Experimental study on hot-air cold staking of PC, PC/ABS and acetal samples

An experimental evaluation to systematically study a hot air cold stake joining process was conducted with PC (reprocess), PC/ABS emd Acetal samples. Six material combinations consisting of three stud plate materials and matched with two hole plate materials (GDT 6400 and 18% talc filled PP) were used in the study. Seven stud designs with variations in size and geometry were used for each material combination. A proper heating temperature was first determined by heat characterization trials. Different heating times and stake heights were studied in the staking experiments. Pull tests were conducted to determine the strength of the joints and their failure mode. Results showed that material characteristics, material combinations, and process parameters all could contribute to variations in pull strength and different failure modes.