Joining processes for plastics

Dr Murugaiyan Amirthalingam

Department of Metallurgical and Materials Engineering,

Indian Institute of Technology Madras

1 / 43
Joining of plastics

Thermosets and Vulcanised Elastomers Thermoplastic polymers

Joining process Joining process

Adhesive bonding or Mechanical fastening

2 / 43
Hot plate welding
Also known - heated tool welding, mirror, platen, butt or butt fusion welding

3 / 43
Hot plate welding
Heated platen welding process

4 / 43
Hot plate welding

Advantages Disadvantages

1 Simple and economical 1 Long cycle time

2 Can be used for small and large 2 High temperatures required for
parts welding
3 Flat, curve or complex 3 Plastic degradation or sticking
geometries can be welded to platen
4 Surface irregularities can be 4 Weld flashing should be removed
removed
5 Materials with difference
melting points can be welded
using different heating tools
6 Process easily be automated

5 / 43
 1.3 Applications
The heated tool (welding by distance) process
Hot plate welding
ward Technology).
Hot tool welding can be used to join parts as small as
a few centimeters to parts as large as 1600 mm (63 inches)
in diameter, such plastics pipes (Section 1.9.2). It can
l is inserted between the parts in Step 2, and
also be used for the continuous welding of lining mem-
e pressed against it in Step 3. Phase I, as
Materials
or welding by pressure, then takes place.
branes (Section 1.9.3).
The heated tool welding method is widely used in
al melts and flows out of the joint interface,
the automotive sector, where one of the most common
part length until, in this case, the melt stops
Any thermoplastic applications is the welding of vehicle tail lights and
polymers
oling stops. Melt thickness then increases
indicators (Fig. 1.3). The housing, usually made of
until the hot plate is removed in Step 4, the
acrylonitrile-butadiene-styrene (ABS) is welded to the
Often
phase (Phase III). The parts are then used
pressed for softer, semicrystalline thermoplastics such as
colored lens which is made from either polymethyl-
Step 5 (Phase IV), forming a weld as the
ls; tooling stops inhibitPP meltandflow. PE,
methacrylate (PMMA) or polycarbonate (PC). These
The
represent one of the few material combinations that are
is then removed in Step 6.
Not suitable forcompatibleNylon for or heated
hightool molecular
welding. ABS weight
to PMMA materials,
antages and Disadvantages
tool welding is a simple economical tech-
hich high strength, hermetic welds can be
ith both large and small parts. Joints with
or complex geometries can be welded, and
gularities can be smoothed out during the
ses. Dissimilar materials that are compatible
fferent melting temperatures can be welded
ools at different temperatures. The welding
n be easily automated with full monitoring
essing parameters. Since the process does
uce any foreign materials into the joint,
elded parts can be easily recycled [1, 3].
jor disadvantage of the process is the long Vehicle lamps
compared with other common techniques Figure 1.3. Hot plate welded vehicle indicator lamps 6 / 43
Hot plate welding
Joint designs

(a) Simple butt joing

(b) Increased joint area
(c) Double flash trap
(d) Skirt joint
7 / 43
Hot plate welding
Completed butt fusion weld

8 / 43
Hot plate welding

Heated wedge welder

9 / 43
Hot gas welding

Also known as hot air welding; quality depends on the welder.

10 / 43
Hot gas welding

Advantages Disadvantages

1 Simple and economical 1 Long cycle time

2 lowest cost of all welding 2 Depends on operators skill
3 Light and easy to use in 3 Not suitable for mass
awkward positions productions
4 Suitable for field repair 4 Needs proper training and
certification (EN13067 or
AWS B2.4)

11 / 43
Hot gas welding

Materials and Applications

Common thermoplastic polymers

PP, PE, PVC, Acrylic, Polyamides and Fluoropolymers,
Chemical storage, ducting and fume extraction systems
Repairing automobile bumpers made from polycarbonate/polyester etc.

