Materials Today: Proceedings 19 (2019) 637–641

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Materials Today: Proceedings

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Process parameters optimization on FSW of Polycarbonate and AA6061

P.V. Chandra Sekhara Rao, E. Mounika, G. Vikram
Department of Mechanical Engineering, RGUKT-Basar, Basar 504107, India

a r t i c l e i n f o a b s t r a c t

Article history: A drastic use of thermoplastics is observed in versatile industries which includes aerospace and automo-
Received 19 July 2019 tive industries where thermoplastics and metal combinations are used. Differences in physical and
Accepted 24 July 2019 mechanical traits of chosen materials FSW (Friction Stir Welding) is mainly utilized in welding metal
Available online 5 September 2019
to thermoplastic. FSW avoids significant changes in microstructure and also solve the conventional prob-
lems in fusion welding. Higher production rate would be achieved if parameters are selected optimally
Keywords: during Friction stir welding by implementing Taguchi method and analysis of variance (ANOVA analysis).
Thermoplastics
To detect the effect of considered parameters like welding speed, plunge depth, rotational speed and joint
Friction stir welding
Taguchi method
strength post FSW of Polycarbonate and AA6061. An orthogonal array of size L4 has been selected to
ANOVA analysis know the optimal levels of FSW of Polycarbonate and AA6061. After analysis from the ANOVA technique
Polycarbonate it has been found that the speed of rotation is the most significant factor and welding speed is least sig-
nificant factor effecting the strength of joint post FSW of Polycarbonate and AA6061. The optimum con-
ditions to achieve the tensile strength maximum value of 10.33 MPa are 1400 rpm, 10 mm/min and
1.2 mm.
Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 1st International
Conference on Manufacturing, Material Science and Engineering.

1. Introduction rotation aids in the joining of materials and plastic deformation

occurs. The rotating tool and heat produced softens and diffuses
Utilization of thermoplastics in engineering structures has the melt near the pin. The tool rotates and traverses along the
increased and its consumptions is 80% of the total plastic consump- length and welding is achieved. Initially, this process was used to
tion because of the lower weight, greater strength, elastic modulus, join metals gradually it was put to use in the joining of plastics
economical and manufacturing flexibility. Thermoplastics are and plastic to metal.
unremarkably put to utilization in electronics, aerospace and
industrial units concerned to packaging. Polymeric material weld-
1.1. Literature review
ing with metal is required for efficient design. It is massively
implemented in automotive and aerospace industries where the
Bozkurt et al. [9] joined the HDPE sheets by FSW where the con-
vital application is the welding of indicators and lights of vehicle
siderably selected parameters are speed of tool rotation, speed
tail. Processes used to join the thermoplastic with metal are
with which the tool traverses and tilt angle. The tool rotation speed
mechanical fasteners, ultrasonic welding, laser beam welding and
contributes 73.85% and welding speed, tilt angle contributes
adhesive bonding. Above process have several limitations such as
20.19%, 5.96 % on ultimate tensile strength (UTS). The best welding
stress concentration, increase in weight, constrains in specimen
parameters considered for the UTS speed of rotation of tool is
dimensions, higher cost. To overcome the above mentioned prob-
3000 rpm, speed of traversing of tool as 115 mm/min and 3° angle
lems FSW is extensively utilized in the joining of metal to thermo-
of tilt. Santosh K. Sahu and Debasish Mishra et al. [10] concluded
plastic effectively.
traditional FSW tool ruptures the fiber on the thermoplastic sur-
FSW is undoubtedly an innovative technique to join different
face resulting in peeling defect and with an increment in rotational
materials in their solid state. It is a patented process. Not-
speed of the tool (500 rpm–750 rpm), there is an increment in ten-
consumable tool which is revolving is passed along the length of
sile strength initially and a decrement is observed with further
the work pieces. The friction and heat liberated during the tool
increment in speed of revolution of tool (750 rpm –1000 rpm).

https://doi.org/10.1016/j.matpr.2019.07.745
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 1st International Conference on Manufacturing, Material Science and Engineering.
638 P.V. Chandra Sekhara Rao et al. / Materials Today: Proceedings 19 (2019) 637–641

