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    Characteristics of Thermoplastics

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    edysson1
    Thermoplastics can be ultrasonically assembled because they melt within a specific temperature range. Near-field welding refers to welding a joint located 1 / 4 inch (6 mm) or less from the area of horn contact. Thermosetting materials, which degrade when heated, are unsuitable for ultrasonic assembly.

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    Characteristics of Thermoplastics

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    edysson1
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    Thermoplastics can be ultrasonically assembled because they melt within a specific temperature range. Near-field welding refers to welding a joint located 1 / 4 inch (6 mm) or less from the area of horn contact. Thermosetting materials, which degrade when heated, are unsuitable for ultrasonic assembly.

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    Thermoplastics can be ultrasonically assembled because they melt within a specific temperature range. Near-field welding refers to welding a joint located 1 / 4 inch (6 mm) or less from the area of horn contact. Thermosetting materials, which degrade when heated, are unsuitable for ultrasonic assembly.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views4 pages

    Characteristics of Thermoplastics

    Uploaded by

    edysson1
    Thermoplastics can be ultrasonically assembled because they melt within a specific temperature range. Near-field welding refers to welding a joint located 1 / 4 inch (6 mm) or less from the area of horn contact. Thermosetting materials, which degrade when heated, are unsuitable for ultrasonic assembly.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    Characteristics of Thermoplastics for Ultrasonic Assembly Applications

    Basic Principles
    The basic principle of ultrasonic assembly involves conversion of high-frequency electrical energy to high-frequency mechanical energy in the form of reciprocating vertical motion, which, when applied to a thermoplastic, can generate frictional heat at the plastic/plastic or plastic/metal interface. In ultrasonic welding, this frictional heat melts the plastic, allowing the two surfaces to fuse together; in ultrasonic staking, forming or insertion, the controlled flow of the molten plastic is used to capture or retain another component in place (staking/forming) or encapsulate a metal insert (insertion). Thermoplastics can be ultrasonically assembled because they melt within a specific temperature range, whereas thermosetting materials, which degrade when heated are unsuitable for ultrasonic assembly. Weldability of any thermoplastic depends on its stiffness or modulus of elasticity, density, coefficient of friction, thermal conductivity, specific heat and Tm or Tg. Rigid plastics exhibit excellent welding properties because they readily transmit vibratory energy. Soft plastics, having a low modulus of elasticity, attenuate the ultrasonic vibrations, and as such are more difficult to weld. In staking, forming or spot welding, the opposite is true. Generally, the softer the plastic, the easier it is to stake, form or spot weld.

    Near-Field / Far-Field Welding


    Before discussing welding characteristics, the difference between near-field and far-field welding must be understood. Near-field welding refers to welding a joint located 1/4 inch (6 mm) or less from the area of horn contact; while far-field welding refers to welding a joint located more that 1/4 inch (6 mm) from the horn contact area. The greater the distance from the point of horn contact to the joint, the more difficult it will be for the vibration to travel through the material, and for the welding process to take place. The differential, if any, in the melt temperature of the materials being welded should not exceed 30 degrees F (17 degrees C), and the materials molecular structure should be compatible; i.e.: blends, alloys, copolymers, and terpolymers. Moisture content, mold release agents, lubricants, plasticizers, fillers, reinforcing agents, regrinds, pigments, flame retardants, and resin grade are all variables that can influence weldability.

    Variables Influencing Weldability


    The moisture content of parts molded from resins that are hygroscopic (moisture absorbent) can be problematical. Nylon (and to a lesser degree polycarbonate and polysulfone) present most of the problem, and parts molded in these resins should be stored in sealed polyethylene bags with an appropriate dessicant immediately after molding. If moist parts are welded, the escaping vapors may cause voids and fissures in the molten material resulting in a weld of poor integrity. Mold release agents such as zinc stearate, aluminum stearate, fluorocarbons and silicones are not compatible with ultrasonic welding. If it is necessary to use a mold release agent, the paintable/printable grades that permit painting and silk screening should be considered. Other release agents should be removed with either TF Freon for crystalline resins or a 50/50 solution of water and liquid detergent. Lubricants, whether waxes, stearates or fatty esters, reduce intermolecular friction within the polymer and inhibit the ultrasonic assembly process. However, since they are generally dispersed internally, their effect is usually negligible. Plasticizers, which usually impart flexibility and softness to a resin can interfere with a resins ability to transmit vibratory energy. FDA-approved plasticizers do not present as much of a problem as metallic plasticizers, but experimentation is recommended. 1

    Resins
    Resins are classified as amorphous or crystalline. Ultrasonic energy is easily transmitted through amorphous resins and as such, these resins lend themselves readily to ultrasonic welding. Amorphous resins are characterized by random molecular arrangements, and a broad melting temperature range that allows the material to soften gradually before melting and flow without prematurely solidifying. Because the molecular structure in the crystalline resins attenuate a great amount of energy, crystalline resins do not readily transmit ultrasonic energy, and they require higher energy levels than amorphous resins. These resins are characterized by a high, sharply defined melting point that causes melting and resolidification to occur rapidly. For these reasons, when welding crystalline resins, higher amplitude and energy levels should be used, and special consideration should be given to joint design.

    .................................................................................

