Plastic Welding

Hot Gas Plastic Welding

Hot gas plastic welding is sort of a dead ringer for gas welding, nevertheless it employs lower temperatures. A specific gun produces hot air by using a feed for plastic, which makes the parts to melt and join them together. Its important for the plastic welding materials to hold similar chemistry. The technique is normally utilized for the manufacture of plumbers fittings, big chemical tanks, as well as heat exchangers, etc.

Contact Plastic Welding
In this process, the parts to become welded are placed together as well as the heated tips to punch them, melt, and join them together. It is similar to the spot welding process; however, electric conduction is replaced together with all the puncher tips to perform the overall task.

Hot Plate welding

In this strategy, a great platen employed to melt the parts to get welded, when the two parts are held inside the nests attached to two anvils placed opposite one another. The recent platen is allowed to move between both parts. The two parts are pressed at the platen and kept for example until the plastic welding materials melt, after which the platen is removed, and parts are pressed together to create a permanent joint.

High frequency welding

High frequency electromagnetic waves are increasingly being employed in this process, as certain plastics having chemical dipoles could possibly be heated with these waves. This can be one of the special variants of plastic welding and has very specific applications.

Ultrasonic welding

In this method, high frequency sound waves are utilized in ultrasonic welding to melt the parts to become welded.

Friction welding

In Friction welding, otherwise known as vibration welding, the parts are made to produce friction between them, and the effect of vibration between clamping along with the parts do the plastic welding causing material to melt, resulting in a weld.

Spin welding

The process involves holding a component stationary as well as the second kind to spin on part to be welded with high velocity and pressure, and hence making a weld.

Laser welding

In this process parts are pressurised even if a laser beam is passing through. The parts that will have to be welded will be needed to be translucent and opaque which has a difference in their opacity.

Solvent Welding

This technique uses a solvent to dissolve the polymers temporarily, for, the polymer chains become free to move and might be made to entangle with other dissolved polymer.

Fields of making use of Plastic Welding Some of many zones of application are provided below, nevertheless the technique could be used in various other fields also.

  • Assembly welding for mass produced domestic appliances
  • Fabrication welding of pipelines
  • High speed seam welding of films and garments
  • Precision welding of medical devices

 

Oxy-Acetylene Welding

Oxy-Acetylene Welding is the welding process of heating two pieces of metal to melting point, bringing the parts together and while still in a molten stage hammered together to form a joint. Learning how to weld using this process will give a complete overview of welding.

The Oxy-Acetylene Welding process requires the use of a special welding torch that mixes oxygen and acetylene gasses that can produce a small intense flame heat of up to 6300 degrees. This temperature is more than twice the melting point of most metals.

This process has been widely used in the past for the manufacture of wrought iron projects such as iron gates and fences. These methods have widely been superseded by the introduction of electric arc welding.

Today Oxy acetylene welding is generally restricted to industries that work with copper pipe and the joining of copper and brass. Other specialized applications include such as building up of brass wear plates and the welding of cast iron housings that may be cracked using brass or bronze rods as a filler.

Gas Cutting Using Oxy-Acetylene.

Most gas torches include a function for gas cutting. This is in the form of a lever style valve that allows an extra burst of oxygen through the cutting torch to the work that has been heated to melting point.
This injection of oxygen to the work causes the parent metal to burn away with great force and speed, producing a small narrow cut in the metal.

Using this method has allowed metals to be cut easily either manually or by machines called profile cutters. Gas cutting manually can easily cut metals of 1/16 of an inch and up to two inches where as profile cutting can cut steels up to four inches thick.

Many profile cutting machines now use LPG gas instead of acetylene as the flame and cut produced is cleaner. Propane torches for auto and manual cutting are constructed differently to acetylene torches and also require different cutting tips

Welding Rods

When choosing welding rods try to avoid buying inferior quality as the better your grade of material in the welding rod the better the end result will be.

