Where To Buy Plastic Welder
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Polyvance's 6059-C Nitro Fuzer Welding System is the most advanced nitrogen plastic welding equipment available. It comes with everything you need to get productive right away doing the fastest, strongest plastic repairs on virtually any type of plastic. Welding with nitrogen gas creates the strongest welds possible because it eliminates oxidation of the plastic during the welding process.
Plastic welding is welding for semi-finished plastic materials, and is described in ISO 472 as a process of uniting softened surfaces of materials, generally with the aid of heat (except solvent welding). Welding of thermoplastics is accomplished in three sequential stages, namely surface preparation, application of heat and pressure, and cooling. Numerous welding methods have been developed for the joining of semi-finished plastic materials. Based on the mechanism of heat generation at the welding interface, welding methods for thermoplastics can be classified as external and internal heating methods, as shown in Fig 1.
Production of a good quality weld does not only depend on the welding methods, but also weldability of base materials. Therefore, the evaluation of weldability is of higher importance than the welding operation (see Rheological weldability) for plastics.
Hot gas welding, also known as hot air welding, is a plastic welding technique using heat. A specially designed heat gun, called a hot air welder, produces a jet of hot air that softens both the parts to be joined and a plastic filler rod, all of which must be of the same or a very similar plastic. (Welding PVC to acrylic is an exception to this rule.)
In the case of webs and films a filler rod may not be used. Two sheets of plastic are heated via a hot gas (or a heating element) and then rolled together. This is a quick welding process and can be performed continuously.
A plastic welding rod, also known as a thermoplastic welding rod, is a rod with circular or triangular cross-section used to bind two pieces of plastic together. They are available in a wide range of colors to match the base material's color. Spooled plastic welding rod is known as "spline".
An important aspect of plastic welding rod design and manufacture is the porosity of the material. A high porosity will lead to air bubbles (known as voids) in the rods, which decrease the quality of the welding. The highest quality of plastic welding rods are therefore those with zero porosity, which are called voidless.
Heat sealing is the process of sealing one thermoplastic to another similar thermoplastic using heat and pressure. The direct contact method of heat sealing utilizes a constantly heated die or sealing bar to apply heat to a specific contact area or path to seal or weld the thermoplastics together. Heat sealing is used for many applications, including heat seal connectors, thermally activated adhesives and film or foil sealing. Common applications for the heat sealing process: Heat seal connectors are used to join LCDs to PCBs in many consumer electronics, as well as in medical and telecommunication devices. Heat sealing of products with thermal adhesives is used to hold clear display screens onto consumer electronic products and for other sealed thermo-plastic assemblies or devices where heat staking or ultrasonic welding is not an option due to part design requirements or other assembly considerations. Heat sealing also is used in the manufacturing of bloodtest film and filter media for the blood, virus and many other test strip devices used in the medical field today. Laminate foils and films often are heat sealed over the top of thermoplastic medical trays, Microtiter (microwell) plates, bottles and containers to seal and/or prevent contamination for medical test devices, sample collection trays and containers used for food products. Medical and the Food Industries manufacturing Bag or flexible containers use heat sealing for either perimeter welding of the plastic material of the bags and/or for sealing ports and tubes into the bags. A variety of heat sealers are available to join thermoplastic materials such as plastic films: Hot bar sealer, Impulse sealer, etc.
With freehand welding, the jet of hot air (or inert gas) from the welder is placed on the weld area and the tip of the weld rod at the same time. As the rod softens, it is pushed into the joint and fuses to the parts. This process is slower than most others, but it can be used in almost any situation.
With speed welding, the plastic welder, similar to a soldering iron in appearance and wattage, is fitted with a feed tube for the plastic weld rod. The speed tip heats the rod and the substrate, while at the same time it presses the molten weld rod into position. A bead of softened plastic is laid into the joint, and the parts and weld rod fuse. With some types of plastic such as polypropylene, the melted welding rod must be "mixed" with the semi-melted base material being fabricated or repaired. These welding techniques have been improved over time and have been utilized for over 50 years by professional plastic fabricators and repairers internationally. Speed tip welding method is a much faster welding technique and with practice can be used in tight corners.A version of the speed tip "gun" is essentially a soldering iron with a broad, flat tip that can be used to melt the weld joint and filler material to create a bond.
