Weldability of Metals:

The term weldability has been coined to describe the ease with which a
metal can be welded properly
In terms of weldability, commonly used materials can be divided into the
following types:
 Steels

 Stainless steels

 Aluminium and its alloys

 Nickel and its alloys

 Copper and its alloys

 Titanium and its alloys

Several factors influence the weldability of metals. Below is a
list of the most common factors.
 Metallurgy: The science of heating or manipulating metals
to produce desired properties or shapes in them.
 Welding Process: there are several types of processes in
welding. Various factors set them apart: how the heat and
pressure are applied, how much heat and pressure are
used, and the type of equipment employed.
 Joint Design: The combination of the dimensions required
for the welded joint and the geometry of the joint.
 Weld Preparation: a set of techniques to execute prior to
welding to prevent defects in the weld.
 Melting Point: The temperature that must be reached for a
solid substance to melt or fuse.
 Electrical Resistance: A metal’s opposition, or resistance, to
the flow of electrical current.
Steels:
Carbon and alloy steels:

Steels alloyed with carbon and only a low concentration of silicon

and manganese are known as plain carbon steels

Alloy steels contain specified larger proportions of alloying

elements.
 Low-Carbon or Mild Steel: have carbon content of less than
0.30%. These steels can be welded easily by all welding
processes.
 Medium-carbon steels: have carbon content of 0.30% to 0.50%
 High-carbon steels usually have a carbon content of
0.50% to 0.90%. These steels are much more difficult to
weld than either the low- or medium-carbon steels.
Because of the high carbon content, the heat-affected
zone can transform to very hard and brittle martensite.
 Tool steel has a carbon content from 0.8% to 1.50%, and
is very difficult to weld.
 High-manganese steel contains 12% or more manganese
and a carbon content ranging from 1% to 1.4%.
 Low-alloy steels are used increasingly because of requirements for
high strength with less weight. These types of steel are readily
weldable by all of the common welding processes.

 Chromium-molybdenum steel is used for high-temperature

service and for aircraft parts. It can be welded by the following
processes: shielded metal arc, gas tungsten arc, gas metal arc, flux
cored, and submerged arc.

 Maraging Steel, which combines nickel and elements such as

cobalt, titanium, molybdenum or aluminum. With a lower carbon
content, this type of steel is known for its high yield strength.
Stainless steels consist of four groups of alloys:

 Austenitic: The austenitic group is by far the most common. Its

chromium content provides corrosion resistance, and its nickel
content produces the tough austenitic microstructure.

 Ferritic: contain almost no nickel

 Martensitic: Martensitic stainless steels are also low in nickel

but contain more carbon than the ferritic

 Precipitation hardening: Can be much stronger than the

austenitic, without losing toughness. Their strength is the result
of a special heat treatment used to develop the precipitate.
 Aluminium and its alloys
 High thermal conductivity: Higher welding current is
needed to assure fusion
 High solidification shrinkage: Aluminum shrinks about
twice as much as steel during solidification due to its
high coefficient of thermal expansion. Causes higher
buildup of residual stresses around the weld and
greater distortion. Shrinks approximately 6% in volume
 High hydrogen solubility: In molten state, aluminum
has a very high hydrogen solubility.
 Oxide coating: One of the characteristics of aluminum and its
alloys is that it has a great affinity for oxygen. Aluminum
forms an oxide layer when it comes in contact with air and
combines oxygen.

 This aluminum-oxide layer is very porous and traps moisture,

grease, oil and other contaminants.

 Pure aluminum melts at 1200°F (650°C). The oxide that

protects the metal melts at 3700°F (2037°C). The metal must
be cleaned prior to welding.

 Aluminum can be arc welded using aluminum welding rods.

