Vibration welding of thermoplastics. Part I: Phenomenology of the welding process

In vibration welding of thermoplastics, frictional work done by vibrating two parts under pressure, along their common interface, is used to generate heat to effect a weld. The main process parameters in vibration welding are the weld frequency, the amplitude of the vibratory motion, the weld pressure, and the weld time. How these parameters affect weld quality, the conditions that result in the best welds, the weldability of dissimilar plastics, and the effect of fillers such as glass are of interest. To address these issues, a research vibration welding machine in which all the parameters can be independently and accurately controlled and monitored was designed and fabricated. The phenomenology of welding, as determined by experiments on the four thermoplastics polycarbonate, poly (butylene terephthalate), polyetherimide, and modified poly (phenylene oxide), is described.     

Vibration welding of thermoplastics. Part III: Strength of polycarbonate butt welds

In vibration welding of thermoplastics, frictional work done by vibrating two parts under pressure, along their common interface, is used to generate heat to effect a weld. The main process parameters are the weld frequency, the amplitude of the vibratory motion, the weld pressure, and the weld time or weld penetration; The effects of these parameters on weld quality were systematically studied by first butt-welding polycarbonate specimens under controlled conditions over a wide range of process parameters, and by then determining the strengths and ductilities of these welds by tensile tests, A significant result is the apparent existence of a weld-penetration threshold above which high weld strengths are attained, but below which the strength drops off. Under the right conditions, the strengths of polycarbonate butt welds are shown to equal the strength of the virgin polymer.     

Estimates for process conditions during the vibration welding of thermoplastics

The aim of this work is to interpret experimental findings of Stokes and Schlarb on the basis of analytical formulas and finite element calculations. In the analytical approach, some simplifications that had to be made proved to be inappropriate. Only computer calculations may reveal the details of the processes involved in vibration welding. Comparison of the computer calculations with the experiments reveals that even transient effects in viscosity have to be considered. Viscosity is dependent not only on temperature and shear rate, but also on the frequency or amplitude of vibration. After correction for these effects, the correlation between theory and experiments proved to be excellent. Based on the calculations, some recommendations are presented to improve weld quality, as ascertained by the type of fracture in a tensile test, by changing the welding parameters.     

Estimates for process conditions during the ultrasonic welding of thermoplastics

Order of magnitude estimates are presented for processes that play a role in ultrasonic welding. The fact that the sonotrode may not always be in contact with the product being welded, which results in the sonotrode repeatedly hammering the product, is accounted for in this study. The calculations do not use estimates for loss or storage modulus of plastics at 20 kHz around the glass or melting point for amorphous or semicrystalline polymers respectively. The flow of molten polymer in the weld zone is shown to be a laminar viscous squeeze flow driven by the welding pressure. An energy balance is used to show that the heat generated by the internal damping is, in part, used in heating cold material and is squeezed out into weld flash. The theoretical findings are correlated with existing practical pointers on ultrasonic welding in series and mass production in industry.     

Vibration welding of thermoplastics. Part IV: Strengths of poly(butylene terephthalate), polyetherimide,and modified polyphenylene oxide butt welds

In vibration welding of thermoplastics, frictional work done by vibrating two parts under pressure, along their common interface, is used to generate heat to effect a weld. The main process parameters are the weld frequency, the amplitude of the vibratory motion, the weld pressure, and the weld time or weld penetration.; The effects of these parameters on weld quality were systematically studied by first butt welding thermoplastic specimens under controlled conditions, over a wide range of process parameters, and by then determining the strengths and ductilities of these welds by tensile tests. The three thermoplastics investigated are poly (butylene terephthalate), polyetherimide, and modified polyphenylene oxide. Changes in the weld pressure are shown to have opposite effects on the strengths of polyetherimide and modified polyphenylene oxide welds; Also, the weld frequency is shown to have a significant effect on the weldability of polyetherimide. The weldability data for these three thermoplastics are compared with data for polycarbonate. Under the right conditions, the strengths of butt welds in these materials are shown to equal the strength of the virgin polymer.     