12 / 43
 tool, 5 mm
of the air s

Hot gas welding It is im

flow to sta
This typic
45°
microproc
bilization
Joint designs
6: HOT GAS WELDING
ing operat
69with
zero
Figure 6.9. Examples of T-joints for hot gas welding
the heatin
(Source: TWI Ltd).
age to the
and the position of the welding gun in relation toheating
the el
joint. The w
The optimal gas temperature will depend oningthe proces
material being welded, and the recommended weldingpressu
ing
45° 0–1 mm practice of
temperature range should be obtained from the mate-
is one me
rial manufacturer. Before welding, the temperature pressure i
should be measured using a temperature calibration place by a
tool, 5 mm (0.2 inches) inside the nozzle, in the center
simultaneo
of the air stream (Fig. 6.11). zle. This i
It is important to allow the temperature of thewelding
gas g
fl ow to stabilize after setting is applied
0–1 mm the hot gas temperature.
60°
The w
This typically takes around ten minutes, although on
45° perature s
microprocessor controlled equipment, temperaturewelded,
sta- a
bilization will be quicker. On completion of the weld-
should be
ing operation, the set temperature should be reducedandtoweld
zero with the gas supply left running. This will allow
Figure 6.9. Examples of T-joints for hot gas welding Figure 6.10. Typical corner joint preparation for hot gas
the(Source:
welding heatingTWIelement
Ltd). to cool naturally, preventing dam-
(Source: TWI Ltd).
age to the torch, and helping to prolong the life of the
heating element.
(a) Single V, The welding pressure is one parameter of the weld-
6.7 Welding Parameters
ing process that can be difficult to control, since weld-
(b) Double V ing pressure
There are four mainis always applied
parameters for hotmanually.
gas weld- Repeated
practice of hot
ing: temperature, gas welding
pressure, ontorch
speed, and a pressure sensitive
position. It table
(c) T-Joints is essential
is onethat
edgepressure
to implement
the operator
method
and
has the necessary
of ensuring
monitor each
knowl- welding
that a consistent
welding parame-
is achieved. For speed welding, fusion takes
ter effectively. Failure to do so could result in the
(d) Corner joints place by applying pressure to the weld rod by hand and
fabrication of a weak weld.
simultaneously applying pressure to the toe of the noz-
Welding temperature is the most important welding
zle. This
parameter, is done
although by pulling at
the temperature down on surface
the joint the handle of the
13 / 43
 liners being welded together.
Hot gas The two surfaces to be joined should be cleaned to
welding
remove any contamination, such as dirt or dust, prior to Figure 6.12. Hot gas lap welding of
welding. The welding temperature and rate of seaming (Source: Leister Process Technologies).
Automated hot gas welding machine

Blower

Pressure and Heating unit

drive rollers

Hot-gas nozzle

Overlap weld Upper/lower

membranes

Hot-gas Figure 6.13. Diagra

automatic hot gas w
Direction of work used for sealing me

14 / 43
Extrusion welding
By extruding molten thermoplasics

15 / 43
Extrusion welding

Advantages Disadvantages

1 Continuous weld bead in single pass 1 Heavy equipment, excess of

2 Less welding time 12 kg
3 More deposition rate 2 Vertical welding is
uncomfortable for operator
3 Welding corners and
confined spaces difficult
4 Needs proper training and
certification.

16 / 43
Extrusion welding

Materials and Applications

Common thermoplastic polymers

PP, PE, PVC with large mass,
In case of PVC, due to its narrow processing temperature range, the extruder should be
purged after each weld run
Large thermoplastic fabrications such as tanks and pipes
Agriculture and water engineering.

17 / 43
Extrusion welding

Extrusion gun

18 / 43
 45–60º
2 mm 45–60º
Extrusion welding

2 mm

Joint designs

t
t

Figure 7.10. An overlap joint for extrusion welding lining

(a) Overlap joint
membranes (Source: TWI Ltd).
(b) V, Double V, T-joints are also possible.

19 / 43
Induction welding

Process

Common thermoplastic polymers

Also called as Electromagnetic or EMA welding
Uses induction heating using 2 to 10 MHz AC to excite an implant placed at the joint
interface,
Implant or gasket is normally a composite of polymer to be welded
Heat melts and fuses the implant
Heat is generated due to induction field by eddy current heating and hysteresis losses.

20 / 43
Induction welding

Induction welding process

(a) Placement of the implant

(b) Application of the pressure
(c) Induction heating and
(d) Cooling under pressure

21 / 43
Induction welding

Applications

(a) Welding of large or irregular parts that are injection moulded, blow-moulded
(b) Household appliances, plastic caps to plastic bottles, solar panels etc.

