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Updated: Jul 16, 2026
08:40
Ultrasonic Welding of Thermoplastic Composite Coupons for Mechanical Characterization of Welded Joints through Single Lap Shear Testing
Published on: February 11, 2016
11.7K
A framework for friction stir multi-spot welding for thermoplastics.
Abdel-Hamid I Mourad1,2, Sawsan Omira3, Shaikha Ismaeel Al-Ali3
1Mechanical and Aerospace Engineering Department, United Arab Emirate University, Al Ain, UAE. ahmourad@uaeu.ac.ae.
Scientific Reports
|July 31, 2025
Summary
Multi-spot friction stir spot welding (FSSW) enhances thermoplastic polymer joint strength. Optimizing weld spots, direction, and spacing significantly improves tensile performance and load distribution in lap joints.
Area of Science:
- Materials Science
- Polymer Engineering
- Manufacturing Processes
Background:
- Friction stir spot welding (FSSW) is a viable joining technique for metals and polymers.
- Studies on thermoplastic FSSW predominantly focus on single-spot joints.
- Carbon black-reinforced high-density polyethylene (HDPE-CB) is a key thermoplastic material for FSSW applications.
Purpose of the Study:
- To develop a framework for multi-spot FSSW joints in thermoplastic polymers.
- To investigate the influence of weld spot configuration on joint strength.
- To analyze the impact of weld direction, edge distance, and spacing on weld performance.
Main Methods:
- Investigated multi-spot FSSW configurations for HDPE-CB lap joints.
- Varied weld spot inclination, spacing, and edge distance.
- Performed tensile testing to determine peak load and failure mechanisms.
Main Results:
- Weld strength increases with the number of weld spots.
- Weld direction critically affects joint performance.
- A double-side weld configuration (T4) yielded the maximum peak load (5207 N).
- Edge distance and weld spacing showed a proportional relationship with peak load.
Conclusions:
- Multi-spot FSSW offers enhanced joint strength compared to single-spot joints.
- Optimized weld alignment and spacing are crucial for maximizing tensile performance.
- This study provides foundational insights into multi-spot FSSW for thermoplastic polymers.
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