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Resent developments were oriented on two high-flow, high-modulus grades fiber-glass reinforced nylon 6 (HMG series) grades for transportation, autos and other industrial applications requiring high stiffness, high strength and high fatigue resistance. These materials combined the following improved technological (injection molding, vibration and hot plate welding, etc.) and mechanical performance properties such as greater dimensional stability, higher short-term (strength and stiffness) and long-term (fatigue and creep with the influence of temperature effects). Both HMG series grades Capron®1 HMG10 and Capron® HMG13 - are for injection molded parts where stiffness, strength, impact resistance, and good surface and improved appearance are preferred. The current and possible applications of these plastics includes auto mirror housing brackets, clutch pedals, clutch master cylinders, ski bindings, steering wheels, levers, auto seat frames, door handles and door lock mechanisms.

A comparative study of the mechanical performance of welded polyamide joints is evaluated. Under optimized welding (linear and orbital vibration, hot plate, transmission laser) conditions, the tensile strength of welded polyamide/nylon (filled and fiber-reinforced) is close or slightly higher (up to 14%) than the tensile strength of the base polymer (non-filled polyamide). In this study, the influence of two important effects (local reinforcement and “memory”) on the mechanical performance of polyamide/nylon welds is analyzed and discussed. The results presented in this study will help plastic part designers, material developers and manufacturers, choose optimized welding conditions for polyamide/nylon parts in a wide range of industrial applications.

Previously we reported to the SAE'99 our findings on selections of nylon (polyamide) based plastics for laser welding (LW) technology. In this current paper, we will try to increase the understanding of the engineering community regarding the usefulness and applicability of an advanced LW technology (and developed thermoplastics), and its increasing use in various automotive applications.

Previously we reported to the SAE 2000 basics in selection of various colored and un-colored/natural nylon 6 (polyamide - PA 6) based plastics for laser welding technology. Later we presented to Antec1 2001 and to SAE 2002 our developments of colored in black through-transmissible grades of PA 6 plastics, which were specially tailored for the specifics of the design and laser welding technology. In this current paper, we will try to enhance the understanding of the engineering community regarding the usefulness and applicability of laser welding technology, developed colored thermoplastics, and its increasing use in various automotive and transportation applications.

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.

The mechanical performance of injection molded glass-fiber reinforced plastic parts is highly anisotropic and depends strongly on the kinetics (orientation and distribution) of the glass-fiber and the part geometry. Similarly, the bulk and local mechanical performance at the ribs, walls and welds is influenced by these glass-fibers and the specific processing technology (including joining) used, as related to melt-flow and melt-pool formation and glass-fiber re-orientation. The purpose of this study is to show: the effect of short glass-fiber orientation at the pre-welded beads, ribs and wall areas for injection molded and subsequently welded parts the short-term mechanical performance of welded butt-joints that have various geometry and thickness, namely “straight” and “T-type” welds.