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<p>Continuous drive friction welding (CDFW) represents a solid-state manufacturing process that converts mechanical energy into heat to achieve bonding without melting. For thermoplastic materials such as polyetheretherketone (PEEK), which exhibits outstanding mechanical strength, thermal stability, and chemical resistance, achieving consistent and defect-free welds remains a manufacturing challenge. Conventional CDFW often suffers from localized thermal degradation, interfacial voids, and non-uniform molten layer formation, which collectively limit joint reliability. This study develops an innovative CDFW-based manufacturing strategy incorporating dissimilar sacrificial interlayers to optimize heat flow, material mixing, and bonding quality at the PEEK interface. Two engineering thermoplastics, polyetherimide (PEI) and polyphenylene sulfide (PPS), are introduced as sacrificial materials to regulate interfacial temperature distribution and enhance diffusion bonding. Experimental characterization reveals that the use of a 1.5&#xa0;mm sacrificial layer markedly improves joint integrity and flexural performance. Compared with conventional PEEK-to-PEEK welds, the incorporation of PEI and PPS layers enhances flexural strength by approximately 48.15% and 49.83%, respectively. The results validate the feasibility of sacrificial interlayer-assisted CDFW as a controllable and scalable manufacturing process for producing high-strength PEEK joints. This approach advances the process–structure–property understanding of thermoplastic friction welding and offers promising potential for high-performance composite structures and biomedical component fabrication.</p>

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Heat-flow-tailored continuous drive friction welding of PEEK using sacrificial polymer interlayers

  • 期刊论文

  • 发表日期：

    2026年6月27日

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  • Chil-Chyuan Kuo,
  • Hsiao-Tse Hsieh,
  • Xuan-Zhi Xiao,
  • Jia-Hong Tu,
  • Armaan Farooqui,
  • Song-Hua Huang,
  • Shih-Feng Tseng

摘要

Continuous drive friction welding (CDFW) represents a solid-state manufacturing process that converts mechanical energy into heat to achieve bonding without melting. For thermoplastic materials such as polyetheretherketone (PEEK), which exhibits outstanding mechanical strength, thermal stability, and chemical resistance, achieving consistent and defect-free welds remains a manufacturing challenge. Conventional CDFW often suffers from localized thermal degradation, interfacial voids, and non-uniform molten layer formation, which collectively limit joint reliability. This study develops an innovative CDFW-based manufacturing strategy incorporating dissimilar sacrificial interlayers to optimize heat flow, material mixing, and bonding quality at the PEEK interface. Two engineering thermoplastics, polyetherimide (PEI) and polyphenylene sulfide (PPS), are introduced as sacrificial materials to regulate interfacial temperature distribution and enhance diffusion bonding. Experimental characterization reveals that the use of a 1.5 mm sacrificial layer markedly improves joint integrity and flexural performance. Compared with conventional PEEK-to-PEEK welds, the incorporation of PEI and PPS layers enhances flexural strength by approximately 48.15% and 49.83%, respectively. The results validate the feasibility of sacrificial interlayer-assisted CDFW as a controllable and scalable manufacturing process for producing high-strength PEEK joints. This approach advances the process–structure–property understanding of thermoplastic friction welding and offers promising potential for high-performance composite structures and biomedical component fabrication.