Journal articles: 'Polymers welding'

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MARCUS, MIRANDA, and EROL SANCAKTAR. "Prediction of Ultrasonic Welding Parameters for Polymer Joining." Welding Journal 103, no. 10 (July 1, 2024): 308–24. http://dx.doi.org/10.29391/2024.103.027.

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Welding of polymers is a useful assembly process that eliminates the need for adhesives or mechanical fasteners, saving consumable costs. One of the most common polymer welding processes is ultrasonic welding. Effective welding requires that the molten polymer chains at the joint surface diffuse across the joint and become entangled with polymer chains in the parts to be welded. This intermolecular diffusion and chain entanglement are the fundamental characteristics of welding. Using fundamental theories of heat generation and melt flow, optimal weld parameters can be calculated to ensure that diffusion across the weld joint occurs during ultrasonic welding.

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Vaz, Cláudio Turani, and Alexandre Queiroz Bracarense. "The Effect of the Use of PTFE as a Covered-Electrode Binder on Metal Transfer." Soldagem & Inspeção 20, no. 2 (June 2015): 160–70. http://dx.doi.org/10.1590/0104-9224/si2002.04.

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AbstractStudies have shown that when used as binders for basic covered electrodes, polymers produce a weld metal microstructure with a high acicular ferrite content. The reasons identified for this behavior include changes in the shielding atmosphere and metal transfer mode. To investigate the effect of polymers on metal transfer, voltage oscillograms and high-speed films were recorded during welding with standard-binder and polymer-binder E7018 electrodes using different welding currents. Electrodes tips collected after the arc had been abruptly interrupted were examined metallographically. For electrodes with a polymer binder, the short-circuit frequency was lower regardless of the welding current used and decreased as welding current increased. In many events characterized as short circuits in the voltage oscillograms for polymer-binder electrodes, metal transfer in fact occurred without any arc interruption. The angle between the outer edge of the metal drop and the inner edge of the coating crater showed that the polymer increased the intensity of the plasma jet, and the pinch effect observed during welding using the polymer-binder electrode indicated that there were changes in surface tension and electromagnetic force.

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Singh, Rupinder, Ranvijay Kumar, and IPS Ahuja. "Mechanical, thermal and melt flow of aluminum-reinforced PA6/ABS blend feedstock filament for fused deposition modeling." Rapid Prototyping Journal 24, no. 9 (November 12, 2018): 1455–68. http://dx.doi.org/10.1108/rpj-05-2017-0094.

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Purpose This study aims to highlights the mechanical, thermal and melting behavior compatibility of aluminum (Al)-reinforced polyamide (PA) 6/acrylonitrile butadiene styrene (ABS)-based functional prototypes prepared using fused deposition modeling (FDM) from the friction welding point of view. Previous studies have highlighted the use of metallic/non-metallic fillers in polymer matrix for preparations of mechanically improved FDM feedstock filaments and functional prototypes. But hitherto, very less has been reported on fabrication of functional prototypes which fulfill the compatibility of two polymers for joining/welding-based applications. The compatibility of two dissimilar polymers enables the friction welding for maintenance applications. Design/methodology/approach The twin screw extrusion process has been used for mechanical mixing of metallic reinforcement in polymer matrix, and final blend of reinforced polymers in the form of extruded feed stock filament has been used on FDM for printing of functional prototypes (for friction welding). The methodology involves melt flow index (MFI) investigations, differential scanning calorimetry (DSC) investigations for thermal properties, tensile and hardness testing for mechanical properties and photo micrographic investigations for metallurgical properties on extruded samples. Findings It was observed that the reinforced ABS and PA6 polymers have better compatibility in the terms of similar melt flow, thermal properties and can lead to the better joint efficiency with friction welding. Originality/value In the present work composite feed stock filament composed of ABS and PA6 with reinforcement of Al powder has been successfully developed for preparation of functional prototype in friction welding applications.

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Qiu, Jian Hui, Yang Zhao, Taku Yamamoto, and Guo Hong Zhang. "Study on Direct-Weld between Bakelite and Aluminum." Materials Science Forum 675-677 (February 2011): 457–60. http://dx.doi.org/10.4028/www.scientific.net/msf.675-677.457.

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Recently in electronic and automobile industry, polymer materials were selected to replace metals in many products because of miniaturization and weight reduction. So the weld between polymers and metals became very important. Currently, the ways were limited to adhesive joint or the mechanical weld which both had obvious defects. In this paper, the direct-welding methods were studied and the welds based on compress-molding were viable and useful. The welding strength enhanced because the reaction between polymers and modified metals were confirmed.

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Liu, Jin-Feng, Ying-Guo Zhou, Shu-Jin Chen, Shao-Qiang Ren, and Jun Zou. "Effects of Friction Stir Welding on the Mechanical Behaviors of Extrusion-Based Additive Manufactured Polymer Parts." Polymers 15, no. 15 (August 3, 2023): 3288. http://dx.doi.org/10.3390/polym15153288.

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The friction stir welding (FSW) of thermoplastic polymers is gradually receiving attention because of its advantages including high efficiency and pollution-free manufacturing. The extrusion-based additive manufacturing (EAM) of polymers has also become one of the main processing methods for thermoplastic parts. In this paper, a hybrid manufacturing method for the FSW process and EAM technology is proposed and explored. The effects of the FSW process using two different welding tools on the mechanical behaviors of 3D printing polymer parts were compared and investigated and the corresponding mechanism was analyzed. The results show that the appropriate welding tool is beneficial for eliminating the anisotropy and decreasing the porosity of 3D-printed parts. Therefore, the improving effects of the FSW process on the mechanical behaviors of the EAM parts are verified. The mechanism was attributed to the high-speed rotation of the welding tool with the appropriate shape, which can promote the flow of polymer melt in the welding region, leading to the formation of dense structures caused by the entanglement of the molecular chains. This study may provide some assistance in modern industrial manufacturing for the processing of large custom components.

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Nonhof, C. J. "Laser welding of polymers." Polymer Engineering and Science 34, no. 20 (October 1994): 1547–49. http://dx.doi.org/10.1002/pen.760342005.

