Session: MF-13-01 Composite and Non-Metallic Systems for Pressure Vessels and Piping (Joint with D&A)

Paper Number: 155560

155560 - Friction Stir Welding of High-Density Polyethylene 

Abstract: 

Friction stir welding (FSW) offers a compelling alternative to adhesive and riveted joining for various applications. This technique has several advantages, including lower energy consumption, reduced weight in the final product, enhanced joint strength, and versatility across diverse materials. In the realm of thermoplastics, particularly high-density polyethylene (HDPE), FSW presents a promising approach due to its ability to generate high-quality welds with minimal defects and superior strength. 

This experimental investigation delves into the application of a custom-designed bobbin tool for Butt welding 5mm thick HDPE carbon black sheets. The study focuses on the influence of two critical FSW process parameters: tool rotation speed (800, 1000, and 1200rpm) and welding speed (33, 42, and 50mm/min). By systematically varying these parameters, the research explores the potential for refinement of FSW for HDPE using a bobbin tool. 

The overarching goal of this work is to identify the critical FSW process parameters that exert the most significant influence on joint strength and overall welding quality. This investigation revealed that tensile strength is maximized at a lower rotation speed (800 rpm) with moderate welding speed (33 mm/min) due to optimal heat input and material mixing at these settings, which is 16.137 MPa, which is approximately 55% of the base metal strength (29.0667 MPa). Lower rotational speed Due to increasing time and pressure for material interaction, this leads to higher tensile strength. The study aims to establish optimal process conditions for achieving high-performance HDPE welds using the bobbin tool FSW technique. This exploration will contribute valuable insights to the development and optimization of FSW for joining thermoplastics, paving the way for its wider adoption in various industrial applications.   

Presenting Author: Filmon Gebrehiwet Surafiel KIng Fahd University of Petroleum and Minerals

Presenting Author Biography: Filmon Gebrehiwet is a graduate student at King Fahd University of Petroleum and Minerals (KFUPM), pursuing a Master’s degree in Materials and Manufacturing. He holds a Bachelor of Science degree in Mechanical Engineering from Arba Minch University. His research interests lie in the areas of Design, Manufacturing, Finite Element Modeling, and Solid-State welding and Processing.

Authors:

Filmon Gebrehiwet Surafiel KIng Fahd University of Petroleum and Minerals
Fadi Al-Badour King Fahd University of Petroleum and Minerals
Rami Suleiman KIng Fahd University of Petroleum and Minerals