Investigation of Carbon Fiber Reinforced Polymer Composite Welding with a New Tool in Friction Stir Welding Method

Document Type : Original Article


1 Department of Mechanical Engineering Manufacturing, Parsian Nonprofit Higher Education Center of Qazvin, Qazvin, Iran.

2 Department Mechanical Engineering, Karaj Branch, Islamic Azad University, Karaj, Iran.

3 Department of Materials Engineering, Imam Khomeini International University of Qazvin, Qazvin, Iran.

4 Materials and Energy Research Center, Karaj, 14155-4777, Iran.

5 Department of Metallurgy and Materials Engineering, Karaj Branch, Islamic Azad University, Karaj, Iran

6 Department of Material Engineering, Karaj Branch, Islamic Azad University, Karaj, Iran.


Application of thermoplastic materials has increased dramatically in recent decades due to its recyclability, low density, resistance to chemical changes. The friction stir welding process is one of the new methods of solid state welding, which has recently undergone significant improvement. In this research, using a new tool Made of plain carbon steel st37 in friction stir welding and low cost turning machine, composite sheets of thermoplastic polymer base have 12% continuous carbon fiber in the form of buttocks with two rotational speeds of 250 and 355 rpm and two advance speeds of 5/6 and 9 mm/min Optical microscope images (OM) showed the complete connection of materials. Increasing the inlet temperature resulted in the formation and growth of cavities and converting them into tunnel cavities. In general, the parameters affecting the connection quality in this study included the main shoulder diameter and rotational speed, so that, based on the results of scanning electron microscopy (SEM), the increase in rotational speed resulted in the grinding of continuous carbon fibers and thus increased tensile strength. The results of the tensile test showed that the failure of the samples is due to microstructural changes in the HAZ, in the joint zone of the welding zone and the base materials. According to the results, it can be said that using this new tool in the friction stir welding method, because of the reduction of rotational speed compared to previous studies and the lack of use of a multi-axial milling machine, can save energy.