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Olowinsky, Alexander, and Andreas Rösner. "Laser Welding of Polymers." Laser Technik Journal 9, no. 2 (April 2012): 52–56. http://dx.doi.org/10.1002/latj.201290023.

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da Conceição, Marceli do N., Javier Anaya-Mancipe, Daniele C. Bastos, Patrícia S. C. Pereira, and Elaine V. D. G. Libano. "Influence of Additional Devices and Polymeric Matrix on In Situ Welding in Material Extrusion: A Review." Processes 13, no. 1 (January 9, 2025): 171. https://doi.org/10.3390/pr13010171.

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The rise of Industry 4.0 has introduced challenges and new production models like additive manufacturing (AM), enabling the creation of complex objects previously unattainable. However, many polymers remain underutilized due to the need for improved mechanical properties and reduced process-induced anisotropy. ME-based part construction involves successive filament deposition, akin to welding. Upon exiting the nozzle, the polymer solidifies within seconds, limiting the time and temperature available for diffusion and efficient bonding with the adjacent filament. Therefore, optimizing this welding process is essential. The primary objective of this review was to report on the equipment utilized to enhance the bonding between filaments deposited during manufacturing. While higher temperatures improve welding, most equipment cannot endure prolonged high-heat operations, limiting the use of engineering-grade polymers. Modifying polymer matrices by incorporating low-molar-mass molecules can boost welding and mechanical strength. Significant gains in mechanical properties have come from matrix modifications and new in situ welding devices. Reported devices use light (laser, UV IR), electric current, radio frequency and heat collection from the nozzle. The simplest device is a heat collector, while a double laser beam system has achieved the highest mechanical properties without matrix modification. There was an improvement in properties ranging from 20% to 200%.

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Tjahjanti, Prantasi Harmi, Iswanto, Edi Widodo, and Sholeh Pamuji. "Examination of Thermoplastic Polymers for Splicing and Bending." Nano Hybrids and Composites 38 (February 3, 2023): 87–97. http://dx.doi.org/10.4028/p-8myjhn.

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Materials of thermoplastic polymer when they break is usually thrown away, or is recycled which requires a long process. The purpose of this study is splicing the broken thermoplastic polymer using hot gas hand welding with different variations of welding wire/electrodes. Materials of thermoplastic polymer used are Polyethylene (PE), Polypropylene (PP), and Polyvinyl chloride (PVC) by using welding wire like the three materials. The method is carried out by using hot gas hand welding, there are two materials that cannot be connected, namely PE with PVC welding wire, and PP with PVC welding wire. The permeable liquid penetrant test is PP with PE welding wire, and PVC with PE welding wire. The longest elongation is PE with PE welding wire is 15.96% and the best of bending result is PVC with PVC welding wire reach value 181.2 kgf/mm2. The microstructure was all described in Scanning Electron Microscopy (SEM) observations.

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Rogale, Dubravko, Siniša Fajt, Snježana Firšt Rogale, and Željko Knezić. "Interdependence of Technical and Technological Parameters in Polymer Ultrasonic Welding." Machines 10, no. 10 (September 23, 2022): 845. http://dx.doi.org/10.3390/machines10100845.

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The welding of foils, textiles, and textile composites made of thermoplastic polymer materials using machines with an ultrasonic rotary sonotrode is a high-tech welding technique. Many authors have dealt with only a few parameters in earlier papers, mainly mentioning the speed, i.e., the welding time, and the power of the ultrasonic generator. In this paper, the acoustic model of ultrasonic welding is defined. Based on the model, a group of 44 different parameters important for ultrasonic welding of polymer materials has been summarised, namely 12 parameters of the polymer material, 11 general acoustic and electroacoustic parameters, and 21 technical parameters depending on the ultrasonic machine. Based on this, a comprehensive mathematical derivation was carried out, linking parameter groups with other findings from acoustics, thermodynamics of polymers, and technical and technological parameters of welding polymer materials. The most important parameters are the power of the ultrasonic generator and the welding time, which in practice are adjusted to produce a solid weld. The method of measuring the amplitude of the sonotrode using a photonic sensor is presented in this paper. For 42 groups of welds done at various welding speeds and ultrasonic generator powers, the breaking forces of ultrasonic welds were measured. There are illustrations of power dependence and breaking forces. The accuracy of the mathematical model was confirmed by comparison with the calculation results based on the findings of these measurements.

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Fabijański, Mariusz, and Guofeng Han. "Polymers welding methods including biodegradable materials." Welding Technology Review 92, no. 2 (March 29, 2020): 41–49. http://dx.doi.org/10.26628/wtr.v92i2.1097.

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Welding is one of the most popular methods of joining elements not only from metal materials, but plastics also. Their great diversity, chemical structure and physical condition in which they are at the temperature of use has a significant impact on the quality of the joints made. Welding is a particularly useful method of joining, for example, during the welding of packaging, where biodegradable plastics that dominate in this technology, for example with aluminum foil, dominate. This article reviews the methods of welding plastics including biodegradable materials.

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Abdallah, Lounis, Ould Chikh El Bahri, Meddah Hadj Miloud, Gueraiche Larbi, and Hachelaf Kaddour. "Parametric Study of the Mechanical Behavior of FSSW Welded Polymer Plates Using a New Form of Welding Tool." Defect and Diffusion Forum 389 (November 2018): 205–15. http://dx.doi.org/10.4028/www.scientific.net/ddf.389.205.

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This research paper aims at studying the friction stir spot welding (FSSW) some of thermoplastic polymer materials (HDPE and HDPE-PMMA) using a specifal geometry tool without a pin. The effect of the tool geometry on the welds static resistance was studied via several tool shape, a flat shape below the tool, a shape with concavity angles ranging from 0° to 16° , a flange shape of the sharp-edged tool, a chamfered flange shape and a rounded shape. This work is done to increase the surface area of the weld and further to maximize the static strength of the friction stir spot welding. Experimental tests have been carried out under various operational parameters such as the tool rotation speed, tool plunge depth and dwell time. This later has been carried out to highlight the effect of the tool’s geometry and the operational parameters of the welding on the surface in virtue on static resistance of the friction stir spot welding of thermoplastic polymers. Tests of lap-shear at speed of 5m/s have showed that the tool geometry plays a very important part. This study shows that a FSSW welding tool with 4° concavity angle tool and a rounded flange shape gives the best welding quality for the polymers studied.

