Examining and Optimizing the Weld Area and Mechanical Performance of Thermoplastic Parts Manufactured by Additive Manufacturing and Welded by Friction Stir Welding

This study presents an experimental investigation into the weldability of ABS M30 (acrylonitrile butadiene styrene) plates produced by Additive Manufacturing (AM) using Friction Stir Welding (FSW). The effects of FSW process parameters on the yield stress and their optimal levels were determined using the Taguchi method. The optimal welding parameters were found to be a 16 mm tool shoulder diameter, 800 rpm tool rotation speed, and 10 mm/min traverse speed. The weld area of each sample welded using FSW was examined at a macroscopic level. The direction of tool rotation significantly affects the quality and strength of the FSW. When the FSW was performed with a clockwise rotation of the welding tool, a perfect weld could not be achieved. The tunnel effect resulted in gaps in the weld area of the samples at high rotation speeds. Differences were observed in the density between the weld area of the samples and the main parts.