Hot plate welding of polypropylene. Part II: Process simulation

A volume of fluid finite difference method based computer code was developed to simulate the heat transfer and squeezing flow in the hot-plate welding process. The simulation results include melt displacement, temperature distribution, and stress build-up and relaxation. By implementing the crystallization kinetic model developed in Part I, the formation of stress-induced crystal structure in the heat affected zone can be revealed.     

Experiments on the induction welding of thermoplastics

In induction welding of thermoplastics, induction heating of a gasket, made of a ferromagnetic‐powder‐filled bonding material and placed at the interface of thermoplastic parts to be joined, is used to melt the interface; subsequent solidification of the melt results in a weld. Tensile tests on induction butt‐welds of polycarbonate (PC), poly(butylene terephthalate) (PBT), and polypropylene (PP) are used to characterize achievable weld strengths, and microscopy is used to correlate weld strength with the morphology of failure surfaces. In PC, PBT, and PP relative weld strengths as high as 48%, 43%, and 55% of the respective strengths of PC, PBT, and PP have been demonstrated. Relative weld strengths on the order of 20% have been demonstrated in PC‐to‐PBT welds.     

Ultrasonic welding of thermoplastics in the far-field

In far-field ultrasonic welding of plastic parts the distance between the ultrasonic horn and the joint is greater than 6 mm. This study investigated the farfield ultrasonic welding of amorphous (acrylo butadiene styrene and polystyrene) and semicrystalline (polyethylene and polypropylene) polymers. Far-field welding worked well for amorphous polymers. Weld strength improved substantially with increasing amplitude of vibration at the joint interface. Increasing the weld pressure and/or the weld time also resulted in higher weld strengths. Far-field ultrasonic welding was not successful for semicrystalline polymers. The parts melted and deformed at the horn/part interface with little or no melting at the joint interface. A model for wave propagation in viscoelastic materials, which was developed to predict the vibration amplitude experienced at the joint interface, indicates that increasing the length of the samples to a half a wavelength should improve the far-field welding of semicrystalline polymers by maximizing the amplitude of vibration at the joint interface.     

Ultrasonic welding of thermoplastics in the near-field

Ultrasonic welding is one of the most popular techniques for joining thermoplastics because it is fast, economical, and easily automated. In near-field ultrasonic welding, the distance between the horn and the joint interface is 6 mm or less. This study investigated the near-field ultrasonic welding of amorphous (acrylonitrile-butadiene-styrene and polystyrene) and semicrystalline (polyethylene and polypropylene) polymers. High frequency ultrasonic wave propagation and attenuation measurements were made in order to estimate the dynamic mechanical moduli of the polymers. The estimated moduli were entered into a lumped parameter model in order to predict heating rates and energy dissipation. Experimental results showed that variations in the welding pressure had little effect on energy dissipation or joint strength; Increasing the amplitude of vibration increased the energy dissipation and the weld strength. For the semicrystalline polymers, increasing the weld time improved strength up to weld times greater than 1.5 s, where strength leveled off. For the amorphous polymers, the weld strength increased with Increasing weld time up to times of 0.8 s; for longer weld times, the power required was too high, causing overloading of the welder. Monitoring of the energy dissipation and static displacement or collapse provided valuable information on weld quality.     

Reprocessing of thermoplastics. II. Polycarbonate

The effect of recycling on the properties of injection molded polycarbonate was investigated. One unreinforced and two glass-reinforced grades were studied. Fiber degradation was distinguished from molecular scission by spiral flow measurements and molecular weight analysis. During the first cycles the average fiber length was significantly reduced, but at later stages it approached an equilibrium. The number of scission per original polymer molecule increased linearly with the number of recycles for all systems studied, but the degradation reaction did not follow random scission kinetics. The glass reinforced grades exhibited degradation rates which were at least twice as high as that of an unreinforced polymer. This discrepancy was most probably the result of a more extensive viscous heating in the glass-reinforced systems. The decrease in molecular weight as well as in fiber length greatly affected the impact strength of the material. The effect of processing temperature on polymer degradation during recycling was evaluated. The fraction of virgin material that has to be added to the regrind to maintain a certain property level was determined. On a 90 percent property level, an icrease in melt temperature by 1°C corresponded to an increase of 1 percent in the required amount of virgin material. Aging tests indicated that there was no significant difference in degradation rate between recycled and virgin material, although the former certainly exhibited lower absolute values of the measured property (impact strength).     