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Zai, Le, and Xin Tong. "FusionWelding of High-Strength Low-Alloy Steel: A Mini- Review." SOJ Materials Science & Engineering 7, no. 1 (March 26, 2019): 1–4. http://dx.doi.org/10.15226/sojmse.2019.00157.

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High-Strength Low-Alloy (HSLA) steel exhibits excellent tensile strength and ductility, and it also possesses good welding performance due to its low carbon equivalent. However, welding defects always inevitably appear during the fusion weldingof HSLA steel. In this paper, the previous investigations on the microstructure of the joined HSLA steel by different fusion welding processes arereviewed, and the mechanical properties of the fabricated joint are analyzed. Also, the practicability of different fusion welding processes on HSLA steel has been systematically analyzed. Finally, the prospect of the welding of HSLA steel is expected according to the research status. Keywords: High-Strength Low-Alloy Steel; Fusion Welding; Welding Defect; Microstructure; Mechanical Properties

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Pereira, Miguel A. R., Ana M. Amaro, Paulo N. B. Reis, and Altino Loureiro. "Effect of Friction Stir Welding Techniques and Parameters on Polymers Joint Efficiency—A Critical Review." Polymers 13, no. 13 (June 23, 2021): 2056. http://dx.doi.org/10.3390/polym13132056.

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The objective of current work is to analyse the influence of different welding techniques and welding parameters on the morphology and mechanical strength of friction stir welds (FSW) in polymers, based on data collected in the literature. In the current work, only articles that provide data on the joint efficiency, or sufficient information to estimate it are considered. The process using conventional tool is presented and compared with new procedures developed for FSW of polymers, such as those using tools with heated stationary shoulder, preheating of the polymer or double-side passage of the tool. The influence of tool rotational speed (w), welding speed (v), tilt angle and geometry of the pin are discussed. This work focuses on the polymers most studied in the literature, polyethylene (PE) and polypropylene (PP). The use of external heating and tools with stationary shoulder proved to be of great importance in improving the surface finish, reducing defects, and increasing the mechanical strength of the welds. The increase in the w/v ratio increased the joint efficiency, especially when using conventional tools on PE. A trend was obtained for conventional FSW, but it was difficult to establish mathematical relationships, because of the variability of welding conditions.

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Nath, Rahul Kanti, Vinayak Jha, Pabitra Maji, and John Deb Barma. "A novel double-side welding approach for friction stir welding of polypropylene plate." International Journal of Advanced Manufacturing Technology 113, no. 3-4 (January 12, 2021): 691–703. http://dx.doi.org/10.1007/s00170-021-06602-9.

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AbstractIn almost every industry, polymer materials are in high demand in recent years due to their lightweight and easy formability. However, eco-friendly, cost-efficient and defect-free joining of polymers is a major concern. In this article, a novel approach is taken for friction stir welding of polypropylene by implementing a double-side welding technique. The effect of tool rotational speed on construction and properties of the welded joints are studied. The torque and forces exerted on the tool during double-side welding are compared with single-side welding. Cross-sectional morphology examination using optical and scanning electron microscope reveals defect-free sound welding by double-side weld with uniform material flow. The molecular bonds of the welded specimens are examined by FTIR analysis. The double-side welding technique yields superior joints in terms of tensile strength and flexural strength than the joints obtained by single-side welding.

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Qiu, Jianhui, Guohong Zhang, Eiichi Sakai, Wendi Liu, and Limin Zang. "Thermal Welding by the Third Phase Between Polymers: A Review for Ultrasonic Weld Technology Developments." Polymers 12, no. 4 (March 31, 2020): 759. http://dx.doi.org/10.3390/polym12040759.

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Ultrasonic welding (USW) is a promising method for the welds between dissimilar materials. Ultrasonic thermal welding by the third phase (TWTP) method was proposed in combination with the formation of a third phase, which was confirmed as an effective technology for polymer welding between the two dissimilar materials compared with the traditional USW. This review focused on the advances of applying the ultrasonic TWTP for thermoplastic materials. The research development on the ultrasonic TWTP of polycarbonate (PC) and polymethyl methacrylate (PMMA), polylactic acid (PLA) and polyformaldehyde (POM), and PLA and PMMA are summarized according to the preparation of the third phase, welded strength, morphologies of rupture surfaces, thermal stability, and others. The review aimed at providing guidance for using ultrasonic TWTP in polymers and a basic understanding of the welding mechanism, i.e., interdiffusion and molecular motion mechanisms between the phases.

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Sealy, Cordelia. "Welding polymers in a flash." Materials Today 7, no. 12 (December 2004): 14. http://dx.doi.org/10.1016/s1369-7021(04)00618-2.

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Duley, W. W., and R. E. Mueller. "CO2 laser welding of polymers." Polymer Engineering and Science 32, no. 9 (May 1992): 582–85. http://dx.doi.org/10.1002/pen.760320903.

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Korab, M. G., M. V. Iurzhenko, A. V. Vashchuk, and I. K. Senchenkov. "Modeling of thermal processes in laser welding of polymers." Paton Welding Journal 2021, no. 11 (November 28, 2021): 3–8. http://dx.doi.org/10.37434/tpwj2021.11.01.

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Rodríguez-Senín, E., Rubén de la Mano, and Lourdes Blanco. "Resistive Implant Welding of Advanced Polymers." Materials Science Forum 706-709 (January 2012): 3004–9. http://dx.doi.org/10.4028/www.scientific.net/msf.706-709.3004.

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Resistive Implant Welding involves an electrically conductive implant (welding rod) placed between the parts to be joined. Heat generation by Joule effect raises the temperature of the implant above the melting temperature of the thermoplastic being joined and a weld is reached. In the present study, resistive implants have been used to weld two HDPE components that make up a tank. RIW represents a good welding technique for advanced thermoplastic polymers contributing to increase the use of those materials and their industrial applications.