    Although fillers and reinforcing agents such as glass and talc can increase the ultrasonic weldability of soft thermoplastics considerably, they should be judiciously used. When additive content exceeds 10%, premature horn wear may result, and specially treated steel or carbide-faced titanium horns might be required. When filler content approaches 35%, there may be insufficient resin at the surface to attain hermetic seals; and when filler content exceeds 40%, insufficient plastic is present at the interface to form a positive bond. Reinforcement composed of long glass fibers are always more problematical than reinforcement composed of short glass fibers. Ultrasonic assembly is one of the few methods that permits regrinding of parts, since no foreign substance is introduced into the resin. Ultrasonically assembling parts which have been manufactured from regrind parts presents no problem provided that the percentage of regrind is not excessive, and the plas-

    tic has not been degraded. Regrind limitations suggested by the resin suppliers should be observed. Although most pigments do not interfere with the ultrasonic process, some oil-based colorants can adversely influence weldability. Non-oil based pigments should be used. Flame retardants greatly affect the weldability of thermoplastics and the effects of these various additives should be investigated experimentally prior to resin selection. The grade of resin can have a significant influence on weldability. There is a great difference between injection/extrusion grades and cast grades. Their molecular weight, melt temperature and modulus of elasticity are quite different. Injection/extrusion grades should only be used with injection/extrusion grades, and cast grades should only be used with cast grades.

    .................................................................................

    Chart I Characteristics of Thermoplastics


    FIELD OF WELDING MATERIAL AMORPHOUS: ABS ABS/POLYCARBONATE ABS/PVC ACRYLIC ACRYLIC MULTI-POLYMER-XT POLYMER ACRYLIC/PVC ACRYLIC IMPACT MODIFIED BUTADIENE STYRENE (BDS) CELLULOSICS CA, CAB, CAP MODIFIED PHENYLENE OXIDE POLYARYLATE POLYCARBONATE POLYETHERIMIDE POLYSTYRENE, G.P. POLYSTYRENE, IMPACT MODIFIED PVC RIGID PVC FLEXIBLE SAN NAS ASA STYRENE-MALEIC-ANHYDRIDE SULFONE POLYMERS CRYSTALLINE: ACETAL COPOLYMER ACETAL HOMOPOLYMERS FLUOROPOLYMERS NYLON PC-PET POLYESTER PBT POLYESTER PET POLYETHERETHERKETONE POLYETHYLENE (LDPE, HDPE) POLYETHYLENE (UHMW) POLYMETHYLPENTENE POLYPHENYLENE SULFIDE POLYPROPYLENE E - Excellent G - Good SPOT WELDING E G G G G G F G P E F G G F F F P F E F F F F G F F G G G F E P - Poor STAKING SWAGING INSERTING E G G F G G F G G E F F G F F G F E F F F F G F F G F F P E E G F G G F P G E E G G E G G E G E G G G G E G G E G E G G NEAR E G G G G G F G P E G G E E G P P E E G G G P G E G G E P F G F-P FAR G F F F F F P F G F F G E P P E G F F F F G F F G P P F P

    F - Fair

    Not Suitable for Ultrasonic Assembly


    3

    .................................................................................

    Chart II Compatibility of Thermoplastics


    ATYRENE-MALEIC-ANHYDRIDE ACRYLIC MULTI POLYMER POLYETHERTHERKETONE

    ABS/POLYCARBONATE

    POLYCARBONATE

    POLYETHERIMIDE

    POLYPROPYLENE

    POLYESTER-PBT

    POLYESTER-PET

    POLYETHYLENE

    POLYSTYRENE

    CELLULOSICS

    POLYARYLATE

    ABS ACRYLIC MULTI POLYMER ACETAL ACRYLICS CELLULOSICS ABS/POLYCARBONATE

    G
    I

    G I
    I

    G
    I I

    G G G G G G G
    I

    G I G G I G G G G G

    G G ABS/PVC G G BDS G
    MPPO NYLON PC/PET

    G G

    G
    I I I I I

    G I G G G
    I I

    G G
    I I I I I

    POLYARYLATE POLYCARBONATE POLYESTER-PBT POLYESTER-PET POLYETHERTHERKETONE POLYETHERIMIDE POLYETHYLENE POLYPROPYLENE POLYSTYRENE PVC SAN ATYRENE-MALEIC-ANHYDRIDE SULFONES I Denotes compatibility

    G G

    G G G G G
    I

    I I

    G G
    I

    G
    I

    G G G

    G G

    G
    I

    G I

    G Denotes some compatibility, but not all grades and compositions are compatible.

    Corporate Headquarters 53 Church Hill Road, Newtown, CT 06470 USA 203.270.4600 800.745.1105 203.270.4610 fax info@sonics.com Asia Office 5/F Building No. 8, 153 Jumen Rd. 200023, Shanghai P.R. CHINA +86-21-53021255 +86-21-53022522 fax

    2011 Sonics & Materials, Inc. Specifications subject to change without notice. Not responsible for typographical errors. Printed in U.S.A. 1C/06/11

    A3787

    ISO 9001

    Sonics & Materials, Inc.

    Registered by UL to ISO 9001

    SULFONES

    ACRYLICS

    ABS/PVC

    ACETAL

    PC/PET

    NYLON

    MPPO

    BDS

    SAN

    PVC

    ABS

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