The Friction Stir Welding FSW process, polymeric materials respond differently than metallic materials. In addition, the same tool design concept is not able to produce good surface quality with strong welds. Because the welding parameter is so important in this procedure the key The goal of this effort was to construct a novel welding tool that could produce reliable seams for all types of polymers, independent of their configurations, without the use of an additional heat source. The study initially concentrated on the development of the tool and the optimization of the welding parameters. Before arriving at the final tool design, which was able to produce more frictional heat and have superior surface polish, various tools were conceived, produced, and tested. Statistical methods were used to optimize the welding procedures, and numerous mechanical tests were carried out to determine the weld strength. To measure the active forces during the welding process, a fixture was created and built. The force platform that was designed allowed for the application of main axial force in the fusion parameter even while welding with a position control approach. Because it generates heat and forges the soft material inside the weld nugget, the axial force’s amplitude is crucial in this process. The welding parameters that have the greatest impact on temperatures are all those that have to do with the design of the welding tool, followed by rotating speed and welding speed. FSW of materials.
