Message from the Chair
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Message from the Chair It is somewhat strange to be waiting until June for our annual meeting of the Society of Plastics Engineers, but the opportunity to add the NPE exhibition to our activities is not to be missed As usual, there are many excellent papers that are being presented in the Special Interest Group on Joining of Plastics and Composites sessions, and it will again be very difficult to select the Best Paper. We are very lucky to have so many superlative groups doing and publishing research in our area. In addition to the papers, we always look forward to the Awards Dinner sponsored by Branson for our SIG, when the plaque for the Best Paper will be presented. We will again be giving a Best Student Presentation Award, so we hope that all who qualify as students will be letting the organizers know so that they can be considered for this award. The definition of “student” includes anyone in a course of study at an academic institution. If the work being presented was part of, for example, a doctoral research project, it still counted as a student presentation, even if the presenter had recently actually received the degree. The chance to experience Chicago should not be missed. It is not only famous for the having produced the new US President, but everyone should also make a point to see the at least one of its many art museums as well as the Museum of Science and Industry, with its magnificent U-boat. If nothing else, the pictures of how it was brought to the museum and a new section of building was created around it is worth the entry fee! See you in Chicago in June!
Bobbye Baylis Chair, Joining SIG
Society of Plastics Engineers
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Spring 2009 Newsletter Featured Paper This paper provides a general introduction to welding fundamentals (section 2) followed by sections on a few selected welding processes that have had significant developments or improvements over the last few years. The processes that are discussed are friction welding (section 3), hot plate welding (section 4), ultrasonic welding (section 5), laser/IR welding (section 6), RF welding (section 7) and hot gas/ extrusion welding (section 8). View this paper in its entirety: http://www.abe.iastate.edu/fileadmin/www.abe.iastate.edu/faculty/Files/Welding_Review.pdf
ANTEC™ @ NPE2009 McCormick Place West, Chicago, Illinois USA June 22-24
Joining of Plastics and Composites SIG Technical Sessions Instrumental Investigations Of Physical Gumminess Of A Medical Grade Epoxy-Amine Adhesive After Curing Xiaoping Guo, St Jude Medical Inc. Session (M13) Adhesives and Ultrasonic and Vibration Welding, 9:00 AM Various factors that might interfere with reaction stoichiometry and result in physical gumminess of the cured mass were investigated for an epoxy-amine adhesive system. Dynamic rheometry and infrared spectrometer (FT-IR) were used to measure dynamic mechanical properties in the adhesive during isothermal curing and the degree of conversion after curing. It was found that physical gumminess of the cured adhesive under a selected, normal curing condition was primarily due to the presences of excessive hardener and also liquid residuals of an industrial cleaner containing hydroxyl and amine functional groups, but not the excessive epoxy resin at a moderate level. Functionalized Polyolefins That Deliver Room Temperature Adhesion To Polyurethanes Laura Weaver, The Dow Chemical Company Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 9:30 AM Maleic anhydride (MAH) modified polymers and ethylene acrylic acid (EAA) copolymers are known to adhere well to polar materials in high temperature processes such as in multi-layer film and sheet extrusion. However, these materials have been found to exhibit unacceptable adhesion to polar materials such as polyurethane foams, adhesives, and coatings in room temperature applications [1-2]. Three new developmental products are now available for sampling which can be co-extruded with either low density polyethylene (LDPE), propyleneethylene elastomers, or ethylene-alpha-olefin elastomers;-olefin elastomers and provide a high functionality surface layer that enables adhesion to urethanes at room temperature. Weldability Of Polylactic Acid Sheets And Films Julius Vogel, Iowa State University Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 10:00 AM Emerging product lines of PLA and PHA based materials has kindled the need to investigate their manufacturability utilizing traditional techniques. This article examines the weld-ability of PLA plastics using Ultrasonic welding. PLA Samples were conditioned and ultrasonically welded under different parameter sets of amplitude, pressure, weld time and weld geometry. Based on preliminary results the range of variables were narrowed down, amplitude ranging from 65 to 100% and weld time 3 to10 seconds. A high weld efficiency of 90% was observed with 75% amplitude and 5 seconds weld-time. Further detailed studies on the flexibility and peeling of the weld were tested for.