This study reports the investigations for repair of thermoplastic based automotive bumpers and bars with modified friction stir welding (MFSW) process. For MFSW, consumable tool of polyamide6 (PA6) composite has been used for joining of acrylonitrile butadiene styrene (ABS) composites. The dissimilar thermoplastics were processed for maintaining a useful range of melt flow properties followed by preparation of feed stock filament for fused deposition modeling (FDM) process through screw extrusion. Finally, 3D printed PA6 based consumable rapid tool (RT) was prepared for MFSW. The joints prepared were subjected to flexural, hardness, morphological and thermal testing. The study has suggested the that maximum mechanical strength was obtained for sample welded at 1400 r/min, 50 mm/min transverse speed and 3 mm plunge depth, whereas the minimum mechanical strength was obtained for sample welded at 1000 r/min, 30 mm/min transverse speed and 2 mm plunge depth. The results are also supported with thermal analysis and photomicrographs.

这项研究报告了通过改进的搅拌摩擦焊（MFSW）工艺修复热塑性塑料汽车保险杠和保险杠的研究。对于MFSW，聚酰胺6（PA6）复合材料的消耗工具已用于连接丙烯腈丁二烯苯乙烯（ABS）复合材料。处理不同的热塑性塑料以保持有用的熔体流动性范围，然后通过螺杆挤出制备用于熔融沉积成型（FDM）工艺的原料长丝。最后，为MFSW准备了基于3D打印PA6的易耗品快速工具（RT）。制备的接缝经受弯曲，硬度，形态和热测试。研究表明，以1400 r / min，横向速度50 mm / min和插入深度3 mm焊接的样品可获得最大的机械强度，而以1000 r / min，30 mm / min的横向速度和2 mm的切入深度焊接的样品则获得了最小的机械强度。热分析和显微照片也支持结果。