22 / 43
Induction welding

Advantages Disadvantages

1 Structural and pressure tight welds 1 Additional cost of the

2 Large parts with bond lines upto 6 implant,
metres, 2 Additional assembly
3 Can be used to weld 3-D parts, operation of placing the
implant
4 Implants add resins in the joint
area providing good cross-link 3 Implant sometimes affect
mechanical performances
5 Dissimilar polymers can be joined,
6 Heat is created precisely where
needed,
7 Fast production cycles

23 / 43
Induction welding

Materials

Almost all thermoplastic polymers

All themoplastics, crystalline, amorphous, high performance
and difficult to weld resins,
Dissimilar materials or thermoplastics containing glass, talc,
minerals, wood etc.

Implant materials
Electromagnetic materials - metallic mesh or ferromagnetic
powders of micon-size (iron, SS or ferrite materials)

24 / 43
Induction welding
Joint designs

(a) Flat to flat

(b) Flat to groove
(c) Tongue and groove
(d) Shear
(e) Step 25 / 43
Resistive implant welding
Another variant is electro-fusion process

26 / 43
Ultrasonic welding

Process

Most widely used for thermoplastics

Uses ultrasonic energy - 20-40 kHz to produce low amplitude vibrations (1-25 µm)
Vibration generates heat at the interface.
Weld time is 0.1 to 1 s.

27 / 43
Ultrasonic welding
Components of ultrasonic welding

28 / 43
Ultrasonic welding
Materials compatibility

29 / 43
Ultrasonic welding

Applications

Major thermoplastic parts with high volumes

Automotive: headlamp parts, dashboards, buttons and switches, fuel filters, fluid
vessels, seat-belt locks, electronic key fobs, lamp assemblies, air ducts.
Electronic and appliances: switches, sensors, data storage keys.
Medical: filters, catheters, medical garments, masks
Packaging: blister packs, pouches, tubes, storage containers, carton spouts

30 / 43
Ultrasonic welding
Joint designs

31 / 43
Vibration welding

Process

Used for thermoplastics

Friction at the interface produces melting
Molten materials flow together under pressure
Weld time is 1 to 10 s,
Two types linear and orbital.

32 / 43
Vibration welding

Components of vibration welding

33 / 43
Vibration welding

Advantages Disadvantages

1 Short cycle time, energy 1 High investment cost

efficient 2 Large parts are difficult
2 Welding of large parts to lock into fixtures
3 Insensitive to surface 3 Generation of fine
preparations particulates at the joints
4 No additional implants 4 Sound generation - 90 to
needed 95 dB.
5 In transparent materials
weld is optically clear

34 / 43
Vibration welding

Applications

Major thermoplastic parts with high volumes

Appliance industry for assembling such items as washer and dishwasher pumps,
particulate-filled soap dispensers, and dishwasher spray arms.
Automotive applications include headlight, tail light, and instrument panel
assemblies,dash-and-trim components, air-conditioning and heater ducts, vacuum
reservoirs, fuel filler doors, and air flow sensors.

35 / 43
Vibration welding
Joint designs

36 / 43
Adhesive bonding

Process

Metals-Ceramics-Polymers by attractive forces

Adsorptive: These forces result from intimate interaction between particles at the joint
surface, due to weak dipolar or van der Walls forces through chemical covalent bonds.
Electrostatic: These forces are due to ionic bonds between oppositely charged species
or molecules.
Diffusive: These forces result from molecular chain entanglements between the
adherend and adhesive.

37 / 43
Adhesive bonding

Classification of adhesives

1 Chemical type
1 Natural polymeric compounds
2 Inorganic materials
3 synthetic polymeric materials (thermoplastics, thermosets, elastomers)
2 Physical form
1 Liquids
2 Pastes
3 Films
4 Foams
3 Cure mechanism
Chemicall reactive, moisture cure, Anaerobic (must cure absence of air), hot melt, Light
cure (needs UV or near UV), Heat cure and pressure sensitive.
4 Function

38 / 43
Adhesive bonding

Curing of adhesives

39 / 43
Adhesive bonding
Joint designs

40 / 43
Adhesive bonding
Joint designs

41 / 43
Adhesive bonding

Applications

Joining dissimilar materials

Cosmetic Containers, Lighting, Optical Components, Sporting
Goods, Office Equipment and Toys,
Engineering applications - Automotive parts
Structural applications - Aerospace

42 / 43
Adhesive bonding

Advantages Disadvantages

1 Efficient, economical in 1 Limited shelf lives

joining dissimilar materials 2 Rigorous surface
2 Very versatile preparation, lengthy cure
3 lightweight to mechanical times
fastening 3 Messy and expensive
clean-up
4 Hazardous vapours
during curing

43 / 43