Skip to content
Licensed Unlicensed Requires Authentication Published by De Gruyter March 26, 2013

Welding of Plastics: Fundamentals and New Developments

  • D. Grewell and A. Benatar

Abstract

This paper provides a general introduction to welding fundamentals (section 2) followed by sections on a few selected welding processes that have had significant developments or improvements over the last few years. The processes that are discussed are friction welding (section 3), hot plate welding (section 4), ultrasonic welding (section 5), laser/IR welding (section 6), RF welding (section 7) and hot gas/extrusion welding (section 8).


Mail address: D. Grewell, ABE, Iowa State University, 100 Davidson Hall, Ames, IA 50011 USA. E-mail:

References

1Grewell, D., et al.: Plastic and Composite Welding Handbook, Hanser Publishers, Munich (2003)Search in Google Scholar

2Tres, P.: Designing Plastic Parts for Assembly, Hanser Publishers, Munich (2005)Search in Google Scholar

3Dixon, J., Grewell, D.: Welding and Fusion Bonding of Plastics, in Welding Handbook, Volume3American Welding Society, Miami FL. (1996)Search in Google Scholar

4Rotheiser, J.: Joining of Plastics in Handbook for Designers and Engineers, Hanser Publishers, Munich (2004)Search in Google Scholar

5DeGennes, P. G.: Reptation of a Polymer Chain in the Presence of Fixed Obstacles, Journal of Chemical Physics55, p. 572 (1971)10.1063/1.1675789Search in Google Scholar

6Wool, R.: Polymer Interfaces, Structure and Strength, Hanser Publishers, Munich (1995)Search in Google Scholar

7Grewell, D., Benatar, A.: Coupled Temperature, Diffusion and Squeeze Flow Models for Interfacial Healing Predictions, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (2006)Search in Google Scholar

8Jud, K., et al.: Fracture Mechanics Studies on Crack Healing and Welding of Polymers, Journal of Material Science16, p. 204 (1981)10.1007/BF00552073Search in Google Scholar

9Loos, A. C., Dara, P. H.: Thermoplastic Matrix Composites Processing Model, Interm Report57 NASE Cooperative Agreement NAG-1-343 (1985)Search in Google Scholar

10Grewell, D.: Modeling of molecular healing for Micro-Laser welding of plastics with diffractive optical elements as spatial modulators, Ph.D. Dissertation, The Ohio State University, Columbus, p.121 (2005)Search in Google Scholar

11Bastien, L. J., GillespieJr., J. W.: A Nonisothermal Healing Model for Strength and Toughness of Fusion Bonded Joints of Amorphous Thermoplastics, Polymer Engineering and Science31, p. 1720 (1991)10.1002/pen.760312406Search in Google Scholar

12Carslaw, H. S., Jaeger, J. C.: Conduction of Heat in Solids, Oxford University Press, London (1959)Search in Google Scholar

13Rohsenow, W. M., Choi, H.: Heat, Mass, and Momentum Transfer. Prentice-Hall, Englewood Cliffs, N.J. (1961)Search in Google Scholar

14Stevens, S. M.: The Evaluation of Molecular Orientation and Structural Changes in Polypropylene Welds, TWI Report (1991)Search in Google Scholar

15Park, J. B., Benatar, A.: Moire Interferometry Measurement of Residual Strains in Implant Resistance Welding of Polycarbonate, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (1992)10.1117/12.57420Search in Google Scholar

16Park, J. B., Benatar, A.: Thermal and Residual Stress Formation during Plastic Welding, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (1991)Search in Google Scholar

17Anantharaman, S., Benatar, A.: Measurement of Residual Stresses in Clearwelds using Photoelasticity, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (1993)Search in Google Scholar

18Anantharaman, S., Benatar, A.: Measurement of Residual Stresses in Laser welded Polycarbonate using Photoelasticity, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (2003)Search in Google Scholar

19Park, J. B.: Theoretical and Experimental Analysis of Residual Stress Formation after Implant Resistance Welding of Polycarbonate, Ph.D. Thesis (1992)Search in Google Scholar

20Schaible, S., Cakmak, M.: Dynamics and Structure Development in Spin Welding of Polyvinylidene Fluoride Cylindrical Rods, Int. Polym. Process. 10, p. 270 (1995)10.3139/217.950270Search in Google Scholar

21Grewell, D., Benatar, A.: A Process Comparison of Orbital and Linear Vibration Welding of Thermoplastics, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastics Engineers, Brookfield, CT (1999)Search in Google Scholar

22Stoke, V. K.: Vibration welding of Thermoplastics. Part I, Polymer Engineering and Science28, p. 718 (1988)10.1002/pen.760281104Search in Google Scholar

23Stokes, V. K.: Analysis of Friction (spin) – Welding Process for Thermoplastics, Journal of Materials Science23, p. 2772 (1988)10.1007/BF00547450Search in Google Scholar

24Bacher, J.: New Advanced Digital Vibration Welder to Weld Thermoplastic Assemblies, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (2002)Search in Google Scholar