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Kuo, Chil-Chyuan, Jing-Yan Xu, and Chong-Hao Lee. "Weld Strength of Friction Welding of Dissimilar Polymer Rods Fabricated by Fused Deposition Modeling." Polymers 14, no. 13 (June 25, 2022): 2582. http://dx.doi.org/10.3390/polym14132582.

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Friction welding (FRW) is a promising method for joining cylindrical components of dissimilar and similar polymers or metals. In particular, FRW is capable of generating defect-free welds. Fused deposition modeling (FDM) has been widely employed in the automotive industry, ranging from lightweight tools, testing models, and functional parts. Conventionally, dissimilar parts fabricated by FDM are joined by glue. However, distinct disadvantages of this approach include both low joining strength and low joining efficiency. Hitherto, little has been reported on the characterizations of weld strength of FRW of dissimilar parts fabricated by FDM. In addition, FRW of dissimilar polymeric materials is a difficult task because different polymers have different physical, rheological, and mechanical properties. In this study, the effects of welding revolution on the weld strength of friction welding dissimilar parts fabricated by FDM are investigated experimentally. It was found that the average flexural strength of dissimilar polymer rods fabricated by FRW is about 1.52 times that of dissimilar polymer rods fabricated by gluing. The highest flexure strength can be obtained by FRW using polylactic acid (PLA) and PC (polycarbonate) rods. The average impact strength of dissimilar polymer rods fabricated by FRW is about 1.04 times that of dissimilar polymer rods joined by gluing. The highest impact strength can be obtained by FRW using PLA to PLA rods.

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Zhai, Kehui, Fuhao Yang, Qiyan Gu, Yu Lin, Minqiu Liu, Deqin Ouyang, Yewang Chen, Ying Zhang, Qitao Lue, and Shuangchen Ruan. "Research on Laser Direct Transmission Welding of Transparent Polystyrene and Polycarbonate Based on Laser Surface Modification." Polymers 17, no. 3 (February 4, 2025): 409. https://doi.org/10.3390/polym17030409.

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The conventional near-infrared laser transmission welding (LTW) process for joining dissimilar transparent polymers is limited by the need to incorporate optical absorbents, which compromises joint performance and raises biocompatibility concerns. To address these issues, this study proposed a surface modification technique using femtosecond laser ablation prior to the welding process. Experiments involved 520 nm femtosecond laser ablation of transparent polymers, followed by LTW of dissimilar transparent polymers using an 808 nm laser, with subsequent characterization and mechanical property evaluations. A maximum joint strength of 13.65 MPa was achieved. A comprehensive investigation was conducted into the physical and chemical mechanisms through which laser ablation improved the welding performance of dissimilar transparent polymers. The results demonstrated that laser ablation generated microstructures that serve as substitutes for optical absorbents while also facilitating the formation of numerous oxygen-containing functional groups. These enhancements improve miscibility and bonding performance between dissimilar polymers, enabling absorbent-free welding between ablated polycarbonate (PC) and polystyrene (PS). This work confirms both the feasibility and potential application of this process for direct LTW of dissimilar transparent polymers.

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Schramkó, Márton, Róbert Gábor Stadler, Péter Pinke, and Tünde Anna Kovács. "Optimization of Ultrasonic Welding of Polypropylene Sheets." Acta Materialia Transylvanica 7, no. 2 (2024): 109–12. https://doi.org/10.33924/amt-2024-02-09.

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Nowadays, polymers have grown into a leading group of materials. Accordingly, many technical polymers are used in industry. As the ending knee absorption increases, the binding design is also being studied continuously. In addition to mechanical and glued joints, different welding processes stand out, such as laser welding, stirrer friction welding, and ultrasound welding. The research was carried out on polypropylene, the plastic called PP. The aim of the study is to examine the ultrasonic welding of polypropylene sheets. During welding processes, we examine the effect of parameters such as welding time, amplitude and main load on the strength of the welding seam. Based on the test results, it was possible to create high-quality joints. The highest seam strengths were obtained with a welding time of 1.2 s and an amplitude of 55 μm. The effect of the main load on the strength of the seams was minimal.

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Bouha, Djilali, Habib Khellafi, El Bahri Ould Chikh, Hadj Miloud Meddah, and Abdellah Kaou. "Effect of Tool Design on the Mechanical Properties of Bobbin Friction Stir Welded High-Density Polyethylene Sheets: Experimental Study." International Journal of Engineering Research in Africa 61 (July 25, 2022): 95–114. http://dx.doi.org/10.4028/p-8c4i2j.

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Welding polymers by the friction stir welding (FSW) technique is one assembly process among several known assembly techniques which consists in welding two materials without filler material. The FSW process is based on the generation of heat due to friction and material deformation under an axial force. Among the main aspects affecting material flow, the choice of welding tool geometry has become of great interest to improve the welds quality. The main objective of this work is the welding of polymers using the FSW technique. A new method of welding HDPE (high density polyethylene) plates, called BT-FSW (bobbin tool friction stir welding) was developed. Standard rectangular shape intended for the distribution of natural gas has been successfully welded by BT-FSW. Tensile tests and hardness measurements were carried out on samples cut from the welded sheets and the results were analyzed to compare the mechanical characteristics of the plates welded by the BT-FSW and conventional FSW (C-FSW) processes. The results of the comparative studies on the micro-hardness characteristics and mechanical properties of the two welding processes indicate that welding using the bobbin tool can significantly reduce hardness and improve both weld formation and mechanical properties of joints. This study showed that the design of the welding tool has a big impact on the weld strength. An improvement in the mechanical properties of the specimens welded by BT-FSW was observed to give a better welding quality for the polymers studied.

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Enriquez, Ian, Colin Noronha, Katrina Teo, Anubhav Sarmah, Surabhit Gupta, Ankush Nandi, Blake Fishbeck, Micah J. Green, and Aniruddh Vashisth. "Closed-Loop Composite Welding and Bonding System Using Radio-Frequency Heating and Pressure." Journal of Composites Science 7, no. 3 (March 13, 2023): 116. http://dx.doi.org/10.3390/jcs7030116.

