Plastic welding fuses plastic parts together by heating and melting them, creating a chemical bond. Different methods are used based on the equipment, materials, and base plastic. Ultrasonic, vibration, laser, and thermoplastic welding are used for airless welding. Plastic welding is used for repairing expensive parts, creating waterproof containers, and manufacturing products like automotive parts and large panels.
Plastic welding is a manufacturing method used to fuse plastic parts together. The process works by heating portions of each piece until they soften or liquefy. As the plastic cools, a chemical bond forms between them that fuses the pieces together. A thermoplastic welding rod is commonly used to act as a glue between the two pieces.
Different plastic welding methods are employed for different purposes. They vary according to the type of welding equipment and the welding materials used. The base material from which the plastic component is made also affects the method used to weld the plastic. Thermoplastics are generally preferred due to their ability to be repeatedly melted and resolidified.
Hot gas welding uses a jet of heated air to weld plastic. The hot air softens and melts the plastic to allow the pieces to fuse. A heat gun designed for this technique guides the airflow for better accuracy. Welding rods, usually of the same material as the two base plastics, fill the space between the pieces.
An airless welder heats the welding rod through a heating machine or process. This method helps prevent excessive material buildup from the member and deformation of the base materials. Airless welding is especially useful for welding thermosets. These are plastics that do not melt easily when exposed to high heat.
Light and vibration are two plastic welding techniques for airless welding. Various materials that cannot be welded with hot gas can often be melted using these processes. They are also used to weld parts that typically need to maintain their relative thinness. These methods include ultrasonic, vibration, laser, and thermoplastic welding.
Ultrasonic welding applies low-amplitude, high-frequency vibrations to weld parts. The vibration produces heat, just like when you rub your hands, which brings the two pieces together. The heat and pressure from the ultrasonic welder creates a quick and seamless weld between the two pieces. This is suitable for manufacturing small components such as flash drives and semiconductors.
Vibration welding has a higher amplitude and lower frequency than ultrasonic welding. The pressure added to materials as they are vibrated causes additional heat. The concentration of energy on the material surfaces reduces unintentional melting and provides a stronger weld without added weight.
Laser welding uses light to melt materials. For laser welding, one material should be transmissive to light while the other should be absorbent. The two materials are joined under pressure. A laser beam is then passed from the transmissive material through the absorbing material. This generates heat and creates a permanent weld.
Thermoplastic welding is the opposite of laser welding. In this technique, the laser passes from a transparent material through a colored material that traps light. The transmissive material then fuses into the absorbent material which fuses them.
There is a wide range of applications for plastic welding. Plastic parts that might be expensive to replace can often be repaired when new parts are welded on. Waterproof and airtight containers such as water tanks and ventilation ducts are sometimes assembled by plastic welding. It is also commonly used to manufacture products such as automotive parts and large panels.
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