Induction welding is a fast and distortion-free method of joining thermoplastic materials. A magnetic powder is used to heat the compound, which melts and forms a strong joint almost instantly.
Induction welding is a welding method often used to join thermoplastic materials. Use a power supply and heating coil to melt a small amount of joint compound at the joint between two pieces of plastic. A typical weld takes only seconds to complete, produces strong joints and does not distort the material being joined.
Thermoplastics are plastics made from polymer resins. When cold, they are solid, but melt easily when heat is applied. Celluloid, acrylic and polyurethane are all common types of thermoplastics. They are used to make everything from bird feeders to car parts.
An operator begins the induction welding process by placing a small amount of thermoplastic compound into the joint between the two pieces to be welded. This compound can take the form of ribbon or wire or be shaped as a gasket. It is made with the same polymer as the pieces to be joined or with a compatible polymer.
The compound contains a magnetic powder at a concentration of approximately 15% by volume. This powder is usually iron, iron oxide or stainless steel and is used to aid in the heating of the compound. The faster the compound heats up, the faster the weld is completed.
The heat is supplied by an induction coil connected to a high frequency power supply such as a radio frequency generator. When the generator is turned on, alternating current (AC) passes through the coil. This produces eddy currents, which heat up the magnetic powder. When the surrounding thermoplastic compound gets hot enough, it softens and melts. At this point, light pressure applied to the pieces to be joined will result in the formation of a joint.
Induction welding has many advantages over other methods of joining parts. First, it’s fast. The thermoplastic compound melts within seconds when heated and cools almost instantly when power is removed, forming a solid joint almost instantly. Secondly, induction welding does not distort the materials being welded. Since the heat is directed at the compound rather than the parts being joined, the parts are less likely to experience heat stress.
Finally, the use of a thermoplastic compound results in strong joints. The compound completely fills any gaps between the two pieces to be joined, preventing weak spots. Also, as the compound completely dissolves and re-solidifies, it actually forms a molecular bond with the materials being joined. This results in a joint that is nearly as strong as the material itself.
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