Recent Advances and Challenges in Induction Welding of Reinforced Nylon in Automotive Applications 2004-01-0733

The advantages of magnetic implant induction welding (Emabond™)¹ technology for various thermoplastics were widely discussed since the mid-eighties in a series of technical articles and reports, and presented to the professional Societies (SAE, SPE, SME, etc). In 1998-2003, we reported to SAE International our technical achievements in optimizing the mechanical performance of welded nylon (6, 66, 6/66, 46, etc.) using frictional (linear and orbital vibration, ultrasonic), contact (hot plate), and non-contact (laser through-transmission) welding technologies.

Our recent developments focused on optimization of mechanical performance of induction welded nylon 6, which has reached a new performance level through continuous improvement of magnetic implant induction welding technology, including properties of the formulated magnetic implant material, new equipment, SPC process control, optimized design of joints, etc. In the current paper, we will try to enhance the understanding of the automotive engineering community regarding the usefulness, unique capability, and applicability of the recently improved Emabond welding technology in the design for heavy-duty and load-bearing automotive plastic parts where requirements for safety and durability are the first priority and fiber-glass reinforced nylon based plastics are widely used.