[Link].

in

मेरा IPU

Notes
HARDWORK❌
SMARTWORK ✅

[Link]
MANUFACTURING PROCESS

ES-119 UNIT -4

Department of Applied Sciences, BVCOE New Delhi

POWDER METALLURGY
 Powder Metallurgy
➢ Essentially, Powder Metallurgy (PM) is an art & science of
producing metal or metallic powders, and using them to make
finished or semi-finished products.
➢ Particulate technology is probably the oldest forming technique
known to man.

➢ There are archeological evidences to prove that the ancient man

knew something about it.
 Powder Metallurgy
➢ An important point that comes out :

➢ The entire material need not be melted to fuse it.

➢ The working temperature is well below the melting point of the

major constituent, making it a very suitable method to work with
refractory materials, such as: W,Mo, Ta, Nb, oxides, carbides, etc.
➢ It began with Platinum technology about 4 centuries ago… in
those days, Platinum, [MP = 1774°C], was "refractory", and
could not be melted.
 Powder Metallurgy Process

➢ Powder production
➢ Blending or mixing
➢ Powder compaction
➢ Sintering
➢ Finishing Operations
Powder Metallurgy Process
Powder Metallurgy
Processing Powder fabrication
POWDER Size and shape characterization
Microstructure (e.g.. dendrite size)
Chemical homogeneity, and ppt. size

Compaction
Sintering
PROCESSING
Forging/Hot pressing

Density, Porosity
Ductility, Strength

PROPERTIES Conductivity
Other functional properties
 Usual PM production
sequence
Blending and mixing (Rotating drums, blade and
screw mixers)
Pressing - powders are compressed into desired
shape to produce green compact
Accomplished in press using punch-and-die
tooling designed for the part
Sintering – green compacts are heated to bond the
particles into a hard, rigid mass.
Performed at temperatures below the melting point
of the metal
 Production of Metallic Powders
➢ In general, producers of metallic powders are not the same
companies as those that make PM parts
➢ Any metal can be made into powder form

➢ Three principal methods by which metallic powders are

commercially produced
➢ Atomization (by gas, water, also centrifugal one)

➢ Chemical

➢ Electrolytic

➢ In addition, mechanical methods are occasionally used to reduce

powder sizes
Particle Shapes in Metal
Powders
 Conventional powder
metallurgy production
sequence:
➢ blending
➢ compacting
➢ Sintering
 Blending and Mixing of
Powders
For successful results in compaction and sintering,
the starting powders must be homogenized
(powders should be blended and mixed).

➢ Blending - powders of same chemistry but possibly different

particle sizes are intermingled
➢ Different particle sizes are often blended to reduce porosity

➢ Mixing - powders of different chemistries are combined .

PM technology allows mixing various metals into alloys that would

be difficult or impossible to produce by other means.
 Blending or Mixing
➢ Blending a coarser fraction with a finer fraction ensures that the
interstices between large particles will be filled out.
➢ Powders of different metals and other materials may be mixed in
order to impart special physical and mechanical properties
through metallic alloying.
➢ Lubricants may be mixed to improve the powder’s flow
characteristics.
➢ Binders such as wax or thermoplastic polymers are added to
improve green strength.
 Blending
To make a homogeneous mass with uniform distribution
of particle size and composition.
➢ Powders made by different processes have different sizes and
shapes
➢ Mixing powders of different metals/materials
Combining is generally carried out in
➢ Air or inert gases to avoid oxidation
➢ Liquids for better mixing, elimination of dusts and reduced
explosion hazards
 Bowl Geometries

Some common equipment geometries used for

blending powders
(a) Cylindrical, (b) rotating cube, (c) double A mixer suitable for blending metal
cone, (d) twin shell
powders.
 Compaction
Application of high pressure to the powders to
form them into the required shape.

Conventional compaction method is pressing, in which

opposing punches squeeze the powders contained in a die.
➢ The work part after pressing is called a green compact,
the word green meaning not yet fully processed.

