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<p>In this study, the effects of novel tool path profiles on the weld quality of friction stir welded butt joints in thermoplastic plates were investigated. PE1000 polyethylene plates were used in the joining processes. Joining was achieved using zigzag, square, and straight tool path profiles with varying spindle speeds and feed rates. After tensile testing, welds with the zigzag tool path profile exhibited the highest tensile strength, followed by the square profile, with the straight tool path resulting in the weakest joint. Additionally, the fractured faces of the samples were subjected to scanning electron microscope (SEM) imaging after the tensile test. SEM images exposed more ductile surfaces and fewer defects in samples welded with zigzag and square profiles, while samples welded with a straight tool path showed lower joint formation and a flawed seam structure. Accordingly, in the SEM images of the specimens where the weakest strength occurred, insufficient melting agglomerations were observed. The Taguchi method was used to design experiments and determine optimal values based on tensile strength responses. Consequently, the optimum process parameters were determined as a spindle speed of 1400&#xa0;rpm, a feed rate of 10&#xa0;mm/min, and a zigzag tool path profile. Analysis of variance based on the signal-to-noise ratio revealed that the most significant parameter affecting the welded joint was the tool path profile.</p>

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Impact of Tool Path Profile on Weld Strength in Friction Stir Welding of PE1000 Plates

  • 期刊论文

  • 发表日期：

    2025年5月8日

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  • Ömer Çerlek,
  • Ömer Seçgin,
  • Fatih Uysal

摘要

In this study, the effects of novel tool path profiles on the weld quality of friction stir welded butt joints in thermoplastic plates were investigated. PE1000 polyethylene plates were used in the joining processes. Joining was achieved using zigzag, square, and straight tool path profiles with varying spindle speeds and feed rates. After tensile testing, welds with the zigzag tool path profile exhibited the highest tensile strength, followed by the square profile, with the straight tool path resulting in the weakest joint. Additionally, the fractured faces of the samples were subjected to scanning electron microscope (SEM) imaging after the tensile test. SEM images exposed more ductile surfaces and fewer defects in samples welded with zigzag and square profiles, while samples welded with a straight tool path showed lower joint formation and a flawed seam structure. Accordingly, in the SEM images of the specimens where the weakest strength occurred, insufficient melting agglomerations were observed. The Taguchi method was used to design experiments and determine optimal values based on tensile strength responses. Consequently, the optimum process parameters were determined as a spindle speed of 1400 rpm, a feed rate of 10 mm/min, and a zigzag tool path profile. Analysis of variance based on the signal-to-noise ratio revealed that the most significant parameter affecting the welded joint was the tool path profile.