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Experiments In Vibration Welding Of PC And PMMA To Metallization Coated PC Chung Wu, Visteon Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 10:30 AM Thin metal coating of plastic parts for increased optical properties or for decoration has gained more importance in recent years. This coating is often found in the weld area and there are concerns regarding its effect on weldability. Therefore, vibration welding of PC and PMMA to metallization coated PC plates was studied to evaluate the effect of the coating on weld strength. The effects of amplitude of vibration, meltdown, and pressure on joint strength were evaluated. It was found that for welding of PMMA to coated PC, using higher pressures and meltdowns resulted in stronger jointsFor welding of PC to coated PC all the joints were as strong as welding of PC to uncoated PC. Vibration Welding Polypropylene – Effect Of MFI On Weld Strength And Microstructure Phil Bates, Royal Military College of Canada Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 11:00 AM Examines the weld strength and microstructure of three polypropylene homopolymers of different melt flow index (MFI). The heat affected zone thickness was observed to be inversely proportional to weld pressure and polymer MFI. The weld strength was observed to decrease with pressure. The weld strengths of lower MFI polymers were more weld-pressure sensitive. Effect Of Molecular Structure On Heat Seal Properties For High Density Polyethylene Film Ken Miyata, Yamagata University Session (M32) Hot Plate and Staking Session, 1:30 PM Effect of molecular structure on heat seal properties for high density polyethylene (HDPE) film was investigated in this study. The HDPE film whose melting temperature was 126 degrees C was heat sealed at 125 and 128 degrees C controlling and varying sealing pressure and temperature. The mechanical property of the sealed films was measured by a T-shape peeling test. Thermal analysis was performed by a differential scanning calorimetry (DSC). We discussed weight fraction of melting region in heat seal process is related to the major factor to decide peeling properties of heat sealed HDPE film. In-Line Process Optimization Of Hot-Plate Welding Using An Innovative Actuation Concept Reinhild Hoffschlag, University of Paderborn Session (M32) Hot Plate and Staking Session, 2:00 PM An innovative actuation concept of a hot-plate welding machine enables to apply haul-off speed against the joining direction. Thus, it is possible to investigate weld strength within the semi-molten state of the weld. To use this data for self-optimization a coherence between the strength in molten and cooled down state has to be detected. Methods can be developed to determine the optimal processing window. Results show that the optimal joining path to melt layer thickness ratio can be detected without knowing the short time tensile strength. Similar results are valid for melt layer to wall thickness ratio. Based on this, a self-optimization and a quality assurance test can be developed. Influence Of Processing Parameters On Microstructure And Properties Of A Polyetherimide Joined By Fricriveting: Investigation Of Rotational Speed Sergio Amancio Filho, GKSS Research Centre Session (M32) Hot Plate and Staking Session, 2:30 PM FricRiveting is a new spot joining technique for polymer-metal structures, recently introduced at ANTEC 08 (ANTEC-0340-2008). It is well known that processing in joining technology plays a central role in dictating joint properties. Its understanding is a key matter for producing reliable connections. It has been reported that rotational speed is an important controlling parameter in FricRiveting. This study will experimentally determine the influence of rotational speed on FricRiveting joint microstructure, local and global strength and thermal history for a thermoplastic polyetherimide joined by threaded aluminum rivets.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Prediction Of Residual Stress Formation In Polycarbonate Welded Samples Using Finite Element Analysis Avraham Benatar, The Ohio State University Session (M32) Hot Plate and Staking Session, 3:00 PM During plastic welding, the localized heating the cooling near the weld results in residual stress formation due to differences in thermal expansion between the hot and cold regions. During cooling, some of that residual stress may be relieved due to stress relaxation of the viscoelastic polymer. ANSYS finite element analysis was used to predict the temperature fields and cooling rates for hot plate welding, through transmission laser welding, and vibration welding of polycarbonate. The temperature history was then used in a viscoelastic ANSYS finite element model to predict the residual stress distribution, which was in good agreement with previously published residual stress measurements. Experimental Study Of Hot Plate Welding Of Polycarbonate Using Displacement Versus Pressure Control Avraham Benatar, The Ohio State University Session (M32) Hot Plate and Staking Session, 3:30 PM During hot plate welding the welding phase can be controlled by either pressure or displacement. When using pressure control, the parts are placed under constant pressure simultaneously squeezing and cooling the melt layer until the interface solidifies. In displacement control, the parts are pressed together until mechanical stops are reached and the weld cools further under no pressure. In this work we studied hot plate welding of polycarbonate using low and high temperature hot plate and with pressure versus displacement control. While high quality welds can be produced in both cases, the welding conditions differ between the two control methods. Experiments With Impulse Heat Staking Of Polypropylene To ABS Avraham Benatar, The Ohio State University Session (M32) Hot Plate and Staking Session, 4:00 PM In staking, a thermoplastic post is melted and reshaped to form a head, thereby mechanically joining the plastic part to another part. In this work, an impulse staking head using a nichrome ribbon was designed and fabricated. The heat staking head was then used to join together PP plates with a post that is 3.04 mm in diameter by 8 mm high to ABS plates with a matching hole. It was found that increasing the impulse heating time squeezed down more of the head reducing its thickness and therefore the joint strength. Pressure had very little effect on the thickness of the head or joint strength. Impulse staking appears to be a promising new approach for rapid staking and joining of parts. SIG Steering Committee