Friction stir welding in plastics?

In summary, the conversation discusses the possibility of using friction stir welding on plastics, specifically in relation to the process being used successfully in assembling fuel tanks for satellite launchers. It is mentioned that while it may be possible with certain plastics, it is not practical due to the availability of other manufacturing methods. The conversation concludes that as long as the plastic is not thermosetting, friction stir welding could be used, but there may be changes in material properties.
  • #1
Flyboy
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I'm familiar with the process of friction stir welding, which has been used with great success for assembling the fuel tanks for satellite launchers like the Delta IV and the Atlas V. However, I was wondering if, from a theoretical aspect, it would be possible to friction stir weld together plastics. I know that it'd be tough, if not outright impossible, with fiber-reinforced plastics. It's also not practical, when you can simply mold the plastic into shape in the first place. But the question remains:

Can it be done at all?
 
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  • #2
No reason why not, provided the plastic is not thermosetting.
However, that means stuff such as the matrix material for aerospace composites is not suitable.
Polyethylene plastics however would be ok, although there may be substantial material property changes if the friction stirring decrystallises the welding zone.
 

1. What is friction stir welding in plastics?

Friction stir welding in plastics is a solid-state welding process that uses a non-consumable tool to join plastic materials together. It involves rotating the tool along the joint line at a high speed while applying downward pressure, creating heat and friction that softens and mixes the plastic materials together.

2. What are the advantages of using friction stir welding in plastics?

Some advantages of using friction stir welding in plastics include: strong and consistent welds, no filler material needed, minimal distortion, and the ability to join dissimilar materials. It is also a relatively quick and environmentally friendly process that does not produce harmful fumes or byproducts.

3. What types of plastics can be joined using friction stir welding?

Friction stir welding can be used to join a variety of thermoplastics, including high-density polyethylene (HDPE), polypropylene (PP), polycarbonate (PC), and more. The process is most effective for materials with similar melting points and low glass transition temperatures.

4. What factors affect the quality of friction stir welds in plastics?

The quality of friction stir welds in plastics can be affected by various factors, such as the speed and pressure of the tool, the rotational speed, the material properties, and the design of the joint. It is important to optimize these factors to ensure a strong and consistent weld.

5. Are there any limitations to using friction stir welding in plastics?

While friction stir welding in plastics has many advantages, there are some limitations to consider. It may not be suitable for all plastic materials and joint designs. Additionally, the initial cost of equipment can be expensive for smaller scale applications. It is important to carefully evaluate the specific needs of a project before choosing to use this welding method.

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