Plastic as a category of material is a very large one with literally thousands of variations within it, and each has its own properties which make it suited for specific applications. Because of this, there is a wide range of plastic welding processes which engineers and product designers need to be familiar with when developing a new product.
Here’s an introduction to what you need to know about plastic welding.
Types of Plastics: Thermoplastic or Thermosetting?
While there are thousands of varieties of plastic, there are two main types which they can be divided into. The type of plastic you use will determine which assembly supplies you require.
- The most common plastics used are thermoplastics as they can go through several cycles of melting and solidifying with compromising its structural integrity. Thermoplastics are often supplied as sheets or pellets so that they can be melted into the desired shape as many times as needed. Such examples of thermoplastics include Polyester, Acrylic, and Nylon.
- Thermosetting plastics or thermosets remain solid and cannot be melted as the molecules will not reform when cooled. It is not possible to recycle thermoplastics.
Plastic Welding Processes
While there are several plastic welding processes, and each has its own pros and cons, depending on the type of job you’re working on, the basic principle of welding uses heat, pressure, and filler material to fuse the two pieces of plastic.
The process itself can be quick and cheap, but knowing which plastic welding process is the best for you can be difficult when there are so many different ways to do so. Here are three types of welding you might consider when starting.
· Hot Gas Welding
This is a manual plastic welding process which uses heat and dry air from a specifically designed hot gas gun, known as a hot air welder which will soften both parts of the plastic joint and a plastic filler rod (these must be the same or a similar type of plastic) and form it as one. This is one of the quickest processes and is ideal for manufacturing small items such as plumbing fittings.
· Friction Welding
Compared to using a specially designed tool like the hot gas gun, this type of welding involves using friction to produce the heat to join the pieces together. Not only is it efficient as it can form the object in seconds, but it also will clean the surfaces that are being joined together.
· Solvent Welding
Instead of using heat to join the plastic pieces, this form of welding uses a solvent which will soften the two pieces. Once this solvent has evaporated, the two pieces will have welded together and hardened.
The Right Welding Equipment
Welding is one of the most effective methods for joining two plastic components as long as you have the right tools so you can carry it out efficiently but also safely. Some of the basic equipment for welding include:
- Welders
- Electrodes
- Angle Grinders
- Clamps
You should also invest in the correct safety and protective gear. To ensure that no harm comes to you while welding, you must wear a helmet, gloves, and leather clothing. However, this can get very warm, so many welders choose to wear long sleeves, gloves, and a leather apron and opt for an open back.