Abstract
Joining often assumes a central position in the manufacturing process. Vibration welding is characterized by its process flexibility, its high energy-efficiency as well as its short cycle times. Polymer welding processes, however, are restricted due to the necessary adhesion compatibility of the joining partners. Therefore, the industrial application of welding is strongly limited for multi-material joints. Generating a form-fit connection by means of the vibration welding process enables an innovative approach for joining adhesion incompatible polymers. For this purpose, pin-like structures are embedded into at least one joining partner using a structuring-tool. Subsequently, these structures are filled by the further joining partner and a form-fit connection is achieved.Within these investigations, the influence of the structuring-tool geometry on the pin-like structures and the resulting form-fit connection is investigated. Tools with similar undercut volumes but different pin geometries (mushroom-like, trapezoidal) were used. Polyamide 66 (PA66) was used as structured-partner and polypropylene (PP) as well as polymethylmethacrylate (PMMA) as bonding-partner. In addition to the resulting shape of the pin-like structures, the mechanical resistance and fracture behavior of the multi-material joint were analyzed depending on the tool geometry and the bonding-partner. The results show that the selected tool geometry has only a minor influence on the maximum achievable force. The fracture behavior of the multi-material combination PA66-PMMA, however, is mainly determined by the structuring-tool geometry. While trapezoidal structures show predominantly adhesive failure, mushroom-like structures show cohesive failure due to fracture of one joining partner. The combination of PA66-PP, show a predominantly adhesive failure for all tool geometries. Thus, the investigations revealed that, in addition to the structuring parameters, the structuring-tool must also be adapted to the selected material combination.
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