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Characterization of Friction Stir-Welded Polylactic Acid/Aluminum Composite Primed through Fused Filament Fabrication

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Abstract

There are many possible reasons for low weld strength in FSW of thermoplastic; low thermal conductivity, high energy losses in friction stir welding (FSW), material spill-out, involvement of high mechanical forces, etc. To counter strike the above-mentioned issues which weaken the joint's strengths, two strategies have been approached. The first approach is based upon the preparation of aluminum (Al) layers-reinforced Polylactic acid (PLA)/Al composite material which must have high thermal conductivity and crystallinity for improved heat generation in FSW. In the second approach, the FSW has been performed using a semi-consumable pin of similar materials which can compensate for the materials loss and void formation during FSW. Alternating layer composite of (PLA)/Al was manufactured by modified fused filament fabrication (FFF) 3D printing process then welded by FSW process in next steps. In this study, the FSW process was performed by using a semi-consumable pin profile of PLA with varying tool rotation speed (TRS) (800, 1100, and 1400rpm), depth of semi-consumable pin (SPD) (2, 3 and 4 mm), and transverse speed (TVS) (20, 30 and 40mm/min). FSW joints were subjected to mechanical (tensile strength, percentage elongation, and modulus of toughness), morphological (fracture by scanning electron microscopy and surface profiling), structural (Fourier-transform infrared spectroscopy, x-ray diffraction) for optimizing the FSW process parameters. Analytic hierarchy process and genetic algorithm are implemented to acquire a single set of parameters which would result in the best value of tensile properties. The suggested levels are 1400 rpm, 2 mm, and 31.79 mm/min. of TRS, SPD, and TVS, respectively.

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Abbreviations

ABS:

Acrylonitrile butadiene styrene

AHP:

Analytic hierarchy process

Al:

Aluminum

AM:

Additive manufacturing

EDS:

Energy-dispersive x-ray spectroscopy

FFF:

Fused filament fabrication

FSW:

Friction-stir welding

FTIR:

Fourier-transform infrared spectroscopy

FTS:

Fracture tensile strength

FWHM:

Full width half maxima

GA:

Genetic algorithm

MOT:

Modulus of toughness

PC:

Polycarbonate

PEB:

Percentage elongation at break

PEEK:

Poly-ether-ether ketone

PMMA:

Poly(methyl methacrylate)

PLA:

Polylactic acid

PPS:

Polyphenyl sulfone

SEM:

Scanning electron microscopy

SPD:

Semi-consumable pin depth

STL:

Standard Tessellation Language

TPU:

Thermoplastic Polyurethane

TRS:

Tool rotational speed

TVS:

Transverse speed

UTM:

Universal testing machine

UTS:

Ultimate tensile strength

XRD:

X-ray diffraction

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Acknowledgment

The authors are highly thankful to University Centre for Research and Development, Chandigarh University and Centre for Manufacturing Research, Guru Nanak Dev Engineering College, Ludhiana, for technical and testing support in this manuscript.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Chandigarh University, Chandigarh, Punjab, India

    Ranvijay Kumar, Nishant Ranjan, Raman Kumar, Jasgurpreet Singh Chohan, Aniket Yadav,  Piyush & Sunpreet Singh

  2. Department of Production Engineering, Guru Nanak Dev Engineering College, Ludhiana, India

    Vinay Kumar

  3. Department of Mechanical Engineering, IK Gujral Punjab Technical University, Jalandhar-Kapurthala Road, Kapurthala, 144603, Punjab, India

    Shubham Sharma

  4. School of Mechanical Engineering, Lovely Professional University, Phagwara, Punjab, India

    Chander Prakash

  5. Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore

    Sunpreet Singh

  6. School of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao, 266520, China

    Changhe Li

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  1. Ranvijay Kumar
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Kumar, R., Ranjan, N., Kumar, V. et al. Characterization of Friction Stir-Welded Polylactic Acid/Aluminum Composite Primed through Fused Filament Fabrication. J. of Materi Eng and Perform 31, 2391–2409 (2022). https://doi.org/10.1007/s11665-021-06329-4

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