WELDLINE STRENGTH IN GLASS-FIBER-REINFORCED POLYAMIDE-66

Presence of weldlines introduces an element of uncertainty to the performance of injection molded parts. Weldlines are particularly problematic in reinforced plastics because, unlike molecular orientation in neat polymers, the flow induced fiber orientation does not relax. This paper deals with the structure and mechanical behavior of weldlines in glass fiber reinforced nylon 66, a plastic known for excellent fiber-matrix adhesion. Two molds were used to generate weldlines: a double gated tensile sample shaped cavity in which the weldline is formed by a head-on collision of melt fronts flowing in opposite directions and a film gated rectangular plaque with a circular insert in which the weldline formation behind the insert is followed by additional flow. In both cases the weldline zone is several millimetres wide: in the plane where the melts fronts have met fibers are oriented parallel to this plane (random-in-plane in the double-gated cavity and unidirectional in the cavity with insert). The transition zone between the weldline plane and the rest of the sample is characterized by an increased presence of microvoids. Weldline tensile depends little on the fiber concentration and on the sample shape or thickness: values close to the matrix strength are found; in samples without weldlines strength increases with the fiber content. However, in instrumented impact penetration test during which the material is subjected to multiaxial loading, the weldline effect appears negligible.