Meeting Session (M32) Hot Plate and Staking Session, 4:30 PM Closed Loop Control in Laser Welding of Plastic Components Richard Davis, Rofin-Sinar, Inc Session (T14) Laser Welding Session, 8:30 AM Laser welding of plastic components places a high demand on control of the melt temperature range of the partnering materials. The use of an integrated pyrometer provides real time closed loop control of the process by monitoring emissions directly from the melt region generated by the incident laser radiation. These emissions are captured, measured, interpolated, and thus correlated to a known temperature. The data generated by the pyrometer can be used to produce an analog output signal that adjusts the current to the direct diode laser source to maintain a predetermined temperature set point and allows for the ability to adaptively control part to part variation and dynamic process conditions.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Closed Loop Control in Laser Welding of Plastic Components Richard Davis, Rofin-Sinar, Inc Session (T14) Laser Welding Session, 8:30 AM Laser welding of plastic components places a high demand on control of the melt temperature range of the partnering materials. The use of an integrated pyrometer provides real time closed loop control of the process by monitoring emissions directly from the melt region generated by the incident laser radiation. These emissions are captured, measured, interpolated, and thus correlated to a known temperature. The data generated by the pyrometer can be used to produce an analog output signal that adjusts the current to the direct diode laser source to maintain a predetermined temperature set point and allows for the ability to adaptively control part to part variation and dynamic process conditions. Laser Welding Of Thermoplastic Urethane Films Ryan Marsico, Gentex Corporation Session (T14) Laser Welding Session, 9:00 AM Laser welding is increasingly becoming a technology of choice in the plastics joining industry. The use of infrared absorbers to laser weld thermoplastic materials, including thermoplastic elastomers, is also of interest to the plastics industry. Therefore, an investigation of the laser welding characteristics of four classes of thermoplastic urethanes using organic infrared absorbing materials was undertaken. In addition, the use of thermoplastic urethanes as intermediate layers with dissimilar plastics has also been examined. This paper reviews the results of these welding studies. Optical Properties Characterization Of Thermoplastics Used In Laser Transmission Welding: Part I. Transmittance And Reflectance C.Y. Wang, Soochow University Session (T14) Laser Welding Session, 9:30 AM A better understanding of the optical properties of plastics at IR wavelengths is important for optimizing the laser transmission welding process. In this study, the optical properties of polypropylene (PP), polycarbonate (PC) and polyamide (PA) were investigated by using spectrophotometer with integrating sphere. The influence of thickness, surface roughness and filler content on optical properties of thermoplastics was evaluated. The results could contribute to a better understanding of the process itself and to success in the practical applications. CO2 Laser Welding Of The PFA Disk Top On A Circular Tube Assisted By A Transparent Solid Heat Sink Yasuo Kurosaki, University of Electro-communications Session (T14) Laser Welding Session, 10:00 AM There has been no adequate laser welding method for fluorocarbon polymer such as PFA and PTFE. An innovative CO2 laser welding method [1] is applied for overlapped PFA polymer film sheet. The features of the welding procedure are: to use a solid heat sink transparent to CO2 laser beam, to use no pigmentation or dye for radiation absorption enhancement, and to sustain thermal damage on the surface. The feasibility of the procedure was confirmed to be usable for joining of thinner PFA film sheet than 0.3 mm. The laser welding machine in a production line was manufactured to weld the top of the circular tube of variable area flow-meters with film disk. Laser Welding Of Nylon Tubes To Plates Using Conical Mirror Phil Bates, Royal Military College of Canada Session (T14) Laser Welding Session, 10:30 AM In this study, nylon tubes were welded to nylon plaques using laser transmission welding. A conical mirror inserted inside the tube was used to guide the laser beam along the weld path following the inner circumference of the tube. The intensity profile of the reflected laser beam reaching the cylindrical tube surface was characterized. Effect of the laser power, the angular motion speed, and the cycle time on the joint shear strength was examined. Process parameters were identified giving good joint strengths.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Laser Transmission Welding Of Glass Fibre Reinforced Nylon 6 – Finite Element Thermal Modeling And Microstructural Validation Phil Bates, Royal Military College of Canada Session (T14) Laser Welding Session, 11:00 AM Presents FEM heat transfer analysis for contour LTW of glass-fibre-reinforced Nylon 6. Simulated temperature fields around the weld interface were compared with weld microstructures. Temperature profiles were compared to the experimentally obtained weld cross sections. Satisfactory agreement was obtained between the predicted and experimental results. Comparison Of Newly Developed Ultrasonic Welder To Standard Ultrasonic Welder Miranda Marcus, Dukane - Intelligent Assembly Solutions (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 1:30 PM Ultrasonic welding is one of the most widely used processes for bonding polymers, valued for it’s speed, flexibility, and low cost. Recently there has been a call for more controlled and consistent welding processes, especially in the medical field. Dukane has worked