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<p>Conventional rotary friction welding (RFW) uses a single-axis unidirectional feeding method. One workpiece moves axially under pressure while the counterpart rotates. This method offers simple operation, easy control, and a stable welding interface. However, it is limited by material properties and workpiece geometry, which can reduce weld quality. This study develops a biaxial RFW method that combines Taguchi-based process optimization with advanced toolpath design. The new dual-axis synchronous feeding mechanism increases the bending strength of polyetheretherketone (PEEK) cylindrical joints. Conventional RFW produces a bending strength of about 210&#xa0;MPa. The proposed method increases the strength to 290&#xa0;MPa, which is a 38% improvement. Further optimization with the Taguchi design of experiments identifies the best process parameters: X-axis offset of 6&#xa0;mm, total upset length of 2.5&#xa0;mm, single upset length of 0.3&#xa0;mm, and Z-axis feed rate of 0.2&#xa0;mm/s. Under these conditions, the bending strength reaches 340&#xa0;MPa, which is a 17% increase. The results show that dual-axis feeding with optimized parameters improves the mechanical performance of PEEK RFW joints. The biaxial RFW method enhances PEEK joint strength and sustainability, benefiting aerospace, automotive, medical, and energy industries seeking lightweight, high-performance polymer components with reduced energy and material waste. The method also supports sustainable manufacturing because it reduces material waste and energy use. It contributes to the United Nations Sustainable Development Goals (SDGs), especially Goal 9: Industry, Innovation, and Infrastructure, and Goal 12: Responsible Consumption and Production.</p>

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Sustainable biaxial rotary friction welding for PEEK cylinders via advanced feed path design and Taguchi-based process optimization

  • 期刊论文

  • 发表日期：

    2026年2月18日

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  • Chil-Chyuan Kuo,
  • Hsiao-Tse Hsieh,
  • Armaan Farooqui,
  • Song-Hua Huang,
  • Shih-Feng Tseng

摘要

Conventional rotary friction welding (RFW) uses a single-axis unidirectional feeding method. One workpiece moves axially under pressure while the counterpart rotates. This method offers simple operation, easy control, and a stable welding interface. However, it is limited by material properties and workpiece geometry, which can reduce weld quality. This study develops a biaxial RFW method that combines Taguchi-based process optimization with advanced toolpath design. The new dual-axis synchronous feeding mechanism increases the bending strength of polyetheretherketone (PEEK) cylindrical joints. Conventional RFW produces a bending strength of about 210 MPa. The proposed method increases the strength to 290 MPa, which is a 38% improvement. Further optimization with the Taguchi design of experiments identifies the best process parameters: X-axis offset of 6 mm, total upset length of 2.5 mm, single upset length of 0.3 mm, and Z-axis feed rate of 0.2 mm/s. Under these conditions, the bending strength reaches 340 MPa, which is a 17% increase. The results show that dual-axis feeding with optimized parameters improves the mechanical performance of PEEK RFW joints. The biaxial RFW method enhances PEEK joint strength and sustainability, benefiting aerospace, automotive, medical, and energy industries seeking lightweight, high-performance polymer components with reduced energy and material waste. The method also supports sustainable manufacturing because it reduces material waste and energy use. It contributes to the United Nations Sustainable Development Goals (SDGs), especially Goal 9: Industry, Innovation, and Infrastructure, and Goal 12: Responsible Consumption and Production.