Your welding rod is used to lay over additional metal to the weld therefore it needs to match the parent metal. If the metals are dissimilar then best efforts to locate a filler rod comprising of a composition of the two metals. For example if welding manganese, or nickel specific welding rods of specific alloys are recommended.

Welding wire and Oxy-Acetylene Welding rods are most always of Norway steel. This grade is most pure and gives a sound soft weld especially suited to machining if required. When welding aluminium the proper rod is most important as aluminium is difficult to weld and requires alloyed rods to ensure even flowing.

Brazing Metals – The Basics

brazing metalsBrazing metals is the method for joining up steel with the aid of a filler metal which is heated up in the top surface area and it is dispersed among several components which are carefully fixed together by way of capillary activity. Taking this filler metal to the temperatures that’s a touch greater than it’s melting stage and also safeguarding it that has an atmosphere that’s ideal is known as flux. This kind of heated filler metal will then be permitted to pass across the base metal to help fusion with the welded components.

Brazing can be used to the various possibilities it supports. For example, you can use it as manually operated torch brazing when the torch will be hand-held to make a excellent joint involving the materials it’s applied to. In contrast producers can make use of machines torch brazing if they require recurring brazing carried out while not having to tie up any specific welder for extended amounts of time. Then there’s the automated torch brazing technique that totally removes the requirement of utilizing manual labour with the brazing procedure.

Silver brazing utilizes filler based on the silver material comprising materials for example gold, zinc, copper, as well as cadmium. This technique can be used in most cases within the tool community in which tips of tools tend to be attached using hard-metal. This is particularly helpful if utilized in those tools as saw blades.

Braze welding implementes brass as well as bronze filler rods which are covered by flux whenever joining work items made from metal. The apparatus employed for this kind of welding is similar for that found in brazing. Because the requirement of this kind of welding is made for greater temperature, acetylene or methylacetylene-propadiene gas MPS) is frequently utilized to achieve this. This system is especially appealing to a few since the metal isn’t melted throughout the procedure and for that reason every part maintain their particular edges, forms, and curves without getting altered or eroded.

Cast iron brazing employs nickel or cast iron rods whenever accessible and it is frequently utilized to inbed copper wire in to tube in order to conduct energy to avoid freezing in the course of inclement weather conditions. Vacuum brazing metals is yet another approach to welding that’s really clean, good quality and helps to create flux-free joints which are robust and still have remarkable integrity.

Dip brazing is actually suited with regard to brazing aluminium simply because that oxygen is not really utilised that helps prevent oxides by developing. Within this kind, the various components tend to be put together and a brazing is usually applied in a slurry, then this complete product will be dropped in to a molten sodium bath that works as a heat transfer channel plus flux.

Furnace brazing metals is yet another approach that’s frequently utilized but it’s only semi-automatic in kind, however frequently employed within manufacturing environments. There are a variety of advantages for making use of this technique particularly when dealing with mass manufacture of products. It is especially good for working by using great amounts of smaller sized components that may be jigged very easily.

 


Aluminum Welding Procedures

Welding aluminumFinding the best aluminum welding procedures is usually challenging based on the procedure utilized and also the size of the aluminum. You will find three general and fundamental welding techniques to weld aluminum; these are Gas, Mig and Tig alloy welding.

Welding Alloys Using Oxy-Acetyleen.

This kind of welding isn’t widespread however, will likely be associated with numerous servicing businesses for example refrigeration repairs. Usually it calls for fusing extremely thin aluminum sheets employing oxy acetylene apparatus with fine welding torch tips.

Aluminum naturally is hard to ascertain the stage when the alloy would actually liquefy. As a result attempting to heat several components of aluminum to join them could lead to the actual aluminum purely ‘dropping out’ once the melting stage is achieved. Oxy acetylene welding aluminum for that reason is really a procedure that can actually just be completed by means of practice until finally natural expertise enables the user recognize if the materials can be near to melting point and whenever filler may be delivered.

Mig Welding Alloy.