to meet this demand through the development of a new ultrasonic welder. Careful comparison, detailed here, has shown that the newly developed welder provides more consistent results than the standard welder. The newly developed welder also offers a number of user friendly ergonomic features, superior Graphic User Interface with Ethernet connectivity as well as more accurate process control capabilities. Advances In Plastics Joining Technologies For The Assembly Of Medical Devices Nitin Phadnis, Branson Ultrasonics Corp (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 2:00 PM The goal of this paper is to discuss the various methods and techniques that a Device Manufacturer can use to insure they meet FDAs QS/ GMP requirements when assembling plastic components as well as to discuss the advances made in plastics joining technologies that will allow Device Manufacturers meet stringent quality requirements for new generation products utilizing MEMs and Micro-Fluidics. Infrastake - Staking At The Speed Of Light Scott Beute, Extol, Inc (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 2:30 PM Long ago, engineers recognized the benefits of eliminating glue, screws, and other fasteners, and as a result, they developed several different methods of heat staking that have been around for quite some time. Against this backdrop, a nonconventional staking process called InfraStake®, a relative newcomer in the business, has been developed. As the name suggests, the energy source is infrared light, and the heat transfer mode is radiation (the safe type!). The InfraStake module clamps the parts together, heats the boss evenly with precisely directed infrared light, and forms the plastic with a non-heated punch driven by a low-force pneumatic cylinder. Quasi-Simultaneous Laser Beam Welding Of Polymers In Closed Loop Wolfgang Horn, DILAS Diodenlaser GmbH (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 3:00 PM Polymer welding with lasers is getting a state-of-the-art tool in medical device manufacturing and automotive production. Most commonly used are track welding and quasi-simultaneous welding. An advantage of track welding is the availability of closed-loop pyrometercontrolled processing optics. On-axis processing optics control the part’s temperature and storage of process data for documentation and quality analysis. The new optics developed combine the benefit of track welding with the speed and addressability of quasi-simultaneous welding. Possibilities and limits of quasi-simultaneous closed-loop welding will be discussed with examples of industrial applications.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Maximize Ultrasonic Welding Efficiency And Safety By Minimizing Non-Productive Time And Energy Consumption Vasko Naumovski, Herrmann Ultrasonics (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 3:30 PM To increase productivity, equipment operations are coupled with automatic start triggering. An ingenious drive mechanism further makes the non-productive times shrink by means of efficient, effective stroke selection. Furthermore, with HiQ evolution, as an answer to rising energy prices, the customer saves up to 80% of the compressed air in his assembly process by optimizing the stroke position and speed. Project changeovers are possible without tools and take just seconds. The ergonomics are exemplary too. With regard to occupational health and safety, the new machine generation already fulfils the EU Machine Directive which goes into effect at the end of 2009. Business Committee Meeting (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 4:00 PM
For more information visit http://www.4spe.org/conferences/antec-2009 or contact: Peter Boergermann Technical Program Coordinator Phone: +1 203-740-5472 Email: [email protected]
Lesley Kyle Senior Event Manager Phone: +1 203-740-5452 Email: [email protected]
SIG Executives Bobbye Baylis Chair MAHLE Filter Systems Canada ULC PH: +1 519-682-0444 x5296 [email protected]
Alex Savitski TPC Baxter Healthcare PH: +1 847-270-2187 [email protected]
Society of Plastics Engineers
Marc St. John Editor EWI PH: +1 614-688-5219 [email protected]
Sophie Morneau Secretary Branson Ultrasonics PH: +1 203-796-0305 [email protected]
Volume 20, No. 1 (Spring 2009)
Message from the Chair It is somewhat strange to be waiting until June for our annual meeting of the Society of Plastics Engineers, but the opportunity to add the NPE exhibition to our activities is not to be missed As usual, there are many excellent papers that are being presented in the Special Interest Group on Joining of Plastics and Composites sessions, and it will again be very difficult to select the Best Paper. We are very lucky to have so many superlative groups doing and publishing research in our area. In addition to the papers, we always look forward to the Awards Dinner sponsored by Branson for our SIG, when the plaque for the Best Paper will be presented. We will again be giving a Best Student Presentation Award, so we hope that all who qualify as students will be letting the organizers know so that they can be considered for this award. The definition of “student” includes anyone in a course of study at an academic institution. If the work being presented was part of, for example, a doctoral research project, it still counted as a student presentation, even if the presenter had recently actually received the degree. The chance to experience Chicago should not be missed. It is not only famous for the having produced the new US President, but everyone should also make a point to see the at least one of its many art museums as well as the Museum of Science and Industry, with its magnificent U-boat. If nothing else, the pictures of how it was brought to the museum and a new section of building was created around it is worth the entry fee! See you in Chicago in June!
