JOINING OF

PLASTICS
BY
S.SUGUMAR
CIPET -
CHENNAI
 JOINING OF PLASTICS
Methods used for Joining of Plastics may be grouped
according to principle on which the bond is made.

I.Cohesion Principle
Involves an actual intermingling of molecules of the
materials being joined.
Some means is employed to cause two materials
to flow together and fuse.
Two techniques in this category
- Solvent cementing
- Thermal welding
Cohesive bonding involves joining of similar pieces.
different materials may be joined only when the flow
properties are similar.
II. Adhesion Principle
makes use of film which adheres to each other material to be
joined.
An adhesive, a substance different from either of the
materials remains in the joint.

III. Mechanical Linkage

Involves production of a linkage between the two materials

which simply holds the two together physically with neither
flow of either material not Sticking
(eg.) Screws for joining of plastics, Rivets, Nut & Bolt
systems, etc.
SOLVENT CEMENTING
Used commonly with amorphous polymers such as
PS,ABS,PC,PMMA which are readily attacked by solvents.
Not commonly used with crystalline thermoplastics.
Not applicable for Thermosets.

Solvents for cementing of plastics

ABS MEK, Methyl Isobutyl Ketone, Methylene Chloride
Acrylic Methylene Chloride, Ethylene dichloride
Cellulosics MEK
Nylon Aqueous Phenol, Solutions of Resorcinol in alcohol.
PP Trichloro ethylene, ethylene dichloride
chloroform and methylene chloride

PVC Cyclohexane, Tetra hydrofurane

Dichlorobenzene

PC Mehtylene Chloride & Ethylene dichloride

PS Styrene, Methylene Chloride, Ethylene

Dichloride Acetone.

Polysulfone Methylene chloride

Dope Cement
solvent + Small quantity of the same plastic
which is to be bonded.
(e.g) PVC + Cyclohexane or THF is the dope
cement for PVC.

Pre treatment of the substrate is essential before

bonding.
Abrasion using emery cloth-solvent wipe with ketene
in the case of PVC.
MEK is the common dope cement for low/medium m.wt
PVC.
Cyclohexane or THF for high m.wt PVC.
SPVC bonding typical formulation:

PVC resin - 100 parts by wt.

THF - 100 parts by wt.

MEK - 200 parts by wt.

Tin organic stabilize - 1.5 parts by wt.

MIBK - 2.5 parts by wt.

 Adhesives
Elastomeric
(e.g.) NR, Neoprene, Nitrile, etc., used for joining plastic to metals
to metal, etc.
Good bond strength and high degree of joint flexibility could be
achieved.
Thermoplastic
Solvent based
Hotmelt Adhesive
Only one of this type cyanoacrylate cure through polymerization.

Thermosetting
(E.G) PF,,epoxide, Polyester resin,
Most versatile and durable
Methods of Adhesive Application

Brushing :- low cost, uniform application is difficult

to achieve.

Dipping :- masking is required for partial

application

Roll coating

Spraying :- rapid method for large area application

 WELDING
Process of joining similar or dissimilar materials with similar flow
behaviour by thermal means.
Joining of Thicker sections welding, Thin films sealing

Direct heat welding

Hot plate or Heated Tool Welding
Hot air welding / Hot gas welding
Resistance wire welding
Thermostacking

Indirect Thermal welding

Ultrasonic welding
Spin/ Friction welding
Vibration welding
Dielectric heating or High frequency sealing.
 HOT plate WELDING:
Plastic components to be welded are
partially melted by being in contact with a
high temperature thermal source or a hot
plate, and then welded together before they
become cold and solidify.
As a method to obtain relatively firm
welding with the relatively simple
equipment, this method has long been used
and is particularly suitable for large
moldings.
 Hot plate WELDING PROCESS
The equipment consists of a hot plate to
simultaneously heat two surfaces to be welded and
a pressurizing mechanism.

First step : Moldings to be joined are kept in

contact with the hot plate to melt the welding
areas.
Second step : Two molten surfaces are kept in
contact each other and held until they are cooled
and solidified.
PROCESS OF HOT PLATE WELDING
Typical hot plate temperature to weld plastics
ABS - 210 Deg-C - 230 Deg C
PP - 190 Deg-C 210 Deg C
PVC - 210 Deg-C 220 Deg C
 Pressure between a work piece
and a hot plate
Minimum pressure to achieve close contact of
the work piece with the hot plate
If the pressure is too high, the dimension can be
smaller than the specification and flash may be
generated.

If the pressure is too high, a flash is generated.

 When the welding machine is not equipped with a
pressure controller, some invention on the side of jigs is
required, for example the installation of stoppers.
 Measures to prevent sticking or the
adhesion of molten resin to a hot plate.

To use polytetrafluoroethylene (PTFE) sheets or to

coat the hot plate with PTFE.
Note : Mirror finish on the surface of the hot plate is
required before the coating with PTFE.

Example of measures to prevent sticking .