25Tucker, D. B., Bates, P., Tucker, R., Sidiropoulos, V.,: Improving Vibration Weld Joint Strength through Process and Equipment Modifications, Science and Technology of Welding and Joining9, p. 443 (2004)10.1179/136217104225021562Search in Google Scholar

26Vetter, J.: Vibration Welding Plus, Plast Europe Kunststoffe95, p. 138 (2005)Search in Google Scholar

27Pontent, H.: Innovations and Potentials of the High-speed Hotplate Welding, Second International Conference on Joining Plastics, A Smithers Group Company, London (2006)Search in Google Scholar

28Ultrasonic Plastics Assembly, Branson Ultrasonics Inc., Danbury, CT (1979)Search in Google Scholar

29Ensminger, D.: Ultrasonics: Fundamentals, Technology, Applications, 2nd Edition, Marcel Dekker, New York (1988)Search in Google Scholar

30Grewell, D., Frantz, J.: Amplitude Control in Ultrasonic Welding of Thermoplastics, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (1994)Search in Google Scholar

31Grewell, D.: Amplitude and Force Profiling: Studies in Ultrasonic Welding of Thermoplastics, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (1996)Search in Google Scholar

32Herrmann, T.: Ultrasonic Twin Converter Technology for Welding Large Plastic Parts or Packages, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastics Engineers, Brookfield, CT (2004)Search in Google Scholar

33http://www.rincoultrasonics.com/english/news.htm, visited 3/20/2006, Dynamic 745 Product LineSearch in Google Scholar

34Sonics, Ultrasonic ElectroPress, Press release, Sonics and Materials (2004)Search in Google Scholar

35 U.S. Patent 5590866 (1997) Cunningham, P.Search in Google Scholar

36CompuWeld 2000/Compuweld Viewer, Branson Ultrasonics, Data Sheet PW-51Search in Google Scholar

37 U.S. Patent 3382343 (1968) Muncheryan. H.Search in Google Scholar

38Grewell, D., Nijenhuis, W.: TTIr Welding of Aliphatic Polyketone, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastics Engineers, Brookfield, CT (2000)Search in Google Scholar

39Pontente, H., Becker, F.: Weld Strength Behavior of Laser Butt Welds, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastics Engineers, Brookfield, CT (1999)Search in Google Scholar

41Grewell, D., et al.: Plastic and Composite Welding Handbook, Munich, p. 291 (2003)Search in Google Scholar

40Prabhakaran, R., et al.: Simulation of Heat Transfer in Laser Transmission Welding, Int. Polym. Process. 20, p. 410 (2005)10.1515/ipp-2005-0069Search in Google Scholar

42Lizotte, T.: Beam Shaping for micro-drilling, PC Fab Magazine26 (2), p. 28 (2003)Search in Google Scholar

43Grewell, D.: Modeling of Molecular Healing for Micro-Laser Welding of Plastics with Diffractive Optical Elements as Spatial Modulators, Ph.D. Dissertation, The Ohio State University, p.41 (2005)Search in Google Scholar

44 Leister Corp, Novolas, Sales Broacher, 10/04Search in Google Scholar

45Kagan, V., Bray, R., Chambers, A.: Forward to Better Understanding of Optical Characterization and Development of Colored Polyamides for the Infra-Red/Laser Welding – Part I: Efficiency of Polyamides for Infra-Red Welding, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (2001)Search in Google Scholar

46Hänsch, D.: Die optischen Eigenschaften von Polymeren und ihre Bedeutung für das Laserdurchstrahlschweißen, Dissertation RWTH Aachen, Aachen (2001)Search in Google Scholar

47NN: Laserschweißen farbiger Kunststoffe – Der Griff in die Trickkiste, Kunststoffea 94, p. 121 (2004)Search in Google Scholar

48Extol's InfraStakeTM Sales Brocher, Extol, Inc.Zeeland, MI (2006)Search in Google Scholar

49Gorbold, J.: On-Demand Bonding & Sealing Of Polyethylene & Polypropylene Components, Technotes, CODACO Inc. (2005)Search in Google Scholar

50 U.S. Patent 7 012 232 (2006) Gruenspecht, R. F.10.1088/1126-6708/2006/10/012Search in Google Scholar

51 Webpage, http://www.colpitt.nl/pages/rf-generators.htm, (2006)Search in Google Scholar

52Ziegler, D.: Introduction to thermoplastics welding in industrial fabrication, International Association of Plastics Distributors Journal Feb./March, p. 13 (2006)Search in Google Scholar

53Grewell, D.: Feasibility Study for the Use of Ultrasonic NDI as a Melt Detection in Heated Tool Welding of PE, Annual Technical Conference for the Society of Plastic Engineers Proceedings, Society of Plastic Engineers, Brookfield, CT (1993)Search in Google Scholar

Received: 2006-4-30
Accepted: 2006-11-17
Published Online: 2013-03-26
Published in Print: 2007-03-01

© 2007, Carl Hanser Verlag, Munich

Downloaded on 19.4.2024 from https://www.degruyter.com/document/doi/10.3139/217.0051/html
Scroll to top button