➢ The green strength of the part when pressed is adequate

for handling but far less than after sintering.
 Compacting

 Press powder into the desired shape and size in dies using a
hydraulic or mechanical press
 Pressed powder is known as “green compact”
 Stages of metal powder compaction:
 Compacting

Powders do not flow like liquid, they simply

compress until an equal and opposing force is
created.
– This opposing force is created from a combination of
(1) resistance by the bottom punch and
(2) friction between the particles and die surface

Compacting consolidates and dandifies the

component for transportation to the sintering
furnace.
 Compacting

Compacting is usually performed at room temperature. Pressures

range from 10 tons per square inch (tons/in2) (138 MPa) to 60
tons/in2 (827 MPa), or more.
 Figure: (Left) Typical press for the compacting of metal powders. A removable die
set (right) allows the machine to be producing parts with one die set while another is
being fitted to produce a second product.
 Compaction
Sequence

Figure: Typical compaction sequence for a single-level part, showing the

functions of the feed shoe, die core rod, and upper and lower punches. Loose
powder is shaded; compacted powder is solid black.
Friction problem in cold
compaction
 Sintering
Heattreatment to bond the metallic particles,
thereby increasing strength and hardness.

Usually carried out at between 70% and 90% of the metal's

melting point (absolute scale)

– Generally agreed among researchers that the primary

driving force for sintering is reduction of surface energy

– Part shrinkage occursduring sintering due to

pore size
reduction
 Sintering

➢ Parts are heated to ~80% of melting temperature.

➢ Transforms compacted mechanical bonds to much stronger metal
bonds.
➢ Many parts are done at this stage. Some will require additional
processing.
 Sintering Sequence
➢ Parts are heated to 0.7~0.9 Tm.
➢ Transforms compacted mechanical bonds to much stronger
metallic bonds.

Figure: Sintering on a microscopic scale: (1) particle bonding is

initiated at contact points; (2) contact points grow into "necks"; (3) the
pores between particles are reduced in size; and (4) grain boundaries
develop between particles in place of the necked regions.
 Sintering
Third stage:
Sintered product is cooled in a controlled atmosphere.
– Prevents oxidation and thermal shock

Gases commonly used for sintering:

H2, N2, inert gases or vacuum
Sintering Cycle and
Furnace
Powder Rolling
 Powder Metallurgy
Merits
 Precision parts can be produced

 The production can be fully automated, therefore,

 Mass production is possible

 Production rate is high

 Over-head costs are low

 Break even point is not too large

 Material loss is small

 Advantages of P/M
➢ Virtually unlimited choice of alloys, composites, and
associated properties
➢ Refractory materials are popular by this process

➢ Can be very economical at large run sizes (100,000

parts)
➢ Long term reliability through close control of
dimensions and physical properties
➢ Wide latitude of shape and design
➢ Very good material utilization
 Limitations and
Disadvantages
➢ High tooling and equipment costs.

➢ Metallic powders are expensive.

➢ Problems in storing and handling metal powders.

➢ Degradation over time, fire hazards with certain metals

➢ Limitations on part geometry because metal powders do not

readily flow laterally in the die during pressing.
➢ Variations in density throughout part may be a problem,
especially for complex geometries.
 Powder Metallurgy
Disadvantages
➢ Porous !! Not always desired.
➢ Large components cannot be produced on a large scale.
➢ Some shapes are difficult to be produced by the conventional
p/m route.

Whatever, the merits are so many that P/M, as a forming

technique, is gaining popularity
PM Parts
 Powdered Metal Transmission Gear Connecting Rods:
➢ Warm compaction method with 1650-ton Forged on left; P/M on
press right
➢ Teeth are molded net shape: No machining
➢ UTS = 155,000 psi
➢ 30% cost savings over the original forged part
 Unit 4

SEMESTER I
Manufacturing of Plastic Components

Department of Applied Sciences, BVCOE New Delhi

 INTRODUCTION
◼Plastic

• Plastic is the general common term for a wide range of synthetic or semi synthetic organic
amorphous solid materials suitable for the manufacture of industrial products.
• Plastics are typically polymers of high molecular weight, and may contain other substances to
improve performance and/or reduce costs.