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Polymer parts often replace traditional metallic parts in load-bearing applications due to their high strength-to-weight ratio, with thermoplastics at the forefront. Conventional manufacturing processes rely on using fasteners or adhesives to hold composite assemblies together, but thermoplastics can be welded together. Ultrasonic welding is widely used but becomes challenging for complex geometries, and new parameters need to be developed for different polymers and specimen geometries. In this work, we developed a closed-loop welding machine that employs the recent discovery of radio-frequency (RF) heating of carbonaceous materials. The machine is successfully able to weld polylactic acid (PLA) coupons with graphitic RF susceptors at the bondline in less than 2 min and using less than 50 W of input RF power. We found that a higher areal density of the graphitic paint lowers the mechanical properties of the weld because the carbonaceous materials hinder polymer chain diffusion. A significant change was not observed in weld properties for welding pressure ranges between 0 and 0.3 MPa. However, increasing out-of-plane welding displacement increased the modulus and strength of the weld. This work provides an interesting new automated system for welding polymer composites using RF fields, with potential applications in various manufacturing industries.

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Huang, Yongxian, Xiangchen Meng, Yuming Xie, Long Wan, Zongliang Lv, Jian Cao, and Jicai Feng. "Friction stir welding/processing of polymers and polymer matrix composites." Composites Part A: Applied Science and Manufacturing 105 (February 2018): 235–57. http://dx.doi.org/10.1016/j.compositesa.2017.12.005.

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Kumar, Nitesh, Nikhil Kumar, and Asish Bandyopadhyay. "A State-of-the-Art Review of Laser Welding of Polymers - Part I: Welding Parameters." Welding Journal 100, no. 7 (July 1, 2021): 221–28. http://dx.doi.org/10.29391/2021.100.019.

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Polymers are widely used in automotive parts and fields like mechatronics and biomedical engineering because of their excellent properties, such as high durability and light weight. Welding of polymers has grown to be an important field of research due to its relevance among products of everyday life. Through transmission laser welding (TTLW) has been frequently selected by the contemporary re-searchers in the field of welding as it is relatively modern and more efficient than other welding processes. This pa-per reviews the influence of different processing parameters, including laser power, scanning speed, standoff distance, and clamping pressure. The present article is expected to provide the reader with a comprehensive under-standing of TTLW and research on the aforementioned four welding parameters in TTLW. The significance of finite element modeling, a few simulation studies, different optimization approaches, morphological characteristics, and other behaviors of laser welded polymers will be included in the next part of the review.

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Khatri, Bilal, Manuel Francis Roth, and Frank Balle. "Ultrasonic Welding of Additively Manufactured PEEK and Carbon-Fiber-Reinforced PEEK with Integrated Energy Directors." Journal of Manufacturing and Materials Processing 7, no. 1 (December 23, 2022): 2. http://dx.doi.org/10.3390/jmmp7010002.

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The thermoplastic polymer polyether ether ketone (PEEK) offers thermal and mechanical properties comparable to thermosetting polymers, while also being thermally re-processable and recyclable as well as compatible with fused filament fabrication (FFF). In this study, the feasibility of joining additively manufactured PEEK in pure and short carbon-fiber-reinforced form (CF-PEEK) is investigated. Coupon-level samples for both materials were fabricated using FFF with tailored integrated welding surfaces in the form of two different energy director (ED) shapes and joined through ultrasonic polymer welding. Using an energy-driven joining process, the two materials were systematically investigated with different welding parameters, such as welding force, oscillation amplitude and welding power, against the resulting weld quality. The strengths of the welded bonds were characterized using lap-shear tests and benchmarked against the monotonic properties of single 3D-printed samples, yielding ultimate lap-shear forces of 2.17kN and 1.97kN and tensile strengths of 3.24MPa and 3.79MPa for PEEK and CF-PEEK, respectively. The weld surfaces were microscopically imaged to characterize the failure behaviors of joints welded using different welding parameters. Samples welded with optimized welding parameters exhibited failures outside the welded region, indicating a higher weld-strength compared to that of the bulk. This study lays the foundation for using ultrasonic welding as a glue-free method to join 3D-printed high-performance thermoplastics to manufacture large load-bearing, as well as non-load-bearing, structures, while minimizing the time and cost limitations of FFF as a fabrication process.

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Adhikari, Sabin, Christopher J. Durning, Jacob Fish, Jaan-Willem Simon, and Sanat K. Kumar. "Modeling Thermal Welding of Semicrystalline Polymers." Macromolecules 55, no. 5 (February 18, 2022): 1719–25. http://dx.doi.org/10.1021/acs.macromol.1c02612.

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Colditz, W. "Optimisation of extrusion welding of polymers." Welding International 2, no. 4 (January 1988): 379–83. http://dx.doi.org/10.1080/09507118809447482.

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Wood, A. S. "The Butt-fusion welding of polymers." Chemical Engineering Science 48, no. 17 (September 1993): 3071–82. http://dx.doi.org/10.1016/0009-2509(93)80173-n.

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Zafar, Adeel, Mokhtar Awang, Sajjad Raza Khan, and Sattar Emamian. "Effect of Double Shoulder Tool Rotational Speed on Thermo-Physical Characteristics of Friction Stir Welded 16mm Thick Nylon6." Applied Mechanics and Materials 799-800 (October 2015): 251–55. http://dx.doi.org/10.4028/www.scientific.net/amm.799-800.251.

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Friction stir welding (FSW) of polymers is relatively a new concept among modern polymer joining techniques. This study demonstrates the applicability of FSW on 16mm thick nylon-6 plates at constant welding rate of 25mm/min and varying rotational speed between 300 to 1000RPM. A special designed tool was fabricated which has double shoulder and right-hand threaded pin profile. It has shown excellent results at relatively lower rotation speeds. Visual inspection and microstructural examination of cross sections showed that the cavities and tunnel defects appeared only at higher rotational speeds. A linear relationship was observed between temperature and rotation speed.

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33

Volkov, S. S., V. M. Nerovny, and G. A. Bigus. "Ultrasonic welding of polymer fi lms." Plasticheskie massy 1, no. 11-12 (January 2, 2020): 59–62. http://dx.doi.org/10.35164/0554-2901-2019-11-12-59-62.

