Comprehensive Insights into Friction Stir Butt Welding (FSBW) of 3D-Printed Novel Nano Chromium (Cr) Particles-Reinforced PLA Composites

Additive manufacturing (AM) is a significant contributor to Industry 4.0. However, one considerable challenge is usually encountered by AM due to the bed size limitations of 3D printers, which prevent them from being adopted. An appropriate post-joining technique should be employed to address this issue properly. This study investigates the influence of key friction stir butt welding (FSBW) factors (FSBWFs), such as tool rotational speed (TRS), tool traverse speed (TTS), and pin profile (PP), on the weldability of 3D-printed PLA–Chromium (PC) composites (3PPCC). A filament containing 10% by weight of chromium reinforced in PLA was used to prepare samples. The material extrusion additive manufacturing process (MEX) was employed to prepare the 3D-printed PCC. A Taguchi-based design of experiments (DOE) (L9 orthogonal array) was employed to systematically assess weld hardness (WH), weld temperature (WT), weld strength (WS), and weld efficiency. As far as the 3D-printed samples were concerned, two distinct infill patterns (linear and tri-hexagonal) were also examined to evaluate their effect on joint performance; however, all other 3D printing factors were kept constant. Experimentally validated findings revealed that weld efficiency varied significantly with PP and infill pattern, with the square PP and tri-hexagonal infill pattern yielding the highest weld efficiency, i.e., 108%, with the corresponding highest WS of 30 MPa. The conical PP resulted in reduced WS. Hardness analysis demonstrated that tri-hexagonal infill patterns exhibited superior hardness retention, i.e., 46.1%, as compared to that of linear infill patterns, i.e., 34%. The highest WTs observed with conical PP were 132 °C and 118 °C for both linear and tri-hexagonal infill patterns, which were far below the melting point of PLA. The lowest WT was evaluated to be 65 °C with a tri-hexagonal infill, which is approximately equal to the glass transition temperature of PLA. Microscopic analysis using a coordinate measuring machine (CMM) indicated that optimal weld zones featured minimal void formation, directly contributing to improved weld performance. In addition, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX) were also performed on four deliberately selected samples to examine the microstructural features and elemental distribution in the weld zones, providing deeper insight into the correlation between morphology, chemical composition, and weld performance.