Types of Plastics
• Plastics can be divided into two major categories:

1. Thermoset or thermosetting plastics. Once cooled and hardened, these plastics retain
their shapes and cannot return to their original form. They are hard and durable. Thermosets
can be used for auto parts, aircraft parts and tires.
Examples include polyurethanes, polyesters, epoxy resins and phenolic resins.

2. Thermoplastics. Less rigid than thermosets, thermoplastics can soften upon heating and
return to their original form. They are easily molded and extruded into films, fibers and
packaging.
Examples include polyethylene (PE), polypropylene (PP) and polyvinyl chloride (PVC).

Department of Applied Sciences, BVCOE New Delhi

Thermoset or Thermosetting Plastics

1. Polyurethane Plastics :- Polyurethane plastics belong to the group that can be thermosetting.
Polyurethane is the only plastic which can be made in both rigid and flexible foams. The flexible
polyurethane foam is used in mattresses, carpets, furniture etc. The rigid polyurethane foam is used
in chair shells, mirror frames and many more. Due to the property of high elasticity, some
polyurethane plastics are used in decorative and protective coatings. The high elasticity makes
these polyurethane plastics resistant to a chemical attack.
2. Epoxy
Epoxies are used in numerous ways. In combination with glass fibers, it is capable of producing
composites that are of high strength and that are heat resistant. This composite is typically used for
filament wound rocket motor casings in missiles, in aircraft components, and in tanks, pipes, tooling
jigs pressure vessels, and fixtures. Epoxies are also found in gymnasium floors, industrial
equipment, sealants, and protective coatings in appliances.
3. Phenolic
Phenolic plastics are thermosetting resins used in potting compounds, casting resins, and laminating
resins. They can also be used for electrical purposes and are a popular binder for holding together
plies of wood for plywood.

Department of Applied Sciences, BVCOE New Delhi

 Thermoplastics
[Link] Plastics :-
Vinyl plastics belong to the thermoplastic group. Vinyl plastics are the sub-polymers of vinyl
derivatives. These are used in laminated safety glasses, flexible tubing, molded products etc.
[Link] Plastics :- Polyacrylics belong to the group of thermoplastics. Polyacrylics are
transparent , decorative and can be shaped in any form like the windshields for airplane.
[Link] Chloride
Polyvinyl Chloride, commonly referred to as PVC or vinyl, was first invented in Germany around
1910. It didn't become a useful product in the United States, however, until the late 1920s. It
became particularly useful during World War II when it was used as a substitute for rubber, which
was in short supply. Polyvinyl Chloride is resistant to abrasion and is both weather and chemical
resistant. Today, it is commonly found in upholstery, wall coverings, flooring, siding, pipe, and even
apparel. In fact, vinyl is perhaps the best known of all plastics.
[Link] Terephthalate (PETE) :- PETE is one the most recycled plastic. It finds usage in
various bottles like that of soda and cooking oil, etc.
[Link] Density Polyethylene (HDPE):-HDPE is generally used in detergent bottles & in milk jugs.
[Link] Chloride (PVC) :- PVC is commonly used in plastic pipes, furniture, water bottles, liquid
detergent jars etc.
[Link] Density Polyethylene (LDPE) :- LDPE finds its usage in dry cleaning bags, food containers
[Link] (PP) :- PP is commonly used in bottle caps and drinking straws.
[Link] (PS) :- PS is used in cups, plastic tableware etc.

