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All Journal JOURNAL OF MECHANICAL ENGINEERING, MANUFACTURES, MATERIALS AND ENERGY Piston: Journal of Technical Engineering
Alkafi, Abu Faqih
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Aerospace Engineering Control & Systems Engineering Energy Engineering Industrial & Manufacturing Engineering Mechanical Engineering

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Characteristics of Aluminium 7075 Tool Profile for HDPE and PP Welding Against Tensile and Bending Malisi, Muhammad Sibro; Darsono, Febri Budi; Kriswanto; Alkafi, Abu Faqih; Rochim, Muhammad Nur; Masruhan, Fahmi Irsad
Piston: Journal of Technical Engineering Vol. 9 No. 1 (2025)
Publisher : Program Studi Teknik Mesin Universitas Pamulang

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.32493/pjte.v9i1.51351

Abstract

The increasing demand for lightweight materials in the automotive industry has led to the replacement of metal vehicle components with polymers such as High-Density Polyethylene (HDPE) and Polypropylene (PP) to support sustainable development and emission reduction. However, welding dissimilar polymers presents a challenge due to the limitations of conventional techniques. Friction Stir Welding (FSW) emerges as a promising solution by enabling solid-state joining below the melting point. This study investigates the effect of AA7075 tool profile variations—plain cylinder, threaded cylinder, and grooved cone—on the mechanical properties and macrostructure of HDPE-PP FSW joints. Experimental welding was performed at a rotational speed of 2920 rpm and a travel speed of 30 mm/min, with analysis including tensile tests (ASTM D638), bending tests (ASTM D790), temperature measurements, and macrostructural observations. Results show that the threaded cylindrical tool yielded the highest tensile strength (4 MPa) due to effective material flow, while the grooved cone tool produced the highest bending strength (6,8 MPa) through improved vertical and radial mixing. The plain cylindrical tool showed the weakest performance with significant welding defects. Overall, tool geometry significantly influences weld quality, and selection should be based on the mechanical requirements of the application. These findings emphasize the importance of tool design optimization to enhance joint strength and structural integrity in dissimilar thermoplastic FSW.
Characteristics of SKD 61 and Aluminium 7075 Tools in High Density Polyethylene (HDPE) and Polypropylene (PP) Welding in Terms of Tensile Strength and Bending strength Alkafi, Abu Faqih; Darsono, Febri Budi; Kriswanto; Rochim, Mohammad Nur
JOURNAL OF MECHANICAL ENGINEERING MANUFACTURES MATERIALS AND ENERGY Vol. 9 No. 2 (2025): December 2025 Edition
Publisher : Universitas Medan Area

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31289/jmemme.v9i2.15550

Abstract

Effective welding procedures are necessary to preserve structural integrity due to the growing usage of lightweight polymers in industry, such as polypropylene (PP) and high density polyethylene (HDPE). This study sought to determine how the tool materials, SKD 61 and Aluminum 7075, affected the tensile and bending strength of HDPE and PP friction stir welded (FSW) joints. A quantitative comparative design was used in the experiment, and the FSW tool was modified milling equipment with screw cylindrical pin tools. Temperature control was observed using a thermogun and no preheating was used to guarantee process stability. Based on the results, SKD 61 generated higher weld quality, which was characterized by fewer flaws, regulated heat input, and more consistent material flow. SKD 61 outperformed than aluminium 7075, which had an average tensile strength of 11.09 MPa and bending strength of 19.11 MPa, while aluminium 7075 had an average tensile strength of 7.8 MPa and bending strengths of 16.28 MPa. This discrepancy is explained by SKD 61's higher heat conductivity and stability, whereas tool geometry had little effect because the screw cylindrical pin profile was the same. SKD 61 is more suited for FSW of HDPE-PP dissimilar joints, according to the study's findings, offering higher joint quality and stronger mechanical performance.
Characteristics of Tool Tilt Variation in Friction Stir Welding HDPE with Tool Made of 7075 Aluminum on Tensile and Bending Strengths Nur Rochim, Mohammad; Darsono, Febri Budi; Kriswanto; Alkafi, Abu Faqih
JOURNAL OF MECHANICAL ENGINEERING MANUFACTURES MATERIALS AND ENERGY Vol. 9 No. 2 (2025): December 2025 Edition
Publisher : Universitas Medan Area

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.31289/jmemme.v9i2.15551

Abstract

High-Density Polyethylene's (HDPE) potential is highlighted by the growing need for lightweight, high-strength materials in the automotive and aerospace industries. Friction Stir Welding (FSW) provides a solid-state joining method with low thermal degradation for producing high-quality joints in this thermoplastic material. With an emphasis on tensile and bending strength, this study attempts to examine how tool tilt angle variation affects HDPE joint quality. Three different tilt angle variations—0°, 1°, and 1.5°—were used in the experiment, which was carried out using an aluminum 7075 tool that was shaped like a grooved conical pin. A modified milling machine was used for welding, and ASTM D638 for tensile and ASTM D790 for bending mechanical tests were conducted. The findings show that the tilt angle has a major impact on the quality of the weld. With a tensile strength of 13 MPa (68.4% of raw HDPE), a bending strength of 16.5 MPa (70.5%), and a dense stir zone with few voids, the best weld was produced at a 1.5° angle. On the other hand, the weakest joint with obvious structural flaws was produced by the 0° angle. Overall, it is determined that the best tilt angle for improving the mechanical and aesthetic performance of FSW joints in HDPE is 1.5°.
Co-Authors Darsono, Febri Budi Kriswanto Malisi, Muhammad Sibro Masruhan, Fahmi Irsad Nur Rochim, Mohammad Rochim, Mohammad Nur Rochim, Muhammad Nur