Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcement
This study investigates the friction stir welding (FSW) of polyamide 66 (PA66) sheets using an induction-heated threaded pin tool with a stationary shoulder. A novel approach was implemented by inserting a 3 mm-thick PA66-GF30 (glass fiber-reinforced polyamide) strip within the welding zone to impro...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425016151 |
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| author | Ammar Elsheikh Mohamed Ahmed Elmosalamy Ninshu Ma Ibrahim Eldeeb Ezzat Showaib Saad Ebied |
| author_facet | Ammar Elsheikh Mohamed Ahmed Elmosalamy Ninshu Ma Ibrahim Eldeeb Ezzat Showaib Saad Ebied |
| author_sort | Ammar Elsheikh |
| collection | DOAJ |
| description | This study investigates the friction stir welding (FSW) of polyamide 66 (PA66) sheets using an induction-heated threaded pin tool with a stationary shoulder. A novel approach was implemented by inserting a 3 mm-thick PA66-GF30 (glass fiber-reinforced polyamide) strip within the welding zone to improve joint performance. Process variables including tool rotational speed, welding speed, and preheat temperature were systematically varied to study their effects on fiber distribution, weld morphology, and mechanical strength. Among the tested conditions, a rotational speed of 1000 RPM and welding speed of 20 mm/min resulted in optimal heat input, promoting uniform fiber dispersion and stable vortex flow within the nugget zone. The microstructural analysis identified five distinct regions in the stir zone, each exhibiting unique material flow behaviors. The inclusion of the PA66-GF30 strip significantly improved mechanical properties, with the best-performing sample achieving 91 % joint efficiency. In contrast, higher rotational speeds caused fiber agglomeration, matrix degradation, and oxidation, leading to reduced weld quality. These findings underscore the importance of optimized heat input and reinforcement integration in enhancing the performance of polymer FSW joints. |
| format | Article |
| id | doaj-art-10a8a313e6a44562b49c34743b88c5af |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-10a8a313e6a44562b49c34743b88c5af2025-08-20T03:27:43ZengElsevierJournal of Materials Research and Technology2238-78542025-07-01374153416410.1016/j.jmrt.2025.06.193Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcementAmmar Elsheikh0Mohamed Ahmed Elmosalamy1Ninshu Ma2Ibrahim Eldeeb3Ezzat Showaib4Saad Ebied5Production Engineering Department, Faculty of Engineering, Tanta University, Tanta, 35424, Egypt; Joining and Welding Research Institute, The University of Osaka, 11-1 Mihogaoka, Ibaragi, Osaka, 567-0047, Japan; Corresponding author. Production Engineering Department, Faculty of Engineering, Tanta University, Tanta, 35424, Egypt.Production Engineering Department, Faculty of Engineering, Tanta University, Tanta, 35424, EgyptJoining and Welding Research Institute, The University of Osaka, 11-1 Mihogaoka, Ibaragi, Osaka, 567-0047, Japan; Corresponding author.Production Engineering Department, Faculty of Engineering, Tanta University, Tanta, 35424, EgyptProduction Engineering Department, Faculty of Engineering, Tanta University, Tanta, 35424, EgyptProduction Engineering Department, Faculty of Engineering, Tanta University, Tanta, 35424, EgyptThis study investigates the friction stir welding (FSW) of polyamide 66 (PA66) sheets using an induction-heated threaded pin tool with a stationary shoulder. A novel approach was implemented by inserting a 3 mm-thick PA66-GF30 (glass fiber-reinforced polyamide) strip within the welding zone to improve joint performance. Process variables including tool rotational speed, welding speed, and preheat temperature were systematically varied to study their effects on fiber distribution, weld morphology, and mechanical strength. Among the tested conditions, a rotational speed of 1000 RPM and welding speed of 20 mm/min resulted in optimal heat input, promoting uniform fiber dispersion and stable vortex flow within the nugget zone. The microstructural analysis identified five distinct regions in the stir zone, each exhibiting unique material flow behaviors. The inclusion of the PA66-GF30 strip significantly improved mechanical properties, with the best-performing sample achieving 91 % joint efficiency. In contrast, higher rotational speeds caused fiber agglomeration, matrix degradation, and oxidation, leading to reduced weld quality. These findings underscore the importance of optimized heat input and reinforcement integration in enhancing the performance of polymer FSW joints.http://www.sciencedirect.com/science/article/pii/S2238785425016151Friction stir weldingPolyamide 66Glass fiber reinforcementInduction-heated threaded pinMechanical properties |
| spellingShingle | Ammar Elsheikh Mohamed Ahmed Elmosalamy Ninshu Ma Ibrahim Eldeeb Ezzat Showaib Saad Ebied Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcement Journal of Materials Research and Technology Friction stir welding Polyamide 66 Glass fiber reinforcement Induction-heated threaded pin Mechanical properties |
| title | Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcement |
| title_full | Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcement |
| title_fullStr | Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcement |
| title_full_unstemmed | Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcement |
| title_short | Enhancing joint efficiency in friction stir welding of PA66 using an induction-heated threaded pin and glass fiber reinforcement |
| title_sort | enhancing joint efficiency in friction stir welding of pa66 using an induction heated threaded pin and glass fiber reinforcement |
| topic | Friction stir welding Polyamide 66 Glass fiber reinforcement Induction-heated threaded pin Mechanical properties |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425016151 |
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