Department of Applied Sciences, BVCOE New Delhi

 Characteristics of Plastics
• Mechanical properties
Mechanical properties refer to displacement or breakage of plastic due to some mechanical change
such as applying some load. Mechanical properties are dependent on the temperature, force (load),
and the duration of time the load is applied.
• Thermal properties
Thermal properties include heat resistance or combustibility. Thermoplastic has a larger coefficient
of thermal expansion or combustibility and a smaller thermal conductivity or specific heat than other
material such as metals.
• Chemical properties
Chemical resistance, environmental stress crack resistance , or resistance to environmental change
are referred as chemical properties. When a plastic contacts chemicals, there is some kind of
change. After having a plastic in contacted with chemicals under no stress for about a week,
changes in appearance, weight and size of the plastic are examined.
• Electric properties
Electric properties are also referred to as electromagnetic properties. Electric properties include
insulation, conductivity and electro-static charges. Due to their good insulation property, plastics are
often used in electric fields. However, plastics do have a defect; they are easily electrified.
• Physical properties
Specific gravity, index of refraction and moisture absorption are called physical properties. The
specific gravity of the plastic is small, and it varies depending on the character of high polymer , or
thermal and mechanical treatment of the plastic.
Department of Applied Sciences, BVCOE New Delhi
 Moulding of Thermoplastics,

Moulding Processes:-

i. Compression Moulding
ii. Transfer Moulding
iii. Injection Moulding
iv. Jet Moulding
v. Extrusion

Department of Applied Sciences, BVCOE New Delhi

 Compression molding
• Compression molding is a method of molding in which the molding material, generally preheated,
is first placed in an open, heated mold cavity. The mold is closed with a top force or plug member,
pressure is applied to force the material into contact with all mold areas, while heat and pressure are
maintained until the molding material has cured.
Common plastics used in compression molding processes include
• Polyester
• Polyimide (PI)
• Polyamide-imide (PAI)
• Polyphenylene Sulfide (PPS)
• Polyetheretherketone (PEEK)
• Fiber reinforced plastics

Department of Applied Sciences, BVCOE New Delhi

 Transfer molding
• Transfer molding is similar to compression
molding in that a carefully calculated, pre-
measured amount of uncured molding
compound is used for the molding process.

• The difference is, instead of loading the

polymer into an open mold, the plastic
material is pre-heated and loaded into a
holding champers called the pot.

• The material is then forced/transferred into

the pre-heated mold cavity by a hydraulic
plunger through a channel called sprue. The
mold remains closed until the material inside
is cured.

Department of Applied Sciences, BVCOE New Delhi

 Injection molding
• Injection molding is a manufacturing process for producing parts from both
thermoplastic and thermosetting plastic materials.
• Material is fed into a heated barrel, mixed, and forced into a mold cavity where it cools
and hardens to the configuration of the mold cavity.
Conventional Single Stage Plunger Type:-

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Jet Moulding
• A modified version of the Injection moulding is known as Jet Moulding Process.
• In this process the Plastic is preheated to about 93’C in the cylinder surrounding to
nozzle.
• It is further heated as the plunger forces the resin through the nozzle.
• After the mould has been filled, the nozzle is cooled by running water to prevent
polymerization of the remaining material.

Extrusion Moulding
• Extrusion is one of the most widely used manufacturing processes across many
industries.
• Essentially, it is not much different from squeezing tooth paste out of the tube.
• Anything that is long with a consistent cross section is probably made by extrusion.
• Common examples are spaghetti, candy canes, chewing gums, drinking straws,
plumbing pipes, door insulation seals, optical fibers, and steel or aluminum I-beams.

Department of Applied Sciences, BVCOE New Delhi

 INJECTION MOULDING

Department of Applied Sciences, BVCOE New Delhi

 INJECTION MOULDING
• Palletized material is fed with use of hopper into a
cylinder where material melts due to heating coils
• Molten metal is impelled through nozzle into the
enclosed cavity
• Outstanding characteristic of this mounding process is
cycle time is very less. i.e. rate of production is very high
• The complete injection molding process is divided into
four stages: clamping, injection, cooling and ejection.

