AbibeABAmancio-FilhoSTSantosJF, et al.Development and analysis of a new joining method for polymer-metal hybrid structures. J Thermoplast Compo Mater2015; 24: 233–249.
17.
EstevesJVGoushegirSMSantosJF, et al.Friction spot joining of aluminum AA6181-T4 and carbon fiber-reinforced poly(phenylene sulfide): effects of process parameters on the microstructure and mechanical strength. Mater Design, 2015; 66: 437–445.
18.
BiliciMK, Application of Taguchi approach to optimize friction stir spot welding parameters of polypropylene. Mater Design2012; 66: 113–119.
19.
LiLPYinBYangMB. Morphology prediction and the effect of core-shell structure on the rheological behavior of PP/EPDM/HDPE ternary blends. Polymer Eng Sci2011; 51: 2425–2433.
20.
LoosJBonnetMPetermannJ. Morphologies and mechanical properties of syndiotactic polypropylene (sPP)/polyethylene (PE) blends. Polymer2000; 41: 351–356.
21.
LiJShanksRALongY. Mechanical properties and morphology of polyethylene-polypropylene blends with controlled thermal history. J Appl Polym Sci2000; 76: 1151–1164.
22.
RachtanapunPSelkeSMatuanaLM. Relationship between cell morphology and impact strength of microcellular foamed high-density polyethylene/polypropylene blends. Polym Eng Sci2004; 44: 1551–1560.
23.
LambiaseFKoDC. Feasibility of mechanical clinching for joining aluminum AA6082-T6 and carbon fiber reinforced polymer sheets. Mater Des2016; 107: 341–352.
24.
MarkJ. Polymer data handbook. Materials Science, 2009.
25.
MaNKunugiAHirashimaT, et al.FEM simulation for friction spot joining process. Weld Inter2009; 23: 9–14.
26.
AydinM. Effects of welding parameters and pre-heating on the friction stir welding of UHMW-polyethylene. Polym Plast Technol Eng2010; 49: 595–601.
27.
AwangMMucinoVHFengZ, et al.Thermo-mechanical modeling of friction stir spot welding (FSSW) process: use of an explicit adaptive meshing scheme. SAE Technical Paper, Soc Auto Eng, 2005; 01: 1251.
28.
CaponeCLandroLDInzoliF, et al.Thermal and mechanical degradation during polymer extrusion processing. Polym Eng Sci2007; 47: 1813–1819.
29.
HusseinM. Effects of strain rate and temperature on the mechanical behavior of carbon black reinforced elastomers based on butyl rubber and high molecular weight polyethylene. Results in Phys2018; 9: 511–517.
30.
SchmidtHHattelJWertJ. An analytical model for the heat generation in friction stir welding. Model Simulat Mater Sci Eng2003; 12: 143–157.
31.
DialamiNCerveraMChiumentiM. Defect formation and material flow in friction stir welding. Euro J Mecha-A/Solids2020; 80: 1–13.
32.
KissZCziganyT. Microscopic analysis of the morphology of seams in friction stir welded polypropylene. eXPRESS Polym Lett2012; 6: 54–62.
33.
YangXWFuTLiWY. Friction stir spot welding: a review on joint macro- and microstructure, property and process modelling. Adv Mater Sci Eng2014; 1: 11.
34.
LambiaseFDerazkolaHASimchiA. Friction stir welding and friction spot stir welding processes of polymers-state of the art. Mater2020; 13(10): 2291–2325.
