Investigation of microstructural and mechanical properties of weld lines in injection‐molded short glass fiber‐reinforced polyamide 6

Abstract This research investigates the impact of weld lines on the mechanical properties and fracture behavior of injection‐molded unfilled and glass fiber‐reinforced polyamide 6 (PA6). The study aims to predict the weld line strength by analyzing the composite's microstructure at the weld line and investigating the influence of injection molding parameters. While weld lines had minimal effects in unfilled PA6 thanks to the matrix's high healing capability, composite samples showed reduced mechanical properties due to unfavorable fiber orientation at the weld line. Fracture surfaces revealed a bell‐shaped structure linked to the ‘underflow’ process caused by flow imbalances during injection molding. This phenomenon impacts fiber orientation at the weld line, affecting mechanical properties. The ‘underflow’ is simulated using Autodesk Moldflow®, predicting enhanced fiber alignment along the flow direction. Regarding processing parameters, both melt and mold temperatures showed negligible impacts, while enhanced mechanical properties were observed at elevated packing pressures. The analysis of fracture surfaces showed intensified “underflow” with increased packing pressure. A relationship is established between weld line strength and fiber orientation at the weld line, potentially serving as a predictive tool for estimating weld line strength. Highlights Weld lines in unfilled PA6:Negligible impact on the mechanical properties. In the PA6 composite: significant drop due to unfavorable fiber orientation. Fracture behavior of the composite: Bell‐shaped weld line linked to “underflow.” Melt and mold temperature: minor effect; packing pressure enhances properties. Correlation established between the weld line strength and fiber orientation.