Effect of nano-powder reinforcements and process parameters on the performance of friction stir-welded ABS-PS plates

The present study examined the effects of various reinforcements, such as nano-powder, silica, eggshell and multi-walled carbon nanotubes, on the mechanical properties of friction stir-welded polystyrene and acrylonitrile–butadiene–styrene plates under different process parameters. Welding experiments were performed at different tool rotational speeds (TRSs) of 800, 900 and 1100 rpm, with traverse speeds of 9, 18 and 27 mm/min, respectively. A pinless tool was used to pack the reinforcement particles into the groove, and a cylindrical H13 steel tool was used to join the base materials. The findings indicated that the mechanical characteristics of the welded joints were significantly affected by the different types of reinforcement and process parameters. The maximum tensile strength of 22.41 MPa and an elongation of 3.81 were achieved at a tool traverse speed (TTS) of 18 mm/min and a TRS of 900 rpm using nano eggshell powder reinforcement, suggesting improved interfacial bonding and particle distribution. Conversely, the highest microhardness was recorded at a TTS of 27 mm/min and a TRS of 900 rpm with silica nano-powder reinforcement, owing to the enhanced resistance to localized deformation and improved load transfer capability.