Strand and Bagheri et al. [11] experimented FSW of ABS sheets Table 2.1
with a controllable shoe of opted temperature. Quality of weld Specified properties of Al alloys and Polycarbonate used.

and the joint strength is high at peak value of speed of rotation, S. No Properties AA6061 Polycarbonate
opted temperature of shoe and a less value of traverse speed of 1. Young’s Modulus (GPa) 68.9 2.0–2.4
the tool. Remarkably to be observed that there is difference in flow 2. Strength at yield point (MPa) 276 60–65
of material at the leading and trailing sides of the chosen speci- 3. UTS (MPa) 310 35–40
mens welded. Low material flow in the trailing side creates brittle
failure in that zone.
Anjal R. Patel et al. [25] observed the influence of speed of rev- Table 2.2
olution of the tool, speed of traversing of tool on the velocity ratio Physical properties of Polycarbonate.
and tensile strength of the AA6061 to Polycarbonate joint. Stated S. No Properties Values
that at low velocity ratio insufficient heat was generated which 1 Temperature of Glass transition(°C) 147
results into improper mixing of materials. At higher velocity ratio 2 Temperature of melting(°C) 154
heat generated was more which melts the material. higher 3 Thermal expansion coefficient (10 6 K 1
) 65–70
strength is achieved between 10–20 rev/mm and 14.91 MPa as
the peak value of tensile strength achieved at 500 rpm, 40 mm/
min. at which sufficient frictional heat was generated. Joint tensile 2.1. Cylindrical tool
strength is varies with polycarbonate and is due to degradation of
tool material and heat of friction soften the melt at the interface of In this project, a simple pin tool of cylindrical shape, as shown
the joint. R. Moshwan et al. [24] explained the results of specifi- in Fig. 1 was used for welding and dimensions of the tool are given
cally chosen parameters such as speed of rotation of tool and speed below:
of traversing on temperature evolution, properties which cannot
be distinguished solely with naked eye and mechanical properties 1. Shoulder dia of 20 mm,
of FS welding of AA 7075 and Polycarbonate specimens. Tensile 2. Pin with length and dia of 4.5 mm and 5 mm respectively.
strength and welded joint hardness were lower compared to base
materials due to the presence of scattered particles and voids at the
2.2. Tensile test
joint interface, results obtained from EDX and XRD analyses proves
insufficient mixing occurred between the molten state of
Tensile tests were performed with the help of high temperature
specimens.
universal testing machine. it is Suitable for testing wide range of
temperatures (RT-1200 °C) with sufficient ease with possibility
1.2. Taguchi method for thermal cycling. Samples of various dimensions (sheets, plates,
rounds etc.) can be employed. And it is manufactured by Zwick,
Genechi Taguchi devised the popular method Taguchi in view of Germany Company.
efficient production. Orthogonal arrays employed in this method
are vital for robust design, which are used to find the optimum 3. Results and discussion
results within minimum experiments carried out. In this paper 3
parameters with two levels were selected for finding the suitable A tool speed of rotation of 1200 rpm was employed in the first
weld parameters of the chosen materials as given in Tables 1.3.1 test experiment with 10 mm/min as speed of welding and 1.2 mm
and 1.3.2. plunge depth mm as shown in Fig. 2 and tensile strength achieved
is 5.91 MPa, as given in Table 1.3.2. At this condition sufficient time
was provided for proper mixing so continuous weld joint was
2. Materials and experimental details formed.
The second test experiment was employed at a speed of
Materials were opted inview of industrial applications. In most 1200 rpm of tool, speed of welding is 20 mm/min and depth of
of the applications, aluminum and polycarbonate combinations plunge of 1.5 mm as shown in Fig. 3 and tensile strength achieved
were used. Composition and mechanical properties were illus- is 3.13 MPa, as given in Table 1.3.2. Compared with previous test,
trated in below Tables 2.1–2.3. in this welding plunge depth and speed were increased. Increment
in the depth of plunge culminated in the decrement of tensile
strength. In this test, increment of weld speed does not influence
the joint strength from the ANOVA analysis.
Table 1.3.1
Levels opted and their parameters. For the third specimen, employed values are a tool speed of
rotation of 1400 rpm, a speed of welding of 10 mm/min and
S. Speed of Rotation Speed of welding (mm/ Depth of Plunge
1.5 mm depth of plunge as shown in Fig. 4 and tensile strength
no (rpm) min) (mm)
achieved is 7.59 MPa, as given in Table 1.3.2. Compared with pre-
1. 1400 20 1.5
vious tests, in this test rotational speed was increased, welding
2. 1200 10 1.2
speed was decreased and depth of plunge was maintained