Bobbye Baylis Chair, Joining SIG
Society of Plastics Engineers
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Spring 2009 Newsletter Featured Paper This paper provides a general introduction to welding fundamentals (section 2) followed by sections on a few selected welding processes that have had significant developments or improvements over the last few years. The processes that are discussed are friction welding (section 3), hot plate welding (section 4), ultrasonic welding (section 5), laser/IR welding (section 6), RF welding (section 7) and hot gas/ extrusion welding (section 8). View this paper in its entirety: http://www.abe.iastate.edu/fileadmin/www.abe.iastate.edu/faculty/Files/Welding_Review.pdf
ANTEC™ @ NPE2009 McCormick Place West, Chicago, Illinois USA June 22-24
Joining of Plastics and Composites SIG Technical Sessions Instrumental Investigations Of Physical Gumminess Of A Medical Grade Epoxy-Amine Adhesive After Curing Xiaoping Guo, St Jude Medical Inc. Session (M13) Adhesives and Ultrasonic and Vibration Welding, 9:00 AM Various factors that might interfere with reaction stoichiometry and result in physical gumminess of the cured mass were investigated for an epoxy-amine adhesive system. Dynamic rheometry and infrared spectrometer (FT-IR) were used to measure dynamic mechanical properties in the adhesive during isothermal curing and the degree of conversion after curing. It was found that physical gumminess of the cured adhesive under a selected, normal curing condition was primarily due to the presences of excessive hardener and also liquid residuals of an industrial cleaner containing hydroxyl and amine functional groups, but not the excessive epoxy resin at a moderate level. Functionalized Polyolefins That Deliver Room Temperature Adhesion To Polyurethanes Laura Weaver, The Dow Chemical Company Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 9:30 AM Maleic anhydride (MAH) modified polymers and ethylene acrylic acid (EAA) copolymers are known to adhere well to polar materials in high temperature processes such as in multi-layer film and sheet extrusion. However, these materials have been found to exhibit unacceptable adhesion to polar materials such as polyurethane foams, adhesives, and coatings in room temperature applications [1-2]. Three new developmental products are now available for sampling which can be co-extruded with either low density polyethylene (LDPE), propyleneethylene elastomers, or ethylene-alpha-olefin elastomers;-olefin elastomers and provide a high functionality surface layer that enables adhesion to urethanes at room temperature. Weldability Of Polylactic Acid Sheets And Films Julius Vogel, Iowa State University Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 10:00 AM Emerging product lines of PLA and PHA based materials has kindled the need to investigate their manufacturability utilizing traditional techniques. This article examines the weld-ability of PLA plastics using Ultrasonic welding. PLA Samples were conditioned and ultrasonically welded under different parameter sets of amplitude, pressure, weld time and weld geometry. Based on preliminary results the range of variables were narrowed down, amplitude ranging from 65 to 100% and weld time 3 to10 seconds. A high weld efficiency of 90% was observed with 75% amplitude and 5 seconds weld-time. Further detailed studies on the flexibility and peeling of the weld were tested for.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Experiments In Vibration Welding Of PC And PMMA To Metallization Coated PC Chung Wu, Visteon Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 10:30 AM Thin metal coating of plastic parts for increased optical properties or for decoration has gained more importance in recent years. This coating is often found in the weld area and there are concerns regarding its effect on weldability. Therefore, vibration welding of PC and PMMA to metallization coated PC plates was studied to evaluate the effect of the coating on weld strength. The effects of amplitude of vibration, meltdown, and pressure on joint strength were evaluated. It was found that for welding of PMMA to coated PC, using higher pressures and meltdowns resulted in stronger jointsFor welding of PC to coated PC all the joints were as strong as welding of PC to uncoated PC. Vibration Welding Polypropylene – Effect Of MFI On Weld Strength And Microstructure Phil Bates, Royal Military College of Canada Session (M13) Adhesives and Ultrasonic and Vibration Welding Session, 11:00 AM Examines the weld strength and microstructure of three polypropylene homopolymers of different melt flow index (MFI). The heat affected zone thickness was observed to be inversely proportional to weld pressure and polymer MFI. The weld strength was observed to decrease with pressure. The weld strengths of lower MFI polymers were more weld-pressure sensitive. Effect Of Molecular Structure On Heat Seal Properties For High Density Polyethylene Film Ken Miyata, Yamagata University Session (M32) Hot Plate and Staking Session, 1:30 PM Effect of molecular structure on