Department of Applied Sciences, BVCOE New Delhi

 INJECTION MOULDING

• Clamping: The two halves of the mold must be tightly

closed, before the molten plastic material is injected into the
mold. One half of the mold is attached to the injection
unit(nozzle) and other half is allowed to slide on the
guideways

• Injection: During this process, the plastic material is

melted by the application of heat and forwarded through the
piston towards the nozzle and finally into the mold. The
amount of material that is injected into the mold is referred
to as the shot volume.
Department of Applied Sciences, BVCOE New Delhi
 INJECTION MOULDING
Cooling:
• The injected molten plastic begins to cool as soonas it comes in
contact with the mold surfaces.
• As the molded part cools, it will solidify into the desired shape
of the product
Ejection:
• The molded part, which is attached to the rear half of the mold
has to be ejected from the mold
• An ejector mechanism is used to push the part out of the mold
• Force must be applied to eject the plastic part because during
cooling the molded part shrinks and adheres to the mold surface
• A mold release agent should be sprayed onto the moldsurfaces
prior to injection of the material.
Department of Applied Sciences, BVCOE New Delhi
 INJECTION MOULDING

Advantages
• Higher production rate
• Close tolerances on small intricate parts
• Minimum wastage of material
• Complex geometry can be easily produced
Disadvantages
• Tooling cost higher
• High setup cost
• Large undercuts can't be formed
Applications
household appliances, electronics, and automotivedash boards,
buckets etc...
Department of Applied Sciences, BVCOE New Delhi
 BLOW MOULDING

Department of Applied Sciences, BVCOE New Delhi

 BLOW MOULDING

Department of Applied Sciences, BVCOE New Delhi

 BLOW MOULDING

• Using this manufacturing process blind parts are made like

bottle or sphere etc
• Air is blown into a thin walled plastic cylinder called the
parison. The parison is formed by melted plastic material
being pushed through an extruder
• When the parison reaches a certain length, the two halves of
the mould close around the parison sealing it at thebottom
• Compressed air is then used to inflate the parison to form
the shape of the cavity inside the mould.

Department of Applied Sciences, BVCOE New Delhi

 BLOW MOULDING

Advantages
• Low tooling cost
• Fast production rates
• Ability to mold complex part with uniform thickness
• Little scrap generated
• Large hollow shape can be produced
Disadvantages
• Limited to hollow parts
• Thick parts can't be manufactured
Applications
• Bottles in different shapeand size, jars, containers, mug
,toys, etc…
Department of Applied Sciences, BVCOE New Delhi
 ROTATIONAL MOULDING

Department of Applied Sciences, BVCOE New Delhi

 ROTATIONAL MOULDING

• Rotational moulding is a process of making hollow articles

• The part is formed inside a closed female mould

• In this process the mould rotates biaxially during heating

and cooling cycle

• Rotational moulded pieces are stress free because the pieces

are produced without any external pressure

Department of Applied Sciences, BVCOE New Delhi

 ROTATIONAL MOULDING

Advantages
• The major advantage of rotational moulding as compared to
other plastic moulding processes is that it can make very
large parts
• It requires comparatively low cost input
• The products are stress free with strong out side corners.
There are no sprue or gate marks
• Good control over wall thickness variation is also
achievable as compared to blow moulding or
thermoforming
• No scrap or very little scrap is produced
• Low tooling cost
Department of Applied Sciences, BVCOE New Delhi
 ROTATIONAL MOULDING

Disadvantages
• The moulding cycles are longer compared to blow
moulding and thermoforming
• In case of big parts loading and unloading isvery labour
intensive
• The process is not suitable for parts with wall thickness less
than 0.03”
• The conversion of plastic granules to powder form
increases the equipment and process cost.

