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Classification of polymers
Thermoplastics
•Above the melting point,
the secondary bonds
weaken, making it easier to
form the plastic into any
desired shape
•On cooling, it returns to its
original strength and
hardness
•reversible process.
Thermosetting Plastics (thermosets)
•Permanent shape
•Cannot be re-melted
•continued heating leads to
degradation or decomposition
•better mechanical, thermal and
chemical properties
•better electrical resistance and
dimensional stability than do
thermoplastics.
There are two major classifications of polymers
Uses of Plastics
 The modern car is made of many
different type of plastics, ranging
from shock absorbing bumper
bars to durable tyres and internal
fittings.
 Some plastics do not react with
other substances and are
chemically inert and non-toxic.
 Many pipes are now made out of a
plastic called polyvinyl chloride
(PVC).
 In kitchen a granite bench top is
actually made of hard, durable
plastic, while the tiles on the floor
are made of vinyl plastic.
 Some plastics (elastomers)are
very flexible and resist
melting,are used in making tyres.
Why Design with
Plastics?
 Corrosion resistance
 Low electrical and thermal
conductivity, insulator
 Easily formed into
complex shapes, can be
formed, casted and joined.
 Wide choice of
appearance, colors and
transparencies
Disadvantages of
using Plastics
 Low strength
 Low useful temperature
range (up to 600 o
F)
 Less dimensional
stability over period of
time (creep effect)
 Aging effect, hardens and
become brittle over time
 Sensitive to environment,
moisture and chemicals
 Poor machinability
Joining Methods of Plastics
Mechanical
Fasteners
Adhesives
Welding
Processes
• can join two components
quickly
do not provide leak
• tight joint
• good properties and fully
sound joints
• difficult to handle and
slow to
• cure
• to produce bonded joints
• confined to thermoplastic
polymers
Ultrasonic Welding
 Internal friction induced by ultrasonic
oscillation melts the boundary surfaces
of the joining partners. Fusion of the
parts is reached by applying a certain
pressure
 Advantages
 • Very short cycle times
 • Limited 3D contours – joints do not
have to be completely flat
 • Low maintenance costs
 Disadvantages
 • Flash generated
 • limited to small components
 • Particulate development – dust-like
particles left behind that may cause part
contamination
 expensive
Applications of Ultrasonic Welding
 Computer and electrical
industries
 Aerospace and automotive
industries
 Medical industry
 Packaging industry
Friction Welding
 Parts are rubbed together, the
friction created from this process
generates heat at the contacting
surfaces where the plastic becomes
molten and weldable
 Advantages
 • inexpensive process
 • Low maintenance
 • Low cycle times
 Disadvantages
 • large flash generated
 • High mechanical load
 • Limited design freedom
 • Large weld line width
Applications of Friction Welding
 domestic appliance
industry
 Automobile industry
Vibration Welding
 the vibrations applied
typically of 100 – 240 Hz, 1-5
mm amplitude
 parts are rubbed together due
to machine vibration
Advantages
 ability to weld a number of
components simultaneously
 Ability to join large no. of
pieces
Disadvantages
 For very small and light
parts
Applications of Vibration Welding
 Automobile industry
 domestic appliance
industry
Plastic and their joining processes for different industrial uses

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Plastic and their joining processes for different industrial uses

  • 1.
  • 2. Classification of polymers Thermoplastics •Above the melting point, the secondary bonds weaken, making it easier to form the plastic into any desired shape •On cooling, it returns to its original strength and hardness •reversible process. Thermosetting Plastics (thermosets) •Permanent shape •Cannot be re-melted •continued heating leads to degradation or decomposition •better mechanical, thermal and chemical properties •better electrical resistance and dimensional stability than do thermoplastics. There are two major classifications of polymers
  • 3. Uses of Plastics  The modern car is made of many different type of plastics, ranging from shock absorbing bumper bars to durable tyres and internal fittings.  Some plastics do not react with other substances and are chemically inert and non-toxic.  Many pipes are now made out of a plastic called polyvinyl chloride (PVC).  In kitchen a granite bench top is actually made of hard, durable plastic, while the tiles on the floor are made of vinyl plastic.  Some plastics (elastomers)are very flexible and resist melting,are used in making tyres.
  • 4. Why Design with Plastics?  Corrosion resistance  Low electrical and thermal conductivity, insulator  Easily formed into complex shapes, can be formed, casted and joined.  Wide choice of appearance, colors and transparencies Disadvantages of using Plastics  Low strength  Low useful temperature range (up to 600 o F)  Less dimensional stability over period of time (creep effect)  Aging effect, hardens and become brittle over time  Sensitive to environment, moisture and chemicals  Poor machinability
  • 5. Joining Methods of Plastics Mechanical Fasteners Adhesives Welding Processes • can join two components quickly do not provide leak • tight joint • good properties and fully sound joints • difficult to handle and slow to • cure • to produce bonded joints • confined to thermoplastic polymers
  • 6. Ultrasonic Welding  Internal friction induced by ultrasonic oscillation melts the boundary surfaces of the joining partners. Fusion of the parts is reached by applying a certain pressure  Advantages  • Very short cycle times  • Limited 3D contours – joints do not have to be completely flat  • Low maintenance costs  Disadvantages  • Flash generated  • limited to small components  • Particulate development – dust-like particles left behind that may cause part contamination  expensive
  • 7. Applications of Ultrasonic Welding  Computer and electrical industries  Aerospace and automotive industries  Medical industry  Packaging industry
  • 8. Friction Welding  Parts are rubbed together, the friction created from this process generates heat at the contacting surfaces where the plastic becomes molten and weldable  Advantages  • inexpensive process  • Low maintenance  • Low cycle times  Disadvantages  • large flash generated  • High mechanical load  • Limited design freedom  • Large weld line width
  • 9. Applications of Friction Welding  domestic appliance industry  Automobile industry
  • 10. Vibration Welding  the vibrations applied typically of 100 – 240 Hz, 1-5 mm amplitude  parts are rubbed together due to machine vibration Advantages  ability to weld a number of components simultaneously  Ability to join large no. of pieces Disadvantages  For very small and light parts
  • 11. Applications of Vibration Welding  Automobile industry  domestic appliance industry