Rotary Friction Welding of Polyetheretherketone Biopolymer Rods Using Variable Rotational Speed

Area of Science:

• Materials Science
• Polymer Engineering
• Biomaterials Manufacturing

Background:

• Polyetheretherketone (PEEK) is a high-performance biomaterial with excellent mechanical properties.
• Current PEEK manufacturing relies on methods like additive manufacturing, injection molding, and grinding.
• Rotary Friction Welding (RFW) is an established bonding technique, but its application to PEEK is underexplored.

Purpose of the Study:

• To investigate the novel application of variable rotational speed in the Rotary Friction Welding (RFW) of Polyetheretherketone (PEEK) polymer rods.
• To evaluate the impact of a three-stage transformation rotational speed on the mechanical properties and cycle time of PEEK welds.
• To assess the sustainability aspects, including environmental impact and energy efficiency, of the proposed RFW method.

Main Methods:

• Utilized computer numerical controlled (CNC) Rotary Friction Welding (RFW) equipment.
• Implemented an innovative three-stage variable rotational speed profile during the welding of PEEK polymer rods.
• Conducted mechanical testing, specifically measuring average bending strength of the welded specimens.
• Quantified the welding cycle time to determine efficiency improvements.

Main Results:

• The average bending strength of PEEK welds achieved with the three-stage variable rotational speed was approximately 140% higher than welds produced at a constant 1000 rpm.
• The proposed variable speed RFW method resulted in a cycle time reduction of about 6% compared to conventional methods.
• The innovative RFW process demonstrated low environmental pollution and high energy efficiency.

Conclusions:

• Variable rotational speed in RFW significantly enhances the mechanical integrity, specifically bending strength, of PEEK welds.
• The optimized RFW process offers improved efficiency through reduced cycle times.
• This approach aligns with sustainable development goals by promoting energy efficiency and minimizing environmental impact in PEEK processing.