heat seal properties for high density polyethylene (HDPE) film was investigated in this study. The HDPE film whose melting temperature was 126 degrees C was heat sealed at 125 and 128 degrees C controlling and varying sealing pressure and temperature. The mechanical property of the sealed films was measured by a T-shape peeling test. Thermal analysis was performed by a differential scanning calorimetry (DSC). We discussed weight fraction of melting region in heat seal process is related to the major factor to decide peeling properties of heat sealed HDPE film. In-Line Process Optimization Of Hot-Plate Welding Using An Innovative Actuation Concept Reinhild Hoffschlag, University of Paderborn Session (M32) Hot Plate and Staking Session, 2:00 PM An innovative actuation concept of a hot-plate welding machine enables to apply haul-off speed against the joining direction. Thus, it is possible to investigate weld strength within the semi-molten state of the weld. To use this data for self-optimization a coherence between the strength in molten and cooled down state has to be detected. Methods can be developed to determine the optimal processing window. Results show that the optimal joining path to melt layer thickness ratio can be detected without knowing the short time tensile strength. Similar results are valid for melt layer to wall thickness ratio. Based on this, a self-optimization and a quality assurance test can be developed. Influence Of Processing Parameters On Microstructure And Properties Of A Polyetherimide Joined By Fricriveting: Investigation Of Rotational Speed Sergio Amancio Filho, GKSS Research Centre Session (M32) Hot Plate and Staking Session, 2:30 PM FricRiveting is a new spot joining technique for polymer-metal structures, recently introduced at ANTEC 08 (ANTEC-0340-2008). It is well known that processing in joining technology plays a central role in dictating joint properties. Its understanding is a key matter for producing reliable connections. It has been reported that rotational speed is an important controlling parameter in FricRiveting. This study will experimentally determine the influence of rotational speed on FricRiveting joint microstructure, local and global strength and thermal history for a thermoplastic polyetherimide joined by threaded aluminum rivets.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Prediction Of Residual Stress Formation In Polycarbonate Welded Samples Using Finite Element Analysis Avraham Benatar, The Ohio State University Session (M32) Hot Plate and Staking Session, 3:00 PM During plastic welding, the localized heating the cooling near the weld results in residual stress formation due to differences in thermal expansion between the hot and cold regions. During cooling, some of that residual stress may be relieved due to stress relaxation of the viscoelastic polymer. ANSYS finite element analysis was used to predict the temperature fields and cooling rates for hot plate welding, through transmission laser welding, and vibration welding of polycarbonate. The temperature history was then used in a viscoelastic ANSYS finite element model to predict the residual stress distribution, which was in good agreement with previously published residual stress measurements. Experimental Study Of Hot Plate Welding Of Polycarbonate Using Displacement Versus Pressure Control Avraham Benatar, The Ohio State University Session (M32) Hot Plate and Staking Session, 3:30 PM During hot plate welding the welding phase can be controlled by either pressure or displacement. When using pressure control, the parts are placed under constant pressure simultaneously squeezing and cooling the melt layer until the interface solidifies. In displacement control, the parts are pressed together until mechanical stops are reached and the weld cools further under no pressure. In this work we studied hot plate welding of polycarbonate using low and high temperature hot plate and with pressure versus displacement control. While high quality welds can be produced in both cases, the welding conditions differ between the two control methods. Experiments With Impulse Heat Staking Of Polypropylene To ABS Avraham Benatar, The Ohio State University Session (M32) Hot Plate and Staking Session, 4:00 PM In staking, a thermoplastic post is melted and reshaped to form a head, thereby mechanically joining the plastic part to another part. In this work, an impulse staking head using a nichrome ribbon was designed and fabricated. The heat staking head was then used to join together PP plates with a post that is 3.04 mm in diameter by 8 mm high to ABS plates with a matching hole. It was found that increasing the impulse heating time squeezed down more of the head reducing its thickness and therefore the joint strength. Pressure had very little effect on the thickness of the head or joint strength. Impulse staking appears to be a promising new approach for rapid staking and joining of parts. SIG Steering Committee Meeting Session (M32) Hot Plate and Staking Session, 4:30 PM Closed Loop Control in Laser Welding of Plastic Components