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The choice of the method of ultrasonic welding of polymer fi lms is substantiated, its advantages over other welding methods are noted.It is shown that the parameters determining the performance of seam ultrasonic welding process for polymer fi lms are the amplitude of the waveguide oscillations, the welding static pressure and the speed of welding with a fi xed gap on a rotating support roller with self-stabilization of the welding seam thickness.

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34

Iftikhar, Syed Haris, Abdel-Hamid Ismail Mourad, Jamal Sheikh-Ahmad, Fahad Almaskari, and S. Vincent. "A Comprehensive Review on Optimal Welding Conditions for Friction Stir Welding of Thermoplastic Polymers and Their Composites." Polymers 13, no. 8 (April 8, 2021): 1208. http://dx.doi.org/10.3390/polym13081208.

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Friction stir welding (FSW) and friction stir spot welding (FSSW) techniques are becoming widely popular joining techniques because of their increasing potential applications in automotive, aerospace, and other structural industries. These techniques have not only successfully joined similar and dissimilar metal and polymer parts but have also successfully developed polymer-metallic hybrid joints. This study classifies the literature available on the FSW and FSSW of thermoplastic polymers and polymer composites on the basis of joining materials (similar or dissimilar), joint configurations, tooling conditions, medium conditions, and study types. It provides a state-of-the-art and detailed review of the experimental studies available on the FSW and FSSW between similar thermoplastics. The mechanical properties of FSW (butt- and lap-joint configurations) and FSSW weld joints depend on various factors. These factors include the welding process parameters (tool rotational speed, tool traverse speed, tool tilt angle, etc.), base material, tool geometry (pin and shoulder size, pin profile, etc.) and tool material, and medium conditions (submerged, non-submerged, heat-assisted tooling, cooling-assisted tooling). Because of the dependence on many factors, it is difficult to optimize the welding conditions to obtain a high-quality weld joint with superior mechanical properties. The general guidelines are established by reviewing the available literature. These guidelines, if followed, will help to achieve high-quality weld joints with least defects and superior mechanical properties. Apart from parametric-based studies, the statistical-based studies (e.g., analysis of variance (ANOVA)-based studies) are covered, which helps with the determination of the influential parameters that affect the FSW and FSSW weld joint strength. Also, the optimal ranges of the most influential process parameters for different thermoplastic materials are established. The current work on the development of general guidelines and determination of influential parameters and their operating ranges from published literature can help with designing smart future experimental studies for obtaining the global optimum welding conditions. The gaps in the available literature and recommendations for future studies are also discussed.

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35

Barakat, Ali A., Basil M. Darras, Mohammad A. Nazzal, and Aser Alaa Ahmed. "A Comprehensive Technical Review of the Friction Stir Welding of Metal-to-Polymer Hybrid Structures." Polymers 15, no. 1 (December 31, 2022): 220. http://dx.doi.org/10.3390/polym15010220.

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Metal–polymer hybrid structures are becoming desirable due to their wide range of applications in the automotive, aerospace, biomedical and construction industries. Properties such as a light weight, high specific strength, and design flexibility along with the low manufacturing costs of metal–polymer hybrid structures make them widely attractive in several applications. One of the main challenges that hinders the widespread utilization of metal–polymer hybrid structures is the challenging dissimilar joining of metals to polymers. Friction stir welding (FSW) shows a promising potential in overcoming most of the issues and limitations faced in the conventional joining methods of such structures. Several works in the literature have explored the FSW of different metal-to-polymer combinations. In some of the works, the joints are examined based on processing parameter optimization, microstructural characteristics, and mechanical performances. It is, therefore, important to summarize the findings of these works as a means of providing a reference to researchers to facilitate further research on the utilization of FSW in joining metals to polymers. Thus, this work aims to present a comprehensive technical review on the FSW technique for joining metals to polymers by reviewing the reported literature findings on the impact of materials, tools, process parameters, and defects on the strength and microstructure of the produced joints. In addition, this work reviews and presents the latest practices aiming to enhance the metal–polymer joint quality that have been reported in the literature.

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36

Korab, Mykola, Maksym Iurzhenko, Alina Vashchuk, and Marina Menzheres. "Welding of polymers by infrared laser radiation." Scientific journal of the Ternopil national technical university 108, no. 4 (2022): 38–42. http://dx.doi.org/10.33108/visnyk_tntu2022.04.038.

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A number of polymeric materials are translucent for infrared radiation. The use of low-power infrared lasers makes it possible to weld polymer sheets due to the penetration of radiation into the material depth. The possibilities of transmission welding of polybutene sheets, as well as several layers of polyethylene film are investigated. Epilog Fiber Mark 20 installation equipped with 20-W fiber infrared laser with 1.062 μm radiation wavelength is used. According to the investigation results, the maximum penetration depth of polybutene sheets at thea given radiation power is determined. The ability of welding up to eight layers of colored polyethylene film of PVD-108 and PVD-158 grade is shown.

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37

Diachenko, S. M., and T. A. Krasovsky. "Modeling of Control Modes of Technological Equipment Diring Ultrasonic Welding of Polymers." Èlektronnoe modelirovanie 45, no. 4 (August 26, 2023): 3–11. http://dx.doi.org/10.15407/emodel.45.04.003.

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Two control modes of technological equipment for ultrasonic welding of polymers are consi-dered: a mode with support of constant time and a mode of support of constant energy during the operation of the ultrasonic generator. The advantages of operation of the oscillating system in the constant energy maintenance mode are shown. A stand for modeling welding processes was developed and manufactured. An example of technological equipment that was manufac-tured based on the results of simulation of welding modes is presented.

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38

Yu, Kai, Qian Shi, Hao Li, John Jabour, Hua Yang, Martin L. Dunn, Tiejun Wang, and H. Jerry Qi. "Interfacial welding of dynamic covalent network polymers." Journal of the Mechanics and Physics of Solids 94 (September 2016): 1–17. http://dx.doi.org/10.1016/j.jmps.2016.03.009.

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39

Wang, Xiaochu, and Isaac C. Sanchez. "Welding Immiscible Polymers with a Supercritical Fluid." Langmuir 23, no. 24 (November 2007): 12192–95. http://dx.doi.org/10.1021/la7010315.

