Plastic Assembly Blog
When welding parts in production, you want to have reliable and consistent assemblies. You may have been churning out ‘good’ parts for years, but suddenly you are finding part inconsistencies and failures when none of your parameters have changed! What happened?
The origins of the verb “trend” mean “revolve or rotate” which has become “change or develop in a general direction”. It is appropriate that we discuss trends with respect to the auto market as the wheels revolve and the axle rotates, so do the trends change. Jabil recently commissioned a survey of the automotive and transportation industry seeking to understand trends from OEM’s and Tier 1’s in this market sector.
The moment is here, the process is set, the machine has cycled. How does it look? “GASP!” My staked part has FLASH!!! If you are not familiar with flash, I’m referring to the displaced plastic material from a staking or welding process that extrudes outwards and does not contribute to the strength of the joint. Flash may be observed as fine dust surrounding the joint, thin strands of plastic material in a disorganized clump, or even smooth rounded material adjacent to the weld joint. So why does flash occur in plastic staking and how can you optimize stake appearance?
Recently, we’ve been discussing conventional vibration welding and hybrid or ‘clean’ vibration welding. Vibration welding, a linear frictional weld method, you probably know all about. Hybrid – the introduction of an infrared preheat function prior to the conventional vibration weld process, is a relatively new method of welding plastic parts.
A quick review: The intent of the IR preheating prior to the introduction of frictional energy is fairly obvious – elevate the temperature of the weld joint. The anticipated result of this preheating is improved flash (plastic displacement from the joint) control and the potential in certain applications to reduce the necessary amplitude and/or force to achieve the ideal weld performance and assembly appearance.
Occasionally people will confuse vibration welding and ultrasonic welding because both processes use vibratory energy to weld plastic assemblies. However, both processes are very different from each other. Let’s look at the differences between the two processes and how you can use them to your advantage.
Extol will be introducing several new plastics joining technologies at NPE 2018. Make sure you are there to participate in a live demonstration. Register for free on our website. NPE 2018 will be in Orlando, FL on May 7-11, 2018.
Have you heard the news? Extol recently partnered with CEMAS to distribute their vibration and hybrid welding machines in the US and Canada. We are thrilled to now be able to offer our customers even more plastic joining options as well as top of the line vibration and hybrid welding equipment, service, and support. Now just in case you’re thinking, “I know about vibration welding, but what is this hybrid welding thing you mentioned?” we’re going to dig into it a bit and explain why it might be a great option for your project.
Extol and CEMAS have reached an agreement that appoints Extol as the sole distributor of CEMAS’s exceptional vibration and hybrid vibration welding machines in the United States and Canada. Effective today, customers in the US and Canada will be able to purchase from CEMAS’s wide selection of vibration welding machines through Extol. In addition, Extol will build and provide tooling, stock and supply spare parts, and offer service and support.
Integration Support is a separate division of Extol that is devoted to supporting integrators. This dedicated team works with machine builders to create an integration package that will meet the end‑user’s specific needs. When it is time to purchase the integration components, the Integration Support team carefully assembles the package and supports the customer as they integrate the technology into the machine they are building.
We all love options – colors, cars, hobbies, music, and of course our favorite, plastic welding!
Let’s talk about a few of the differences between vibration and hot plate welding that may help in discerning when to choose one over the other. Ah, but first we should briefly review the two welding processes.