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Joining technologies have a crucial role in the product development process, e.g. to achieve local part properties or functional integrations. This often requires multi-material joints, which are challenging for conventional joining processes. Therefore, innovative processes are needed to generate bonds between adhesion-incompatible material combinations, such as joining using pin-like structures in the vibration welding process. Investigations into this novel process have provided initial findings; however, a specific pin design is not possible at this time. For this reason, the influence of the pin-foot width of the two joining partners was analyzed numerically by simulation. The results of the simulation were validated by experimental tests. The investigations show, that the simulation model is suitable for predicting the bond quality as well as the fracture behavior of the multi-material joint based on pin-like structures. The developed correlations between material, pin-like structure, and resulting bond quality allow design criteria for the pin-like structures to be derived. These allow a specific dimensioning of the pin-foot ratio depending on the used material combination. Thus, for example, the fracture behavior of the multi-material connection can be selectively adjusted, as well as the bond strength can be maximally utilized.

Design criteria for the pin-foot ratio for joining adhesion-incompatible polymers using pin-like structures in vibration welding process