Plastic welding

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.

On the other hand, production of a good quality weld can not only depend on the welding methods, but also weldability of base materials. Therefore, the evaluation of weldability is of critical importance before welding operation (see Rheological Weldability) for plastics.

A number of techniques are used for welding of semi-finished plastic products as given below:

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.)

Hot air/gas welding is a common fabrication technique for manufacturing smaller items such as chemical tanks, water tanks, heat exchangers, and plumbing fittings.

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.

...
Wikipedia