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40

Azarsa, Ehsan, Amir Mostafapour Asl, and Vahid Tavakolkhah. "Effect of Process Parameters and Tool Coating on Mechanical Properties and Microstructure of Heat Assisted Friction Stir Welded Polyethylene Sheets." Advanced Materials Research 445 (January 2012): 765–70. http://dx.doi.org/10.4028/www.scientific.net/amr.445.765.

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With the increasing growth of engineering plastics, the demand for reliable, rapid, high productivity and cost effective joining methods (similar to those used in the case of metals) is an undeniable requirement [. Furthermore, the need to produce larger and more complex parts from polymers has created an increased demand for joining, particularly in thermoplastic materials. In the case of creating a joint with high efficiency (the ratio of joint strength to base material strength) between currently available joining methods, welding is the best option [2,3]. Plastic welding processes can be divided into two groups: (1) Processes involving mechanical movement to produce heating (ultrasonic welding, friction welding, vibration welding) (2) processes involving external heating (hot plate welding, hot gas welding and resistive and implant welding) [. The welding method presented in this study utilizes both mechanical movement and external heating to produce heat.

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41

Perrin, Henri, Masoud Bodaghi, Vincent Berthé, Sébastien Klein, and Régis Vaudemont. "On the Hot-Plate Welding of Reactively Compatibilized Acrylic-Based Composites/Polyamide (PA)-12." Materials 16, no. 2 (January 10, 2023): 691. http://dx.doi.org/10.3390/ma16020691.

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Joining of dissimilar thermoplastics and their composites is a challenge for thermal welding techniques due to different melting points. Reactive welding with an auxiliary functional material can offer the clear opportunities to develop joining processes due to robustness to joining dissimilar thermoplastic polymers and their composites. The current study employed reactive compatibilization to offer the possibility of joining an acrylic-based glass fiber composite to polyamide (PA)-12 by applying a hot-tool welding technique. For this purpose, composite plates are fabricated by a typical vacuum infusion and thin layer thermoplastic films are formed by a thermostamping of PA12 granules. Subsequently, the reactive welding of the interposed PA12 sheet and Elium®-GMA-Glass composite is conducted by hot-plate welding. A glycidyl methacrylate (GMA) as a compatibilizing agent is copolymerized with methyl methacrylate Elium® resin. During the hot-tool welding process of dissimilar thermoplastic material, GMA can react with the polyamide end groups. The heat distribution at the Elium® GMA/PA-12 interface is responsible for obtaining a strong joint. This study focuses on the functionality of the compatibilizer on the welding of acrylic-based composites with polyamide (PA)-12 while varying the assembly temperature. The flatwise tensile test proved the effectiveness of GMA on the interface bounding. The excellent bounding incompatible polymers Elium® resin (PMMA) and PA12 was achieved at 200 °C.

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42

Wool, R. P., B. L. Yuan, and O. J. McGarel. "Welding of polymer interfaces." Polymer Engineering and Science 29, no. 19 (October 1989): 1340–67. http://dx.doi.org/10.1002/pen.760291906.

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43

Epstein, Arthur J. "Electrically Conducting Polymers: Science and Technology." MRS Bulletin 22, no. 6 (June 1997): 16–23. http://dx.doi.org/10.1557/s0883769400033583.

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For the past 50 years, conventional insulating-polymer systems have increasingly been used as substitutes for structural materials such as wood, ceramics, and metals because of their high strength, light weight, ease of chemical modification/customization, and processability at low temperatures. In 1977 the first intrinsic electrically conducting organic polymer—doped polyacetylene—was reported, spurring interest in “conducting polymers.” Intrinsically conducting polymers are completely different from conducting polymers that are merely a physical mixture of a nonconductive polymer with a conducting material such as metal or carbon powder. Although initially these intrinsically conducting polymers were neither processable nor air-stable, new generations of these materials now are processable into powders, films, and fibers from a wide variety of solvents, and also are airstable. Some forms of these intrinsically conducting polymers can be blended into traditional polymers to form electrically conductive blends. The electrical conductivities of the intrinsically conductingpolymer systems now range from those typical of insulators (<10−10 S/cm (10−10 Ω−1 cm1)) to those typical of semiconductors such as silicon (~10 5 S/cm) to those greater than 10+4 S/cm (nearly that of a good metal such as copper, 5 × 105 S/cm). Applications of these polymers, especially polyanilines, have begun to emerge. These include coatings and blends for electrostatic dissipation and electromagnetic-interference (EMI) shielding, electromagnetic-radiation absorbers for welding (joining) of plastics, conductive layers for light-emitting polymer devices, and anticorrosion coatings for iron and steel.The common electronic feature of pris tine (undoped) conducting polymers is the π-conjugated system, which is formed by the overlap of carbon pz orbitals and alternating carbon-carbon bond lengths.

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44

Bilici, Mustafa Kemal. "Investigation of the effects of welding variables on the welding defects of the friction stir welded high density polyethylene sheets." Journal of Elastomers & Plastics 54, no. 3 (December 7, 2021): 457–76. http://dx.doi.org/10.1177/00952443211058845.

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Modern thermoplastic materials are used in an expanding range of engineering applications, such as in the automotive industry, due to their enhanced stress-to-weight ratios, toughness, a very short time of solidification, and a low thermal conductivity. Recently, friction stir welding has started to be used in joining processes in these areas. There are many factors that affect weld performance and weld quality in friction stir welding (FSW). These factors must be compatible with each other. Due to the large number of welding variables in friction stir welding processes, it is very difficult to achieve high strength FSW joints, high welding performance, and control the welding process. Welding variables that form the basis of friction stir welding; machine parameters, tool variables, and material properties are divided into three main groups. Each welding variable has different effects on the weld joint. In this study, friction stir welds were made on high density polyethylene (HDPE) sheets with factors selected from machine parameters and welding tool variables. Although the welding performance, quality, and strength gave good results in some conditions, successful joints could not be realized in some conditions. In particular, welding defects occurring in the combination of HDPE material with FSW were investigated. Welding quality, defects, and performances were examined with macrostructure. In addition, the tensile strength values of some the joints were determined. The main purpose of this study is to determine the welding defects that occur at the joints. The causes of welding defects, prevention methods, and which weld variables caused were investigated. Welding parameters and welding defects caused by welding tools were examined in detail. In addition, the factors causing welding defects were changed in a wide range and the changes in the defects were observed.