Department of Applied Sciences, BVCOE New Delhi

EXTRUSION MOULDING

Department of Applied Sciences, BVCOE New Delhi

Department of Applied Sciences, BVCOE New Delhi
Advantages & Disadvantages of
Extrusion Moulding

Department of Applied Sciences, BVCOE New Delhi

Applications of Extrusion
Mouldling

Department of Applied Sciences, BVCOE New Delhi

 FILM BLOWING
➢ Film blowing or Blown film is another extrusion
processes used to fabricate film products.
➢ In this case the extrusion die is shaped as a circle and
air pressure is used to further expand the film. After it is
expanded to the desired dimensions it is cooled to
solidify the polymer.
➢ Plastic melt is extruded through an annular slit die,
usually vertically, to form a thin walled tube. Air is
introduced via a hole in the centre of the die to blow up
the tube like a balloon. Mounted on top of the die, a
high-speed air ring blows onto the hot film to cool it.
Department of Applied Sciences, BVCOE New Delhi
 FILM BLOWING
➢ Blown Film Extrusion is an established process which is
used to manufacture a wide range of commodity &
specialized plastic films for the packaging industry.
➢ Also known as Film Blowing Process, this extrusion
process generally comprises extrusion of molten
thermoplastic tube and its constant inflation to several
times of its initial diameter. This forms a thin, tubular
product which may be used directly, or indirectly by
slitting it to create a flat film.

Department of Applied Sciences, BVCOE New Delhi

 FILM BLOWING

Schematic of blown film process

Department of Applied Sciences, BVCOE New Delhi

 Photograph of film production by blowing process

Department of Applied Sciences, BVCOE New Delhi

 Materials Used
➢ In the process of Blown Film Extrusion, the common
resins that are used are Polyethylenes (LDPE, HDPE and
LLDPE).
➢ Though, various other materials can also be used in this
process, as a blend with resins or even as single layers in
the multi-layer film structure. Some of these materials
are PP, PP, and EVOH.
➢ In few instances when these materials are not able to gel
together, then a multi-layer film might get de-laminate.
Hence, to overcome this issue, various tiny layers of
special adhesive resins are used purposefully in between.
These tiny layers are called “tie layers”.
Department of Applied Sciences, BVCOE New Delhi
 Advantages of Film blowing
In a single operation, flat as well as gusseted tubing are
formed
Regulation of film thickness and width with the control of air
volume in the bubble
Elimination of the end effects like edge bead trim along with
non-uniform temperature which can cause from flat die film
extrusion
Capability of biaxial orientation, which allows uniformity in
all the mechanical properties
Very high productivity
Allows combination of different materials as well as
properties
Department of Applied Sciences, BVCOE New Delhi
 Applications Of Blown
Film Extrusion
In this extrusion process, the blown film is used either
in tube form (for plastic sacks and bags) or a sheet can
be used by slitting the tube. Typical applications of the
Blown Film Extrusion or Film Blowing includes
following:
1. Industry Packaging
2. Consumer Packaging
3. Laminating film
4. Barrier film
5. Films for packaging medical products

Department of Applied Sciences, BVCOE New Delhi

 THERMOFORMING

Department of Applied Sciences, BVCOE New Delhi

 THERMOFORMING

Department of Applied Sciences, BVCOE New Delhi

TYPES OF THERMOFORMING

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Department of Applied Sciences, BVCOE New Delhi
Department of Applied Sciences, BVCOE New Delhi
Advantages & Disadvantages of
Thermoforming

Department of Applied Sciences, BVCOE New Delhi

Applications of Thermoforming

Department of Applied Sciences, BVCOE New Delhi

Compression Moulding
 Compression Moulding
•First, the charge is loaded into the lower half of mold which is
preheated to maintain the temperature of charge during the
process.

•The placed charge is compressed by bringing both halves of

mold close together.

•The charge is heated by means of the hot mold to polymerize

and cure it into a solidified desired shaped molded plastic
component.

