The advantages of magnetic implant induction welding technology for various thermoplastics were widely discussed since the mid-1980s in a series of technical articles and reports. In 1998-2003, we reported to the Society of Automotive Engineers, 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 noncontact (laser through-transmission) welding technologies. Recent developments in magnetic implant induction welding have focused on optimizing the mechanical performance of joints in reinforced plastics through continuous improvement to the welding technology (including magnetic implant material properties, SPC process control, joint design optimization, etc.). In this study, 33 wt.% fiber-glass reinforced nylon 6 is used in a chain-optimization study to conduct a critical comparison of two alternatives for thermoplastic welding. Results demonstrate interactions between material composition, joint design, and welding process conditions.

The advantages of magnetic implant induction welding (Emabond TM) 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 loadbearing automotive plastic parts where requirements for safety and durability are the first priority and fiberglass reinforced nylon based plastics are widely used.

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ABSTRACT

Within a normal operating range of extruders, it has been well established that the output increases nearly proportionally to the screw speed but the screw horsepower increases more than proportionally to the screw speed, making the screw HP difficult to predict. It has been also known in scale-up of extruders that the output may be predicted with reasonable accuracy but the screw HP is difficult to predict. No sound theoretical or empirical method predicting screw HP in a scale-up calculation has been offered heretofore. Since a screw performs solid conveying, melting and pumping (or metering) functions simultaneously, any theoretical analysis of screw HP has to consider all three extrusion theories; solid conveying theory, melting theory and pumping theory. In this paper, semi-theoretical equations for predicting screw HP as a function of screw speed and size are developed. Experiments are conducted to test the utility of these equations and the implications of the experimental results on extrusion theories are discussed.