Table 1.3.2
Experiments conducted according to L-4 orthogonal array and tensile test results.

Experiment number Rotational Speed (rpm) Speed of welding (mm/min) Depth of plunge (mm) Tensile Strength (MPa)
1. 1200 10 1.2 5.91
2. 1200 20 1.5 3.13
3. 1400 10 1.5 7.59
4 1400 20 1.2 10.31
 P.V. Chandra Sekhara Rao et al. / Materials Today: Proceedings 19 (2019) 637–641 639

Table 2.3
Composition of AA6061 by % of weight.

Composition Si Fe Mg W Others each Others total Mn Zn Cu Cr Al

%by wt. 0.8–0.4 0.7 1.2–0.8 0.15–0 0.05–0 0.15–0 0.15 0.25–0 0.4–0.15 0.35–0.4 95.85–98.56

Fig. 1. Tool used for FS welding (a) Front view, (b) Top view.

Fig. 2. At 1200 rpm, 10 mm/min and 1.2 mm.

Fig. 5. At 1400 rpm, 20 mm/min and 1.2 mm.

constant. Increment in the speed of revolving increases the heat

generation which in turn increases the strength of joint.
According to L-4 array, next test experiment, values employed
are a tool speed of rotation of 1400 rpm, 20 mm/min as speed of
welding and a depth of plunge of 1.2 mm as shown in Fig. 5 and
the tensile strength achieved is 10.31 MPa, as given in Table 1.3.2.
Compared with previous tests, in this constant speed of rotation
was maintained and speed of welding was increased and plunge
depth was decreased. In this test due to high speed of rotation
and low depth of plunge, peak tensile value of joint was achieved.

Fig. 3. At 1200 rpm, 20 mm/min and 1.5 mm. 3.1. Effect of process parameters on the joint tensile strength

Increment in the speed of rotation subsequently ensures the

increment of the joint tensile strength and plunge depth has an
inverse relationship with the tensile strength is shown in Fig. 3.1.
The influence of speed of welding is negligible on the joint tensile
strength.

3.2. Contribution of process parameters on tensile strength:

Fig. 4. At 1400 rpm, 10 mm/min and 1.5 mm.
From the ANOVA analysis major helping parameter for the ten-
sile value is revolving speed of tool which is of 72.2% contribution
and the next major contributing parameter is plunge depth which
is of 27.81% contribution. The contribution of speed of welding on
the tensile strength is negligible which is of 0.003% as shown in
Fig. 3.2.
640 P.V. Chandra Sekhara Rao et al. / Materials Today: Proceedings 19 (2019) 637–641
Fig. 3.1. Effect of process parameters on tensile strength.
Fig. 3.2. Parameters contributing for tensile strength.
4. Conclusions
1. The most Contributing parameters for the joint tensile strength
are speed of rotation (72.181%), and plunge depth of (27.815%)
contribution.
2. Increment in speed of revolving simultaneously helps in the
increment of tensile value and plunge depth has an inverse rela-
tionship with tensile strength. Peak tensile strength of
10.31 MPa is achieved at 1400 rpm, 20 mm/min and 1.2 mm.
3. Optimum conditions to achieve the peak tensile strength of
10.33 MPa are 1400 rpm, 10 mm/min and 1.2 mm.
4. Thickness of the joint is reduced about 3–6% of original thick-
ness of parent materials which culminates in the decrement
of the joint strength.
Acknowledgement
The experimentation work was carried out with the help of
resources and facilities available at FSW lab, RGUKT-Basar.
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