Iftikhar Syed Haris, Mourad Abdel-Hamid Ismail, Sheikh-Ahmad Jamal, Almaskari Fahad, Vincent S
Department of Mechanical Engineering, United Arab Emirates University, Al Ain 15551, United Arab Emirates.
Department of Mechanical Engineering, Khalifa University of Science and Technology, Abu Dhabi 127788, United Arab Emirates.
Polymers (Basel). 2021 Apr 8;13(8):1208. doi: 10.3390/polym13081208.
Friction stir welding (FSW) and friction stir spot welding (FSSW) techniques are becoming widely popular joining techniques because of their increasing potential applications in automotive, aerospace, and other structural industries. These techniques have not only successfully joined similar and dissimilar metal and polymer parts but have also successfully developed polymer-metallic hybrid joints. This study classifies the literature available on the FSW and FSSW of thermoplastic polymers and polymer composites on the basis of joining materials (similar or dissimilar), joint configurations, tooling conditions, medium conditions, and study types. It provides a state-of-the-art and detailed review of the experimental studies available on the FSW and FSSW between similar thermoplastics. The mechanical properties of FSW (butt- and lap-joint configurations) and FSSW weld joints depend on various factors. These factors include the welding process parameters (tool rotational speed, tool traverse speed, tool tilt angle, etc.), base material, tool geometry (pin and shoulder size, pin profile, etc.) and tool material, and medium conditions (submerged, non-submerged, heat-assisted tooling, cooling-assisted tooling). Because of the dependence on many factors, it is difficult to optimize the welding conditions to obtain a high-quality weld joint with superior mechanical properties. The general guidelines are established by reviewing the available literature. These guidelines, if followed, will help to achieve high-quality weld joints with least defects and superior mechanical properties. Apart from parametric-based studies, the statistical-based studies (e.g., analysis of variance (ANOVA)-based studies) are covered, which helps with the determination of the influential parameters that affect the FSW and FSSW weld joint strength. Also, the optimal ranges of the most influential process parameters for different thermoplastic materials are established. The current work on the development of general guidelines and determination of influential parameters and their operating ranges from published literature can help with designing smart future experimental studies for obtaining the global optimum welding conditions. The gaps in the available literature and recommendations for future studies are also discussed.
搅拌摩擦焊（FSW）和搅拌摩擦点焊（FSSW）技术正成为广泛流行的连接技术，因为它们在汽车、航空航天及其他结构行业的潜在应用日益增加。这些技术不仅成功地连接了同种和异种金属及聚合物部件，还成功开发了聚合物-金属混合接头。本研究基于连接材料（同种或异种）、接头构型、工具条件、介质条件和研究类型，对热塑性聚合物和聚合物复合材料的搅拌摩擦焊及搅拌摩擦点焊的现有文献进行了分类。它对同种热塑性塑料之间搅拌摩擦焊和搅拌摩擦点焊的实验研究进行了最新的详细综述。搅拌摩擦焊（对接和搭接接头构型）和搅拌摩擦点焊焊缝的力学性能取决于多种因素。这些因素包括焊接工艺参数（工具转速、工具行进速度、工具倾斜角度等）、母材、工具几何形状（销钉和肩部尺寸、销钉轮廓等）和工具材料，以及介质条件（浸没、非浸没、热辅助工具、冷却辅助工具）。由于依赖多种因素，很难优化焊接条件以获得具有优异力学性能的高质量焊缝。通过回顾现有文献制定了一般准则。遵循这些准则将有助于获得缺陷最少且力学性能优异的高质量焊缝。除了基于参数的研究外，还涵盖了基于统计的研究（例如基于方差分析（ANOVA）的研究），这有助于确定影响搅拌摩擦焊和搅拌摩擦点焊焊缝强度的影响参数。此外，还确定了不同热塑性材料最具影响力的工艺参数的最佳范围。目前从已发表文献中制定一般准则、确定影响参数及其操作范围的工作，有助于设计未来的智能实验研究以获得全局最优焊接条件。还讨论了现有文献中的空白以及对未来研究的建议。
