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Weldability study has been performed on Polypropylene (PP) and PC/ABS samples to investigate how the paint layer along the weld joint affects the vibration weldability. The plastic used for this study were PP representing semicrystalline thermoplastics and PC/ABS representing amorphous thermoplastics. Both resins were molded to generate sample plaques for the study. Design of Experiment (DOE) studies were initially conducted with unpainted plaques and then repeated with the painted plaques for comparison. Optimal welding parameters were determined through DOE and the maximum weld strength under optimized welding conditions were determined and compared. Following each DOE, a regression analysis, using the weld strength as a response, was performed.

Nonlinear crash finite element analysis was performed to simulate the dynamic response of the instrument panel substrate in the head impact test. The finite element software used for this study was LS-DYNA3D. This paper describes the modeling strategy such as boundary conditions and loading condition. Energy absorption rate and deflection of the instrument panel substrate were investigated. The impact performance of various substrate designs were also simulated and compared with the baseline design. It was found that thinner substrate in the areas of impact can give substrate additional compliance which results in a greater crash energy absorption.