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Repair of automotive bumpers and bars with modified friction stir welding

改良搅拌摩擦焊修复汽车保险杠

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Abstract

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.

摘要

本文研究了改良搅拌摩擦焊(MFSW)修复热塑性汽车保险杠。聚酰胺(PA6)复合材料常被用于改 良搅拌摩擦焊中连接丙烯腈丁二烯苯乙烯(ABS)复合材料。为保证有效范围内的熔体流动特性,对不 同的热塑性塑料进行了处理。然后,通过螺杆挤压制备了用于熔融沉积建模(FDM)过程的原料长丝。 最后,为改良搅拌摩擦焊制备了基于PA6 的3D 打印耗材快速模具(RT),并对制备的接头进行了弯曲、 硬度、形态和热性能测试。结果表明,在1400 r/min、50 mm/min 横向速度和3 mm 深度下焊接的样 品力学强度最大,在1000 r/min、30 mm/min 横向速度和2 mm 深度下焊接的样品力学强度最小,该 结果与热成像和显微结果一致。

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Acknowledgement

The authors are highly thankful to Board of Research in Nuclear Science (BRNS) No: 34/14/10/2016-BRNS/34036 and Center for Manufacturing Research, GNDEC, Ludhiana for providing financial/technical assistance to carry out the research work.

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Authors and Affiliations

  1. University Center for Research and Development, Chandigarh University, Mohali, 140413, India

    Ranvijay Kumar

  2. Department of Production Engineering, Guru Nanak Dev Engineering College, Ludhiana, 141106, India

    Ranvijay Kumar & Rupinder Singh

  3. Department of Mechanical Engineering, Punjabi University, Patiala, 147002, India

    Ranvijay Kumar & I. P. S. Ahuja

  4. Department of Mechanical Engineering, National Institute of Technical Teachers Training and Research, Chandigarh, 160019, India

    Rupinder Singh

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  1. Ranvijay Kumar
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Correspondence to Rupinder Singh.

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Kumar, R., Singh, R. & Ahuja, I.P.S. Repair of automotive bumpers and bars with modified friction stir welding. J. Cent. South Univ. 27, 2239–2248 (2020). https://doi.org/10.1007/s11771-020-4445-4

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  • DOI: https://doi.org/10.1007/s11771-020-4445-4

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