Analysis of reaction injection molding process of polyurethane-unsaturated polyester blends. Part II: Mechanical properties

The mechanical properties of polyurethane-unsaturated polyester interpenetrating polymer networks (IPNs) that were prepared by reaction injection molding (RIM) process were measured with variations In composition, cross-link density, and relative reaction rate. From dynamic mechanical analysis (DMA), it was found that the two component polymers had a good compatibility over the whole composition range. The tensile strengths of the blends were greater than those of the pure components and had a maximum value at 50/50 composition. The modulus of elasticity and surface hardness decreased and the impact strength increased as the polyurethane content was increased, but the changes were not high at low polyurethane content, below 50%. For higher cross-link density, the compatibility was enhanced and the mechanical properties were improved. When the reaction rates of the components were different, some extent of phase separation was found in DMA and the properties were affected adversely.     

Process data acquisition in vibration welding of thermoplastics

A measuring method is presented for process monitoring and process analysis of linear vibration welding of thermoplastics. The method works by recording and evaluating time-dependent signals that describe the process—such as the frequency-dependent signals of the displacement of the two parts being joined, the tangential force in the welding plane—and the nonperiodic signals of the welding process, i.e. the normal force in the welding plane and the melting or joining displacement of the parts being joined. It is possible to determine the energy input into the welding zone as a function of the selected machine parameters and the process sequence over time.     

Recent developments in hot plate welding of thermoplastics

This paper considers the hot plate welding process applied to three injection molded thermoplastic materials: polypropylene, high impact polystyrene, and poly(phenylene oxide). Weld quality was assessed by tensile testing. The process was found to be suitable for all three materials, although tolerance to variations in process parameters varied. The parameters in the heating phase, i.e., hot plate temperature and time, were the most important for achieving good welds, whereas parameter variations in the consolidation phase were relatively unimportant.     

Analysis of surfactants: Part II

We present a comprehensive review of the literature devoted to the analysis of surfactants. The period covered is 1995 through 1998. We address patents, reviews, books, journal articles, and any conference proceedings abstracted by Chemical Abstract Services. We consider classical, instrumental, and state-of-the-art analytical applications, including those not in common practice but in a developmental stage. We also include analytical techniques that make use of surfactants for improved performance, although such treatment is not comprehensive. Literature from foreign language sources is covered as completely as practical.     

Support studies for the U-GAS coal gasification process. Part II: Combustion characteristics

This is the second part of a series of papers providing the details of support studies conducted as part of the development of the U-GAS fluidized-bed coal gasification process. (Part I: Fluidization; published in Fuel Processing Technology, Vol. 17(2) (1987) 169–186). The medium-Btu industrial fuel gas (IFG) produced in the gasifier, which consists mainly of CO, H₂, CO₂, and CH₄, was evaluated for its combustion characteristics in a sub-scale, spud-type boiler burner. The gas was evaluated for flame stability, furnace efficiency, flame temperatures, flame size, and pollutants created. In the event of planned or unscheduled gasifier downtime, a gas mixture consisting of 30% natural gas and 70% air has been proposed as a backup to the industrial fuel gas-produced in the U-GAS process. The proposed backup gas was tested according to the same criteria to determine its suitability as a temporary replacement fuel. The combustion characteristics of these gases were compared with the combustion characteristics of natural gas.     

