Optimization of Friction Stir Welding Parameters in Hybrid Additive Manufacturing: Weldability of 3D-Printed Poly(methyl methacrylate) Plates

Abstract

In this work, the expansion of friction stir welding (FSW) in parts made via material extrusion (MEX) 3D printing was investigated. Poly(methyl methacrylate) (PMMA) plates were joined in a full factorial experimental design. The effects of three FSW parameters (weld tool pin geometry, rotating speed, and travel speed) on the weld results were studied. The tensile strength was investigated using statistical modeling tools. A morphological characterization study was also conducted on the weld zone, with microscopy. The state of the material during the FSW process was monitored via real-time temperature measurements. The feasibility of the process was verified. The results show high industrial merit for the process. The highest tensile strength was reported for the sample welded with the frustum tool, at 1400 rpm and a 9 mm/min travel speed (the highest studied), with a welding efficiency > 1. This can be attributed to the reduced porosity of the weld area compared to the 3D printed structure, and indicates a high potential for joining 3D-printed PMMA sheets via the FSW process. © 2022 by the authors.