This is actually the smart way and the most typical method to weld aluminum. Mig welding utilizes a constant wire feed of aluminum wire put on to the weld area. Mig welding aluminum makes it possible for welding of 1mm thick alloy and up-wards. Dependent upon the amperage power from the Mig welding machine. Thinner aluminum might need to get spot welded to prevent blowing through, once again that is dependent upon the size of your wire electrode being employed, the lesser gauge wire applied the finer any aluminum you’ll be able to operate on. Typically a .09mm welding wire would be capable of welding sheet metals of 1mm up to 2.5mm.

Sheet metals are generally welded making use of mig welders; typical use is on aluminum watercraft building, gates, fencing and lightweight architectural and architectural work. Welding aluminum on hefty gauges is comparable to that of welding metal, here wire size of 1.2mm will be ideal. The easiest of aluminum welding procedures.

When switching a mig welder from steel welding to alloy welding, you will have to customize the welding cable liner to one created from Teflon that will enable easy running with the filler wire. Aluminum wire is much weaker compared with metal and needs much less friction throughout the cable and also gun. Additionally you will probably need to make use of 100 % pure argon gas rather than cO2 found in metal welding migs.

Aluminum Welding Procedures using a Tig welder.

Tig welding aluminum can also be challenging and needs a good amount of training. Comparable in a manner to gas welding it includes heating up the actual aluminum to melting stage utilizing a tig welding torch as well as presenting a filler rod in the appropriate instant to produce a welding bead. Mastering to weld aluminum employing a Tig machine is most fulfilling because the completed job is really a form of artwork. It takes a reasonable level of expertise and will allow your completed weld to get as tiny as 1/16 inches wide.

Gas Welding – How It Works

gas weldingGas welding or oxygen-acetylene welding is made possible because there are some gasses that burn at extremely high temperatures. With this process, oxygen as well as acetylene are fed from holding tanks to a torch and then when needed ignited. This combination makes a gas that burns at an incredible 5500 degrees Fahrenheit. This process was first put into use during the early part of the 1900s. The individual doing the welding holds a filler metal rod in one hand and the torch in the other, and using the intense heat at the end of the torch melts the filler metal into a joint which fuses two pieces of metal together.

This process can be used to fuse pipe together or to repair splits. It is particularly useful with pipe that is less than 2 inches diameter. It can also be used to work with sheet metal, as well as just about any metal that is used in industry. Gas welding is a bit slower than when using arc welding but it is also seen to give the welder much more control over the work they are trying to do.

There are some things to remember when working with gas welding that must be kept in mind for the sake of safety.

  • For the sake of safe storage, keep cylinders of oxygen and other gases stored separately with at least 20 feet between them, or they can be divided by a proper firewall.
  • Cylinders can burn easily so it is recommended that they be kept away from any combustible and flammable materials.
  • Maintain cylinders in storage areas where others cannot get to them to tamper with them, away from heat and to prevent damage to them.
  • Cylinders should always be maintained in an upright position, and when possible, chained to retain this position even when jostling takes place.
  • Always check the valves to assure they are closed prior to moving the cylinders.
  • Always have regulators and defending caps in place.
  • Never pull cylinders. Instead roll them on their bottom edges when moving is necessary.
  • During transport, reduce the cylinder movement by placing chains around them to prevent falling and extreme movement.

Oxy-acetylene is the typical combination used in gas welding and is generally chosen for general cutting and welding work including work to repair rips and tears in metal. Each gas is contained in its own cylinder and combined through the use of separate hoses leading from regulators attached to the top of the cylinders. These hoses then lead to the torch where they are attached to create the mixture needed to create the intense heated to work with metals.

The regulators are necessary to control the flow of gases, and a non-return valve is also needed to prevent the possibility of detonation of the acetylene tank. This valve is all part of the checks needed for proper and safe use of oxy-acetylene gas welding.

Other equipment required to work with oxy-acetylene gas welding would be a check valve, welding torch, cutting torch, rose-but torch, and injector torch. All of this equipment do different types of gas welding and allow the user to make the right cuts or joints that are required for the work they are completing.