Typical joints-Hot Plate Welding
 FEATURES OF HOT PLATE WELDING:
merits
High weld strength and efficiency. The highest in all
known welding processes.
Relatively large degree of freedom in the total shape of
the component and in the design of welding portion.
Demerits
Since the transfer of heat from the hot plate to the
moldings is required, processing cycle time becomes
relatively long.
Measures to prevent the sticking of molten plastics to the
hot plate is necessary, otherwise stringing may happen.
Hot gas welding / Hot air welding
Applies only to thermoplastics
Hot air/ Hot gas (Nitrogen) is used
The principle of welding with hot air is to make plastic flow at the
conjunction of two pieces (or two pieces and a welding rod of parent
material) such that under a small amount of pressure the material
will intermix and fuse together to give a homogeneous bond.
Materials to be welded must be of the same type or similar flow
behaviour.
The temperature of the hot air should be sufficient to make the
plastic begin to flow
Temperature required varies with plastics, usually between 270
Deg-c 350Deg-c under 3 to 4 lbs/sq in pressure.
Preparation Stages
Supply air to hot air gun should be free water or oil.
The material to be welded together and the welding rod
must of the same grade of plastic.

Some plastic need special attention

PMMA, PC, ABS, easily absorb moisture and therefore

they should be stored at warm and dry conditions prior to
welding.
PE & PP may quickly oxidise. Therefore the surfaces to
be welded, including the welding rod should either be
mechanically scraped or cleaned with solvent such as
Trichloro Ethylene or Acetone.
Thermostacking
Thermostacking uses a system of hot air and cold stacking to form a stud
that joins plastic to plastic or plastic to metal, producing a tight assembly.

Process
A holding fixture secures the plastic part to be stacked. Plastic studs
protrude through holes in the material of the connection part. A heating manifold
covers the protruding plastic studs and soften the plastic with finely controlled hot
air. When plastic reaches a sufficiently molten stage, the heat ceases and a cold
stake head descends. The cold stake head forms the plastic stud, solifides it and
creates a permanent head.

Advantages :
Tight mechanical connection
Low production cost : can simultaneous stake multiple studs.
High speed production
No damaged to outside surface.
Resistance wire and Induction Welding

A wire of high electrical resistance (nichrome wire) is placed

between the mating surfaces of the two thermoplastic parts.

Current flow in the wire generates heat to soften the adjacent

plastic surfaces which can be pressed together to complete the

joint

The wire will remain in the joint

High speed welding process.

Any thermoplastic could be welded.

Dielectric or High frequency heat
sealing
Involves the use of electronic waves from an AC
generator passing through a plastic sheet or film.
These waves causes high level molecular friction
with in the plastic so that heat is generated with in the
plastic and the plastic will melt at the point of contact.
By applying pressure at this point and allowing
sufficient cooling time, a permanent bond is formed.
Plastics commonly used ABS, PVD, PMMA.
Biggest use vinyl films raincoats, inflatable etc.
Spin Welding / Friction Welding
The generation of frictional heat by two rubbing surfaces is utilized to
join materials in the friction welding process.
The temperature at the rubbing surfaces raises to beyond the melting
point of the plastic material in few seconds.
Final forging action ensures the weld is cooled in compression and forms a
high integrity joint.

Materials
Both amorphous and semi- crystalline thermoplastic can be
joined by friction welding
The major welding variables are :-
- rotation speed, pressure and cooling time

Applications
- Plastic floats - Pipes
- Shafts - Pressure vessels.
Vibration Welding
Also called linear friction welding.

Instead of rotary motion causing frictional heat in friction

welding, in vibration welding the movement consists of linear
oscillations.

Once molten material has been generated at the interface,

vibration is stopped and the parts are aligned and weld
consolidates on cooling.

Weld time 1 to 5 sec.

Vibrations applied 100 240 Hz

Pressure 1 to 4 n/mm 2
Main Advantages
Very large complex linear joints can be produced at
high production rates.
Suitable to weld almost all thermoplastics.

Examples:
Automobiles parts Front and rear light assemblies,
fuel filter, instrument panel, reservoirs for brake, etc.
 ULTRASONIC WELDING
PROCESS
Ultrasonic welding is a process in
which strong frictional heat is
generated at the portions of moldings
to be welded by simultaneously
applying pressure and ultrasonic
vibration, to melt and weld these
portions.
Ultrasonic Welding : Equipment consists of:-

Generator : - Converts electrical energy from main supply

frequency of 50 HZ to an ultrasonic frequency of 20 KHz.

Mechanical Resonance Unit:-

Converts electrical output from generator into mechanical

vibrations which consists of transducer, booster and sonotrode.

Transducer : uses a piezo electric material (lead zirconate

titanate ) for conversion of electrical energy to mechanical
vibrations.

Transformer(Booster) : Transmits mechanical vibratory energy to

the sonotrode and transforms the vibrations amplitude delivered by
the transducer to the value required at the sonotrode.
Sonotrode:- is welding, stacking and insertion tool,
performs the function of transmitting vibratory energy,
and contact force and carrying on the forming
operation.
Welding with rigid PVC is good and SPVC is poor
Metal insertion is also possible.