When joining two plastics together, a key component is the type of plastic to be heated and joined. It is essential to weld like-plastic with like-plastic, such as polypropylene to polypropylene, polyurethane to polyurethane, or polyethylene to polyethylene.
Below are some tips to help you get ready to weld. There are several things to consider when welding plastics. Plastic welds have a similar appearance to metal welds, and therefore, many of the same welding techniques are used. Below are the six most common types of plastic welds:. A quality plastic welder can make you a hero! We know that you can buy plastic welding guns, tools, equipment, and kits from Harbor Freight, Amazon, Walmart, Home Depot, and the like - the choice is really up to you.
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Three Main Steps in Plastic Welding? A Plastic Repair Guide How to weld plastic? Three Main Steps in Plastic Welding There are three main steps for a good join between thermoplastics, which are pressing ensuring sufficient pressure when pushing the plastics together , heating achieving the right melt temperature , and cooling length of time the join is allowed to cool before releasing the pressure.
Pressing: The application of pressure, which is often used throughout both the heating and cooling stages, is used to retain the parts in the proper orientation and to improve melt flow across the interface. Heating: The purpose of the heating stage is to allow intermolecular diffusion from one part to the other across the faying surface melt mixing. Cooling: Cooling is necessary to solidify the newly-formed bond; the execution of this stage can have a significant effect on weld strength.
Methods of Plastic Welds There are several methods of plastic welding, which are primarily differentiated by their heating methods, and all processes are divided into two general categories of internal and external heating. The most common methods of plastic welding are the following: Hot Air Welding Hot air welding is also known as hot gas welding and is a process that utilizes the heat of hot gas, usually air that has been heated by electric heating elements in the welding gun.
Ultrasonic Welding Ultrasonic plastic welding is the joining or re-forming of thermoplastics through the use of heat generated from high-frequency acoustic vibration. Radio Frequency Welding Radio frequency welding is similar to ultrasonic welding, but instead of using acoustic vibrations, it uses high-frequency electrical energy radio waves.
Spin Welding The spin welding process consists of two parts brought together by friction from the rotation of one part at high velocity while the other part remains stationary. Vibration Welding The vibration welding process also known as friction welding is when parts are rubbed together at a certain frequency and amplitude, causing friction and generating heat. Laser Welding In the laser welding method, two parts are pressed together, and a laser beam moves along the joining line.
Hot Plate Welding The hot plate welding process also known as Butt welding applies heat from a hot plate hot plates are made from aluminum alloys that is placed between the plastic surfaces needing bonding. Contact Welding In contact welding, the heat is supplied with thermal conduction.
Automatic Welding Automatic welding is a chosen process to manual welding. Benefits and Advantages of Plastic Welding Joining plastics together can be done with adhesives, mechanical fasteners, and through welding. A plastic weld is permanent, whereas mechanical fasteners and adhesives may not be. Plastic welds are light in weight. Plastic welding can provide a leak-tight, airtight seal. Are there any specific advantages to the different methods of plastic welds?
Work in a well-ventilated area and use heat-resistant gloves and long-sleeved clothing for protection. Clean the plastic with soap and water, or if needed, with a cleaning solvent like MEK methyl ethyl ketone. Ensure to remove all debris and dry plastic with a lint-free cloth. If your plastic has paint on it, remove the paint with grit sandpaper — but be careful not to scratch the plastic! Then choose a welding rod that matches that type of plastic.
Hold the pieces of plastic together with a clamp and tape and form the joint before you turn on the torch. Pre-heat the welding gun for at least 2 minutes. Using a tacking nozzle, run the tip of the nozzle along the weld line, which ensures a slight melting of the two plastics together, thus closing up the joint interface and preventing the plastics from moving as you complete the weld.
Trim the end of the welding rod using angle cutting pliers. Insert the welding rod into a speed nozzle on your welding gun. Move the tip of your welding gun over the plastic, touching just the edge of the nozzle to the plastic. Heat until you see the plastic begin to melt. Be consistent in terms of pressure and pace. Move at a steady, deliberate pace so you can melt the plastic just enough to bind them without burning them.
Upon completion of your weld, wait at least 5 minutes for the plastic to cool. What to consider when welding plastics? Below or above that range will result in not melting enough or burning the plastic. Ensure to know what temperature you need based on what type of plastic you are welding.
The Welding Gun — Manual hand-held welding tools are used for small fabrication work, detailed projects, and repair work, and should not be used for thicknesses beyond 10mm. For larger fabrications, use extrusion welding tools. A Welding Kit — For beginners, plastic welding kits are a great option because they are fully equipped with what you need for most repairs. Kits come with a welder, varying welder rods, welding tips, and a guide to help you through your welding process.
Types of Plastic Welding Seams Plastic welds have a similar appearance to metal welds, and therefore, many of the same welding techniques are used. Plastic Welding Hand Tools A hand tool is essential for welding plastic materials upto 10mm thick or tacking structures of thicker material together prior to welding with an extruder. Plastic Welding Extruders For thicker materials over 10mm thick a hand extruder becomes the desired tool for efficiency and professional finish.
Plastic Welding Kits For a straight 'Out of the Box' solution for general plastic welding and repair we have a selection of pre-configured plastic welding kits available to Buy Online.
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