•Then, the halves are opened & molded plastic part is removed
by pressing knockout pins towards inside.
 Compression Moulding
Advantages
•Low initial setup costs and fast setup time
•Heavy plastic parts can be molded
•Complex intricate parts can be made
•Good surface finish of the molded parts
•Wastes relatively little material as compared with other
methods
•The molding process is cheaper as compared to injection
molding
Disadvantages
• Low production rate
• Limited largely to flat or moderately curved parts with no
undercuts
 Compression Moulding
Applications
•Electrical and electronic equipments, brush and mirror
handles, trays, cookware knobs, aircraft main power
terminal housing, pot handles, dinnerware plates,
automotive parts.
Transfer Moulding
 Transfer Moulding
•It is similar to compression molding. The difference is,
instead of loading the polymer into an open mold, the
plastic material is preheated and loaded into a holding
chamber called pot.
•The material is then forced into a preheated mold cavity
using a ram or hydraulic plunger through a channel called
sprue.
•The mold remains closed until the material inside is cured.
•Then, the final molded part is removed by using ejector
pin.
 Transfer Moulding
Advantages
•Fast setup time and lower setup costs
•Low maintenance cost
•Plastic parts with metal inserts can be made
•Design flexibility
•Dimensionally stable
•Uniform thickness of parts
•Large production rate
Disadvantages
• Wastage of material
• Production rate lower than injection molding
• Air can be trapped in the mold
 Transfer Moulding
Applications
•Integrated circuits, plugs, connectors, pins, coils,
studs, radio, television cabinets and car body shells.
 Bonding
•It is performed by the application of Heat & Pressure
•Laminated plastics consists of sheets of paper, fabric, wood or
other similar materials that are coated with resin.
•The layers are properly cut as per the requirement
•Layers of sheet like metal foil, paper bonded together in a
stack.
•Sheet Thickness— 0.05 — 0.12mm
•Pressure = 8 -24Mpa
•Resin = Phenolics, Polyesters, Epoxies & Silicones.
 Vibration Welding
Vibration Welding
• To produce pressure tight joints in circular,
rectangular or irregular shaped
components made from thermoplastics

•Weld joint in single plane

•Hollow container can be welded

•The friction is developed by pressing two

plastic components & vibrating them at 120
cycles/sec in the plane of joint.

•The pressure should be maintained until

soften plastic cools
 Spin Welding

•One component is fixed

•Another component is attached to the spindle
•The spindle is rotated at predetermined speed and then forced
against the stationary component
•Heat generated at the junction due to friction
•Only symmetrical components can be joined
 Ultrasonic Welding
•The two plastic pieces to be joined is assembled
in the nest (anvil or fixture)
•The horn is made to contact at upper part of the
piece.
•A pressure is applied on the two pieces against
the fixture. The pressure is applied through the
pneumatic or electric driven press.
•Due to local plastic deformation & heat generate
due to friction between contact surfaces, Joint
formation will takes place.
•A clamping force is applied on the two pieces for
a predetermined amount of time to fuse them
together to form a strong weld on cooling and
solidification.
•After solidification, the clamping force is
removed and horn retracted. The welded plastic
part is taken out of the fixture as one piece.
 Ultrasonic Welding
Advantages
•It is fast welding process.
•It can be easily automated.
•It produces clean and precise joint.
•It produces low thermal impact on the materials.
Disadvantages
• It cannot be used to produce large joints (greater than 250 x 300
mm).
• It requires especially designed joints, so it can make tip contact
during welding process.
• High tooling cost for the fixtures.
•Ultrasonic welding process is restricted to the lap joints.
 Ultrasonic Welding
Applications
•Computer and Electrical Industries: Here it is used to join
wired connections and to create connections in small
delicate circuits.
•It is used for packaging dangerous materials like
explosives, fireworks and chemical.
•Items such as anesthesia filters, blood filters, dialysis
tubes
 Induction/Electromagnetic Bonding
• Suitable for thermoplatic
•Two components are pressed together
•High frequency magnetic field is supplied
to the joint by the working coil.
•This magnetic field heating the matrix
polymer, then melting the plastic &
compression produces good fusion weld.
•High cost technique
•Metal powders may be added to the
original plastic moulding, but it requires
high frequency.
 Solvent Bonding
•Only thermoplastics can be joined by
softening them by solvent & then
clamping or pressing together.
•The plastic molecules intermingle &
the components bond together as the
solvent evaporates.
•Time of fusion is direct function of
solvents evaporation rate.
•The pressure applied on the component
is critical because high pressure may
deflect the components.