Extrusion welding allows the application of bigger welds in a single weld pass. It is the preferred technique for joining material over 6 mm thick. Welding rod is drawn into a miniature hand held plastic extruder, plasticized, and forced out of the extruder against the parts being joined, which are softened with a jet of hot air to allow bonding to take place.
This is the same as spot welding except that heat is supplied with thermal conduction of the pincher tips instead of electrical conduction. Two plastic parts are brought together where heated tips pinch them, melting and joining the parts in the process.
Related to contact welding, this technique is used to weld larger parts, or parts that have a complex weld joint geometry. The two parts to be welded are placed in the tooling attached to the two opposing platens of a press. A hot plate, with a shape that matches the weld joint geometry of the parts to be welded, is moved in position between the two parts. The two opposing platens move the parts into contact with the hot plate until the heat softens the interfaces to the melting point of the plastic. When this condition is achieved the hot plate is removed, and the parts are pressed together and held until the weld joint cools and re-solidifies to create a permanent bond.
High Frequency welding, also known as Dielectric Sealing or Radio Frequency (R.F.) Heat Sealing is a very mature technology that has been around since the 1940s. High frequency electromagnetic waves in the range of radio frequencies can heat certain polymers up to soften the plastics for joining. Heated plastics under pressure weld together. Heat is generated within the polymer by the rapid reorientation of some chemical dipoles of the polymer, which means that the heating can be localized, and the process can be continuous.
Only certain polymers which contain dipoles can be heated by RF waves, in particular polymers with high loss power. Among these, PVC, polyamides (PA) and acetates are commonly welded with this technology. In practice, two pieces of material are placed on a table press that applies pressure to both surface areas. Dies are used to direct the welding process. When the press comes together, high frequency waves (usually 27.120 MHz) are passed through the small area between the die and the table where the weld takes place. This high frequency (radio frequency) heats the plastic which welds under pressure, taking the shape of the die.
RF welding is fast and relatively easy to perform, produces a limited degradation of the polymer even welding thick layers, does not create fumes, requires a moderate amount of energy and can produce water-, air-, and bacteria-proof welds. Welding parameters are welding power, (heating and cooling) time and pressure, while temperature is generally not controlled directly. Auxiliary materials can also be used to solve some welding problems. This type of welding is used to connect polymer films used in a variety of industries where a strong consistent leak-proof seal is required. In the fabrics industry, RF is most often used to weld PVC and polyurethane (PU) coated fabrics. Other materials commonly welded using this technology are nylon, PET, PEVA, EVA and some ABS plastics. Exercise caution when welding urethane as it has been known to give off cyanide gasses when melting.
When an electrical insulator, like a plastic, is embedded with a material having high electrical conductivity, like metals or carbon fibers, induction welding can be performed. The welding apparatus contains an induction coil that is energised with a radio-frequency electric current. This generates an electromagnetic field that acts on either an electrically conductive or a ferromagnetic workpiece. In an electrically conductive workpiece, the main heating effect is resistive heating, which is due to induced currents called eddy currents. Induction welding of carbon fiber reinforced thermoplastic materials is a technology commonly used in for instance the aerospace industry.
In a ferromagnetic workpiece, plastics can be induction-welded by formulating them with metallic or ferromagnetic compounds, called susceptors. These susceptors absorb electromagnetic energy from an induction coil, become hot, and lose their heat energy to the surrounding material by thermal conduction.
Injection welding is similar/identical to extrusion welding, except, using certain tips on the handheld welder, one can insert the tip into plastic defect holes of various sizes and patch them from the inside out. The advantage is that no access is needed to the rear of the defect hole. The alternative is a patch, except that the patch can not be sanded flush with the original surrounding plastic to the same thickness. PE and PP are most suitable for this type of process. The Drader injectiweld is an example of such tool. 781b155fdc