Comparison of orbital and linear vibration welding of thermoplastics

This work was conducted to determine if there were any benefits with orbital vibration welding compared to linear vibration welding. The experiments were conducted using standard full‐factorial designs with each process and each material. Four materials, polypropylene/polyethylene copolymer (PP/PE), polycarbonate (PC), acrylonitrile‐butadiene‐styrene (ABS) and Nylon (PA), were studied with each process. The equipment used was a modified Branson VW‐4 with an orbital head that had isolated magnets. The same machine was used to weld with both linear and orbital motions. This was achieved by modifying the controlling parameters of the drive. It was found that compared to linear vibration welding, orbital welding had a reduction of cycle time by 36% and 50% in Phase I and Phase III, respectively. It was also found that orbital welding dissipated 56% and 100% more power than linear vibration welding in Phase I and Phase III, respectively. In addition, it was seen that orbital welding was able to universally join unsupported walls with higher strengths and better consistency compared to linear welding. Other benefits included: a difference in the appearance of weld flash and small increase in weld strength. Some of the limitations of orbital welding that were identified included the effects of disengagement and residual stresses. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

Hot embossing in microfabrication. Part II: Rheological characterization and process analysis

The dynamic shear viscosity and the transient extensional viscosity of polycarbonate (PC), polymethyl methacrylate (PMMA), and polyvinyl butyral (PVB) were measured at temperatures near and far above their glass transition temperatures. The temperature sensitivity of rheological properties was used to explain the displacement curves during embossing. Numerical simulation of the embossing process was also carried out to compare with the observed polymer flow patterns. It was found that the simulated flow pattern during isothermal embossing agrees fairly well with the experimental observation. The deviation between the simulated and experimental results at the late stage of embossing may be due to air entrapment between the mold feature and the polymer substrate. For non‐isothermal embossing, the observed flow pattern can also be reasonably simulated, i.e. the polymer flows upward along the wall of the heated mold feature, and then compresses downward and squeezes outward. Temperature sensitivity of the dynamic shear viscosity and the transient extensional viscosity is similar for all three polymers. This correlates well with the initial displacement curves in isothermal embossing. Over a longer time, the strain hardening effect of the transient extensional viscosity seems to play a major role in the displacement curves.     

Heating and bonding mechanisms in ultrasonic welding of thermoplastics

An experimental study of the heating and bonding mechanisms in ultrasonic welding is described. Polystyrene specimens were joined under a variety of welding conditions while the temperatures at the interface and within the interior of these specimens were measured. The power input, amplitude of vibrations, and amount of deformation during welding were measured concurrently. In general, the rate of heating at the interface is greatest at the beginning of the weld cycle, but slows markedly after the interface temperature reaches approximately 250°C. The interface temperature peaks well before the weld is completed. Temperatures within the body increase most rapidly at temperatures near the glass transition temperature. Welded specimens were broken on a special testing apparatus under combined torsional and compressional loads to determine the weld strength. The results show that weld strength is dependent on the amount of energy input and the degree to which material flows out of the interface region. Possible mechanisms for heating and bonding during ultrasonic welding are discussed in light of the observed behavior.     

Development of polyurethane engineering thermoplastics. II. Structure and properties

Rigid, tough thermoplastic polyurethanes were synthesized by a two–step technique. These materials presented a complex structure consisting of a continuous, rigid, amorphous, or semicrystalline matrix with a dispersed soft phase. The influence of soft–segment content upon rigidity modulus, heat–distortion temperature, and fracture behavior has been deter-mined on model amorphous polyurethanes. The influence of crystallinity upon final prop-erties has been studied on two materials: a preparation of ours and a commercial product. Various degrees of crystallinity have been induced in the samples by annealing. Phase structure was characterized by differential scanning calorimetry and wide–angle X–ray scat-tering. Some of the polyurethane samples assayed in this paper exhibited similar properties to those reported in respect of more conventional engineering thermoplastics, such as ABS or nylon. © 1993 John Wiley & Sons, Inc.