Thermal modeling of tool-work interface during polymer's friction welding process by mechanical, pneumatic and electrical sources

Abstract The High-density polyethylene (HDPE) has become an essential material, widely used in daily life, especially in water transportation networks. What enhances the use of this material is its adaptability to many manufacturing processes, especially with contemporary friction stir welding technology. At present, many researches have studied the welding of joints of polyethylene parts using mechanical energy, that is, in the same way as welding aluminum parts. This study aims to add advantages to welding this material by proving the existence of other energies for polyethylene, such as pneumatic and electrical energy (with an aluminum welding tool). It relies on easy-to-move equipment, especially in difficult cases of treating cracked pipes. The FSW process parameters: rotation speed, advance speed, and tool inclination angle were varied while using the three power sources. The maximum temperature was monitored. The thermal efficiency of the three energies was verified using the experimental design method. Tensile testing was also used to examine the resistance of the weld area.