article · International Polymer Processing
This research investigates the use of top surface lubrication during the friction stir welding of polycarbonate sheets. A homogeneous layer of paraffin wax, wide enough to cover the tool shoulder diameter, was placed on the joint area before welding. Welding was performed using a conventional tool with a rotating pin and shoulder across various rotational speeds and welding speeds. The melting wax acted as a lubricant between the tool shoulder and the polycarbonate plate. This process produced a defect-free surface with no loss of the original plate thickness. Internal examinations of the transverse cross-sections confirmed defect-free joints across most tested parameters. Although tensile strength decreased after welding, higher rotation or welding speeds improved tensile performance. Fracture analysis revealed that failure occurred in the joint zone, with scanning electron microscopy identifying a spherulitic structure in the weld.
Polycarbonate is a widely used industrial plastic, but joining it effectively without causing surface damage or thinning can be difficult. Demonstrating that a simple paraffin wax layer prevents surface defects and maintains sheet thickness offers a practical way to improve weld quality in thermoplastic manufacturing.
This technique could benefit manufacturing and plastics processing industries that assemble polycarbonate components using friction stir welding. Because the method was tested in an experimental setting using standard welding equipment and conventional paraffin wax, it sits at an applied, laboratory-tested stage. Further work would be needed before implementation in production lines.
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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.
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DOI: 10.1515/ipp-2020-3991
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