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45

Lambiase, Francesco, Hamed Aghajani Derazkola, and Abdolreza Simchi. "Friction Stir Welding and Friction Spot Stir Welding Processes of Polymers—State of the Art." Materials 13, no. 10 (May 15, 2020): 2291. http://dx.doi.org/10.3390/ma13102291.

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In the last decade, the friction stir welding of polymers has been increasingly investigated by the means of more and more sophisticated approaches. Since the early studies, which were aimed at proving the feasibility of the process for polymers and identifying suitable processing windows, great improvements have been achieved. This owes to the increasing care of academic researchers and industrial demands. These improvements have their roots in the promising results from pioneer studies; however, they are also the fruits of the adoption of more comprehensive approaches and the multidisciplinary analyses of results. The introduction of instrumented machines has enabled the online measurement of processing loads and temperature, and critical understanding of the principal aspects affecting the material flow and welds quality. Such improvements are also clearly demonstrated by the increase of the strength of recent joints (up to 99% of joining efficiency) as compared to those reached in early researches (almost 47%). This article provides a comprehensive review of the recent progresses on the process fundamentals, quality assessment and the influence of process parameters on the mechanical behavior. In addition, emphasis is given to new developments and future perspectives.

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46

Zeng, Yanning, Weiming Yang, Shuxin Liu, Xiahui Shi, Aoqian Xi, and Faai Zhang. "Dynamic Semi IPNs with Duple Dynamic Linkers: Self-Healing, Reprocessing, Welding, and Shape Memory Behaviors." Polymers 13, no. 11 (May 21, 2021): 1679. http://dx.doi.org/10.3390/polym13111679.

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Thermoset polymers show favorable material properties, while bringing about environmental pollution due to non-reprocessing and unrecyclable. Diels–Alder (DA) chemistry or reversible exchange boronic ester bonds have been employed to fabricate recycled polymers with covalent adaptable networks (CANs). Herein, a novel type of CANs with multiple dynamic linkers (DA chemistry and boronic ester bonds) was firstly constructed based on a linear copolymer of styrene and furfuryl methacrylate and boronic ester crosslinker. Thermoplastic polyurethane is introduced into the CANs to give a semi Interpenetrating Polymer Networks (semi IPNs) to enhance the properties of the CANs. We describe the synthesis and dynamic properties of semi IPNs. Because of the DA reaction and transesterification of boronic ester bonds, the topologies of semi IPNs can be altered, contributing to the reprocessing, self-healing, welding, and shape memory behaviors of the produced polymer. Through a microinjection technique, the cut samples of the semi IPNs can be reshaped and mechanical properties of the recycled samples can be well-restored after being remolded at 190 °C for 5 min.

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47

Dave, Foram, Muhammad Mahmood Ali, Richard Sherlock, Asokan Kandasami, and David Tormey. "Laser Transmission Welding of Semi-Crystalline Polymers and Their Composites: A Critical Review." Polymers 13, no. 5 (February 24, 2021): 675. http://dx.doi.org/10.3390/polym13050675.

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The present review provides an overview of the current status and future perspectives of one of the smart manufacturing techniques of Industry 4.0, laser transmission welding (LTW) of semi-crystalline (SC) polymers and their composites. It is one of the most versatile techniques used to join polymeric components with varying thickness and configuration using a laser source. This article focuses on various parameters and phenomena such as inter-diffusion and microstructural changes that occur due to the laser interaction with SC polymers (specifically polypropylene). The effect of carbon black (size, shape, structure, thermal conductivity, dispersion, distribution, etc.) in the laser absorptive part and nucleating agent in the laser transmissive part and its processing conditions impacting the weld strength is discussed in detail. Among the laser parameters, laser power, scanning speed and clamping pressure are considered to be the most critical. This review also highlights innovative ideas such as incorporating metal as an absorber in the laser absorptive part, hybrid carbon black, dual clamping device, and an increasing number of scans and patterns. Finally, there is presented an overview of the essential characterisation techniques that help to determine the weld quality. This review demonstrates that LTW has excellent potential in polymer joining applications and the challenges including the cost-effectiveness, innovative ideas to provide state-of-the-art design and fabrication of complex products in a wide range of applications. This work will be of keen interest to other researchers and practitioners who are involved in the welding of polymers.

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48

Hassan, Gailan I., and Younis Kh Khdir. "Effect of Rotary Friction Welding Parameters on the Mechanical Behavior ABS/PE Polymers." Academic Journal of Nawroz University 7, no. 4 (December 21, 2018): 104. http://dx.doi.org/10.25007/ajnu.v7n4a278.

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This study deals with the Rotary Friction Welding, (RFW) as a variation of friction welding in which the energy required to make the weld is supplied primarily by the stored rotational kinetic energy of the welding machine. The mechanical energy generated in overcoming friction is continuously transformed into heat. In most circumstances the thermal energy generated is regarded as undesirable, but under controlled conditions it can be used to join materials, as in the case of rotary friction welding. In this paper, similar and dissimilar joints of Acrylonitrile butadiene styrene (ABS) (chemical formula (C8H8)x· (C4H6)y· (C3H3N)z) and Polyethylene (PE) or polyethene or poly(methylene)) are studied. The effects of different rotational rates, plunge depths, and traverse speeds on the microstructure and tensile strength of joints were investigated. Some defects such as pores and cracks were found at inappropriate processing parameters. The tensile test was carried out as the mechanical properties of joints. Different significant parameters were discussed. The maximal and minimal tensile strength indicated and evaluated.

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49

He, Xu, Drew W. Hanzon, and Kai Yu. "Cyclic welding behavior of covalent adaptable network polymers." Journal of Polymer Science Part B: Polymer Physics 56, no. 5 (December 7, 2017): 402–13. http://dx.doi.org/10.1002/polb.24553.

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50

Kathirgamanathan, Poopathy. "Microwave welding of thermoplastics using inherently conducting polymers." Polymer 34, no. 14 (January 1993): 3105–6. http://dx.doi.org/10.1016/0032-3861(93)90641-m.

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Journal articles on the topic 'Polymers welding'

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