Laser Welding Technology of Nylon: A Challenge for Innovative Design of Welded Parts

摘要

Since 1999, we have presented annually to GPC (Global Powertrain Congress) and the automotive community our recent developments, and our vision for car weight reduction by the efficient material substitution by plastics and light alloys, and advances in assembly technologies for various thermoplastic parts for powertrain applications. In our initial three reports 1999-2001, we presented to the GPC our vision for the basic advantages of frictional (linear and orbital vibration, ultrasonic), hot plate and infra-red/laser welding technologies for nylon based plastics. One of our two reports at GPC 2002 was focused on the advances in mechanical fastening of reinforced thermoplastics using aluminum-made self-tapping screws. This "smart structure" allows one to manage efficiently the stiffness consideration, short-and long-term mechanical performance of assembled automotive parts, and reduce weight of the assembly. The laser welding process for permanent assembly of thermoplastics has been in continuous experimental use for the last ten years, yet this technology is still not familiar to many automotive and plastics engineers. In this current paper, we will try to enhance the understanding of the automotive engineering community regarding the usefulness and applicability of laser (infra-red) welding technology and various industrial welding systems, developed nylon based plastics (un-reinforced, reinforced, and modified), and its increasing use in various powertrain and automotive body applications.