College of electrical and mechanical Engineering

Department of manufacturing Engineering

Specialization: mechanical Engineering Stream
Composite material and technology
Name TEKLE ZEBRHE ID:GSR0374/11
 Content/outline
 Introduction
 Method of joining
Adhesive bonding
Mechanical fastening
Welding
Introduction
 Why engineer develop polymer material ?
 As we know from the engineering material metal are
strong and tough but heavy ,ceramics are strong but brittle
,this is why polymer developed by engineer.
 Polymer have low density and high flexible.
 Polymer are a raw material for plastics.
Cont.…
Rubber
elastomers
Thermoplastic
elastomers
Polymeric
Thermoset
material

Thermoplastics
Cont.…
 The Goal of designer to produce molding of single component
products (free joint), but this is not realistic due to many reasons:

 Needing of disassembly for maintenances i.e. repairing,

cleaning, lubricating etc..
 Increasing the design of hybrid structure
 Limitation of the size of the components by its production
process
Cont.….
 If producing of a single component product by molding is impossible
we need other method to joining the components to produce product.

 The joining method or technique for plastic components can be

categorized in to three.

1. Mechanical fastening,
2. Adhesive and solvent bonding, and
3. Welding
 JOINING OF POLYMERS
 Joining is process blend or combine of similar or
dissimilar parts together.
 Joints are necessary always when:

 part integration is impossible because of complexity

and/or high costs,
 using different materials in the same component
 disassembly is required, and
 Repair of damage is needed
Cont.…
 The methods for joining plastics and composites can be
divided into three major categories:

Adhesive and
joining

solvent bonding
Mechanical
fastening

Welding
 Adhesive Bonding
 Adhesive bonding is a technique often used consumable (adhesive like that of glues,

epoxies ) placed between the part (adherents) where it service as the material that

joining the parte and transfers the load through the joint.

 Adhesive bonding process consists of the following steps:

 surface preparation of adherents by degreasing, grinding etching, or by applying a

primer layer for increasing adhesion

 joining partners are firmly clamped and adhesive is applied

 joining surfaces are brought in contact and kept under pressure

 Adhesive cures and joint is formed; cure can take place at either elevated or room

temperatures
Cont.…
 Strength of the adhesive bonding depend on cure time .
 Advantages of adhesive Bonding

 Bonding of dissimilar materials

Low stress concentration
Improvement of fatigue resistance
Weight reduction
Good surface finishing
No holes required
Disadvantages of adhesive Bonding
 Difficulty of disassembling
 Good surface preparation is required
 Engineering design confidence is not so high compared
with fasteners
 Resistant only to shear loading
 Difficulty in predicting bond failure
 Temperature sensitivity
Application of adhesive Bonding
 automotive industry
 Railway industry
 Adhesive bonding :is used to join for all plastics that is for
 thermoplastic
 thermoset
 elastomer
 Mechanical Fastening
 Mechanical fastening: involves separate fasteners,
such as metallic or polymeric screw ,bolt ,rivet or it relies
on integrated design elements that are mold on the part
such as snap-fit or press-fit joint.
Advantages of Mechanical
Fastening
 Reopen ability of the assembled pieces

 Easy technology and machinery

 Joint of dissimilar materials

 Ease of joint inspection

 Little surface preparation and cleaning is required, and

 Repair or replacement of pieces is facilitated

Disadvantages of Mechanical Fastening
 Augmented stress concentration,

 Loosening of fasteners due to creep, moisture, and stress

relaxation

 Increasing weight
Application of Mechanical
Fastening
 aerospace
 automotive, and

 construction industry
N.B Mechanical fastening is used for all types of polymers.
 Welding
 Joining parts through heating in order to melt (or
eventually soften) and fuse the polymer at the interface.
 Thermoplastics and thermoplastic elastomers (TPE) can
be joined using the fusion welding process.
 Due to cross-linking structure thermoset component does
not join by welding.
Fundamental Welding Steps
 Surface preparation : includes machining and/or cleaning
(degreasing)

 Heating

 Pressing

 Intermolecular diffusion

 Cooling
Classification of Welding
Techniques
 Welding techniques are often classified and identified by
the heating method that is used.
 Welding methods can be divided into two general
categories: external and internal heating.
 Internal heating is also classified in to two those are
internal mechanical heating and internal electromagnetic
heating.
Cont.…
 External heating methods rely on convection and/or
conduction to heat to the weld surface. These welding
techniques include:
 hot tool (hot plate) welding
 hot gas welding
 extrusion welding
 induction welding, and
 resistance welding.
Cont.….
 Internal mechanical heating methods rely on the conversion of
mechanical energy into heat through surface friction and
intermolecular friction.
 These welding techniques include:
 ultrasonic welding,
 vibration welding, and
 spin welding.
 Internal electromagnetic heating methods rely on the absorption
and conversion of electromagnetic radiation into heat.
 These welding techniques include:
 infrared/laser welding,
 dielectric (radio frequency) welding, and
 microwave welding .
Hot Tool Welding
Cont.… .

The main advantages of hot tool welding Disadvantages of hot tool welding
 No filler materials are required  High energy consumption
 ease of assembly  Slow start-up (15–30 min) due to the warm-
 A big range of materials are weld up of the tool
able by hot tool  Residual stress is normally present
 Shape freedom  Cleaning of accumulated residual plastic on
 High production rates, and the tool is required, and
 Welding of large parts (up to 1372  Expensive equipment when comparing with
mm) other welding methods
Hot Gas Welding
Cont.…
Advantage Disadvantage
Portable equipment Low welding speeds
Low skill operating level Use of filler material
Great range of materials can joined
Cheaper welding equipment
Extrusion Welding
 welding parameters are includes
 the surface preparation
 the position of the extruder to the weld seam
 the design and finishing of the shoe-tool surface
 the gas and extrusion temperature
 the welding speed, and pressure
Resistive Implant Welding
 Melting heat is generated by the insertion of a metallic
wire in the joint region.
 Electrical current is applied in the wire, and heat is
generated through resistance.
Spin Welding
 welding pieces are placed into contact and rotated, aiming
to accomplish heating by friction.
 Parameters in this welding method are the
 rotational speed,
 the friction pressure,
 the forging pressure,
 the burn-off (axial displacement of the moving joining
partner), and
 the welding duration.
Advantages of the spin welding
no additional filler material
 ease of assembly
 energy efficiency
 low level of emissions
inexpensive equipment
Disadvantages spin welding
 limited production rate
 low level of geometric tolerance
 limited to circular geometries