Advances in understanding of multiple factors affecting vibration weld strength of thermoplastic polymers

Joining is a key part of the manufacturing process including automobile, household appliances, aircraft manufacture, and medical sectors. Vibration welding (VW), also known as linear friction welding, is the most used technique to join thermoplastic components and composites mostly due to its simplicity, controllability, versatility of applications, and cost-effectiveness in terms of thermal efficiency, compared to conventional adhesive, mechanical fastening, and other fusion bonding techniques. This review aims to provide a comprehensive overview of the recent advances in understanding the multiple factors affecting vibration weld strength of thermoplastic polymers and their composites. The key process parameters such as weld pressure, frequency, amplitude and time are discussed along with their influence on weld strength of various materials. The effects of material characteristics like crystallinity, fiber reinforcement, and nanoparticles are summarized. Furthermore, the impact of joint design factors like thickness and geometry on mechanical performance is reviewed. The current challenges and future research directions for optimizing vibration weld strength through process, material, and design selections are highlighted. The overall goal is to present updated understanding on achieving strong vibration welded joints by considering the complex interplay between processing, structure, and properties.