Joining plastics - can friction stir welding compete?

As plastics become candidates for an increasing number of applications, it is important to continue developing processes to join them efficiently. In the past, a few processes have dominated the area. Now a new process, Friction Stir Welding, enters the arena of competition with the established practices. This paper delivers a comparison of several processes for joining plastic materials. Process parameters investigated include machine and tool costs, part preparation, weld rate, joint efficiency, consumables, reproducibility, and process capability. When compared on these bases, Friction Stir Welding stands as an able competitor with established processes.