Friction stir spot welding of recycled scrap thermoplastics

There is a real demand for sustainable lightweight structures because of the growing environmental concerns. One important solution is developing structures through recycled scrap/waste thermoplastic materials. The current work studies the friction stir spot weldability of recycled thermoplastics, which will help to analyze the potential of friction stir-based welding techniques towards developing these sustainable structures. The combined behavior of recycling-welding procedures is investigated, as they may cause degradations; to ensure that the base thermoplastic polymer's chemical, thermal, and mechanical properties are retained. Scrapped milk bottles made from HDPE material are used as a case study. The highest lap-shear load of 1528 N was achieved at the optimum welding conditions of 1600 rpm rotational speed, 1 mm plunge depth, and 60 s dwell time. Fractographic studies (macroscopic and SEM-based) suggested four types of fracture morphologies depending on welding conditions used. The DSC results showed no significant differences in melting temperature and crystalline content of the polymeric material. The TGA tests showed no significant thermal degradations. The FTIR analysis of all the samples (bottle, recycled sheet, weld material) exhibited characteristic HDPE peaks. All these results suggest combined-welding recycling had a minimal impact on the polymeric structure. Thus, friction stir spot welding (FSSW) technique joins recycled thermoplastic scrap/waste materials with high lap-shear load and without any significant polymer degradations.