Optimization of Vibration Weld Joint Strength for Plastic Air Intake Manifold

Joint strength of a vibration welded air intake manifold has been optimized by controlling the process parameters. Key process parameters are: Clamp pressure, bead melt down displacement and vibration amplitude.

The present study has investigated the combined effect of the vibration welding process parameters on the weld joint strength of a manifold by using a factorial DOE (Design of Experiment) with center points.

The result of the DOE study revealed that the burst strength can vary as much as 50% across the process window investigated. Response surface of strength, which was developed as a function of the process variables, can be used for process control in the production plant.

The weld strength values of Nylon 6 and Nylon 66 materials are also compared across the wide range of the process window.