Richard Davis, Rofin-Sinar, Inc Session (T14) Laser Welding Session, 8:30 AM Laser welding of plastic components places a high demand on control of the melt temperature range of the partnering materials. The use of an integrated pyrometer provides real time closed loop control of the process by monitoring emissions directly from the melt region generated by the incident laser radiation. These emissions are captured, measured, interpolated, and thus correlated to a known temperature. The data generated by the pyrometer can be used to produce an analog output signal that adjusts the current to the direct diode laser source to maintain a predetermined temperature set point and allows for the ability to adaptively control part to part variation and dynamic process conditions.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Closed Loop Control in Laser Welding of Plastic Components Richard Davis, Rofin-Sinar, Inc Session (T14) Laser Welding Session, 8:30 AM Laser welding of plastic components places a high demand on control of the melt temperature range of the partnering materials. The use of an integrated pyrometer provides real time closed loop control of the process by monitoring emissions directly from the melt region generated by the incident laser radiation. These emissions are captured, measured, interpolated, and thus correlated to a known temperature. The data generated by the pyrometer can be used to produce an analog output signal that adjusts the current to the direct diode laser source to maintain a predetermined temperature set point and allows for the ability to adaptively control part to part variation and dynamic process conditions. Laser Welding Of Thermoplastic Urethane Films Ryan Marsico, Gentex Corporation Session (T14) Laser Welding Session, 9:00 AM Laser welding is increasingly becoming a technology of choice in the plastics joining industry. The use of infrared absorbers to laser weld thermoplastic materials, including thermoplastic elastomers, is also of interest to the plastics industry. Therefore, an investigation of the laser welding characteristics of four classes of thermoplastic urethanes using organic infrared absorbing materials was undertaken. In addition, the use of thermoplastic urethanes as intermediate layers with dissimilar plastics has also been examined. This paper reviews the results of these welding studies. Optical Properties Characterization Of Thermoplastics Used In Laser Transmission Welding: Part I. Transmittance And Reflectance C.Y. Wang, Soochow University Session (T14) Laser Welding Session, 9:30 AM A better understanding of the optical properties of plastics at IR wavelengths is important for optimizing the laser transmission welding process. In this study, the optical properties of polypropylene (PP), polycarbonate (PC) and polyamide (PA) were investigated by using spectrophotometer with integrating sphere. The influence of thickness, surface roughness and filler content on optical properties of thermoplastics was evaluated. The results could contribute to a better understanding of the process itself and to success in the practical applications. CO2 Laser Welding Of The PFA Disk Top On A Circular Tube Assisted By A Transparent Solid Heat Sink Yasuo Kurosaki, University of Electro-communications Session (T14) Laser Welding Session, 10:00 AM There has been no adequate laser welding method for fluorocarbon polymer such as PFA and PTFE. An innovative CO2 laser welding method [1] is applied for overlapped PFA polymer film sheet. The features of the welding procedure are: to use a solid heat sink transparent to CO2 laser beam, to use no pigmentation or dye for radiation absorption enhancement, and to sustain thermal damage on the surface. The feasibility of the procedure was confirmed to be usable for joining of thinner PFA film sheet than 0.3 mm. The laser welding machine in a production line was manufactured to weld the top of the circular tube of variable area flow-meters with film disk. Laser Welding Of Nylon Tubes To Plates Using Conical Mirror Phil Bates, Royal Military College of Canada Session (T14) Laser Welding Session, 10:30 AM In this study, nylon tubes were welded to nylon plaques using laser transmission welding. A conical mirror inserted inside the tube was used to guide the laser beam along the weld path following the inner circumference of the tube. The intensity profile of the reflected laser beam reaching the cylindrical tube surface was characterized. Effect of the laser power, the angular motion speed, and the cycle time on the joint shear strength was examined. Process parameters were identified giving good joint strengths.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Laser Transmission Welding Of Glass Fibre Reinforced Nylon 6 – Finite Element Thermal Modeling And Microstructural Validation Phil Bates, Royal Military College of Canada Session (T14) Laser Welding Session, 11:00 AM Presents FEM heat transfer analysis for contour LTW of glass-fibre-reinforced Nylon 6. Simulated temperature fields around the weld interface were compared with weld microstructures. Temperature profiles were compared to the experimentally obtained weld cross sections. Satisfactory agreement was obtained between the predicted and experimental results. Comparison Of Newly Developed Ultrasonic Welder To Standard Ultrasonic Welder Miranda Marcus, Dukane - Intelligent Assembly Solutions (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 1:30 PM Ultrasonic welding is one of the most widely used processes for bonding polymers, valued for it’s speed, flexibility, and low cost. Recently there has been a call for more controlled and consistent welding processes, especially in the medical field. Dukane has worked to meet this demand through the development of a new ultrasonic welder. Careful comparison, detailed here, has shown that the newly developed welder provides more consistent results than the standard welder. The newly developed welder also offers a number of user friendly ergonomic features, superior Graphic User Interface with Ethernet connectivity as well as more accurate process control capabilities. Advances In Plastics Joining Technologies For The Assembly Of Medical Devices Nitin Phadnis, Branson Ultrasonics Corp (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 2:00 PM The goal of this paper is to discuss the various methods and techniques that a Device Manufacturer can use to insure they meet FDAs QS/ GMP requirements when assembling plastic components as well as to discuss the advances made in plastics joining technologies that will allow Device Manufacturers meet stringent quality requirements for new generation products utilizing MEMs and Micro-Fluidics. Infrastake - Staking At The Speed Of Light Scott Beute, Extol, Inc (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 2:30 PM Long ago, engineers recognized the benefits of eliminating glue, screws, and other fasteners, and as a result, they developed several different methods of heat staking that have been around for quite some time. Against this backdrop, a nonconventional staking process called InfraStake®, a relative newcomer in the business, has been developed. As the name suggests, the energy source is infrared light, and the heat transfer mode is radiation (the safe type!). The InfraStake module clamps the parts together, heats the boss evenly with precisely directed infrared light, and forms the plastic with a non-heated punch driven by a low-force pneumatic cylinder. Quasi-Simultaneous Laser Beam Welding Of Polymers In Closed Loop Wolfgang Horn, DILAS Diodenlaser GmbH (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 3:00 PM Polymer welding with lasers is getting a state-of-the-art tool in medical device manufacturing and automotive production. Most commonly used are track welding and quasi-simultaneous welding. An advantage of track welding is the availability of closed-loop pyrometercontrolled processing optics. On-axis processing optics control the part’s temperature and storage of process data for documentation and quality analysis. The new optics developed combine the benefit of track welding with the speed and addressability of quasi-simultaneous welding. Possibilities and limits of quasi-simultaneous closed-loop welding will be discussed with examples of industrial applications.
JOINING NEWS NEWSLETTER OF THE SOCIETY OF PLASTICS ENGINEERS JOINING OF PLASTICS AND COMPOSITES SPECIAL INTEREST GROUP
Volume 20, No. 1 (Spring 2009)
Joining of Plastics and Composites SIG Technical Sessions cont’d. Maximize Ultrasonic Welding Efficiency And Safety By Minimizing Non-Productive Time And Energy Consumption Vasko Naumovski, Herrmann Ultrasonics (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 3:30 PM To increase productivity, equipment operations are coupled with automatic start triggering. An ingenious drive mechanism further makes the non-productive times shrink by means of efficient, effective stroke selection. Furthermore, with HiQ evolution, as an answer to rising energy prices, the customer saves up to 80% of the compressed air in his assembly process by optimizing the stroke position and speed. Project changeovers are possible without tools and take just seconds. The ergonomics are exemplary too. With regard to occupational health and safety, the new machine generation already fulfils the EU Machine Directive which goes into effect at the end of 2009. Business Committee Meeting (T31) Industrial Panel: Advances in Plastic Joining Technologies for Medical Applications Session, 4:00 PM
For more information visit http://www.4spe.org/conferences/antec-2009 or contact: Peter Boergermann Technical Program Coordinator Phone: +1 203-740-5472 Email: [email protected]
Lesley Kyle Senior Event Manager Phone: +1 203-740-5452 Email: [email protected]
SIG Executives Bobbye Baylis Chair MAHLE Filter Systems Canada ULC PH: +1 519-682-0444 x5296 [email protected]
Alex Savitski TPC Baxter Healthcare PH: +1 847-270-2187 [email protected]
Society of Plastics Engineers
Marc St. John Editor EWI PH: +1 614-688-5219 [email protected]
Sophie Morneau Secretary Branson Ultrasonics PH: +1 203-796-0305 [email protected]