 Copper and its alloys
 There are many different types of copper alloys. Copper is
often alloyed with other metals such as tin, zinc, nickel,
silicon, aluminum, and iron.
 Copper and copper alloys can be joined by most of the
commonly used methods such as gas welding, arc welding,
resistance welding, brazing, and soldering.
 When you are welding copper, the welding current should
be considerably higher than when welding steel.
 Cast iron
Types of Cast Iron:
 Gray cast iron is the most widely used type. It contains so much

free carbon that a fracture surface has a uniform dark gray

color. Gray cast iron is easily welded, but because it is

somewhat porous it can absorb oils into the surface, which

must be baked out before welding.

 White cast iron is the hardest and most brittle of the cast irons

because almost all of the carbon atoms are combined with the

iron atoms. White cast iron is practically unweldable.

 Malleable cast iron is white cast iron that has undergone a

transformation as the result of a long heat treating

process to reduce the brittleness. Malleable cast iron can

easily be welded. To prevent it from reverting back to

white cast iron, do not preheat above 1200°F (650°C).

 Alloy cast iron has alloying elements such as chromium,

copper, manganese, molybdenum, or nickel added to

obtain special properties.

Titanium and its alloys:
 Titanium is a silver-gray metal weighing approximately half
as much as steel or approximately one and one half times
as much as aluminum.

Properties of titanium
 Extremely high strength-to-weight ratio (in alloy form)

 Corrosion resistance.

 Titanium alloys, unlike most other light metals, retain their

strength at temperatures up to approximately 800°F
(426°C).
Nickel and its alloys:
 Nickel alloys can be joined reliably by all types of welding
processes or methods, with the exception of forge
welding and oxyacetylene welding.
 Welding of Cast Nickel Alloys: Cast nickel alloys can be
joined by the GTAW, GMAW and SMAW processes. For
optimum results, casting should be solution annealed
before welding to relieve some of the casting stresses and
provide some homogenization of the cast structure.
 Advanced soldering and brazing processes
Soldering:
 Soldering is a process that joins two or more types of metals
through melting solder. The first soldering iron was developed
in 1896 by Richard Schneider and August Tinnerhol and was
called the “First Electric Heating Apparatus”.

 Soldering is commonly used in electronics, as it is simple and

safe in joining sensitive materials. Likewise, the process is also
known for metalworking, plumbing, roofing and joining wires.
Let’s take an in-depth look into soldering to find out more.
 Soldering uses a filler metal with a low melting point, also known as solder,
to join metal surfaces. The solder is usually made up of an alloy consisting
of tin and lead whose melting point is around 235°C and 350°C,
respectively.

 But when tin and lead are mixed then the melting point of the mixture is
reduced to 183°C. The alloy is melted by using a hot iron at above 316 °C
(600 °F).

 As the solder cools, it creates a strong electrical and mechanical bond

between the metal surfaces. The bond allows the metal parts to achieve
electrical contact while it is held in place.

 Note that lead-free solders are increasingly used as an alternative to

environmentally harmful lead-based solders due to regulations.
Soldering Process:
 The first step in soldering is to wear protective gear in a well-ventilated area.

Next, the soldering iron should be preheated. For cleaning the soldering tip, you

can use a wet sponge. Likewise, any residue on the workpiece surface should be

wiped off.

 After finishing the preparations, it’s time to heat the base metal to a working

temperature using the hot iron. Doing so will help prevent thermal shock,

activate the solder, and overall improve the quality of the joint.

 A good indicator that the metals are well-heated is when the molten solder

freely flows into the joint. The filler material solidifies as it cools down, making

it the best time for inspection. The key to successful soldering is ensuring that

the metals being joined are clean and free of any oxides or other contaminants.
Desoldering:
 From time to time, components fail and need replacement. When

these components are mechanically held in place with solder, a

process called desoldering removes the material cleanly and
safely.

 A soldering iron or a heat gun can be utilised to melt the solder,

allowing you to safely remove any soldered components. To

remove the liquid solder, you can use a desoldering pump as a
vacuum, or a soldering wick to absorb the molten solder.

 Alternatively, you can resort to an aggressive method using

Soldering v/s Welding:
 While soldering and welding are processes that join two pieces of
metal alloy together, there are some key differences in how the
metals are joined.
 Soldering uses melted filler metals to bond heated base materials.
It works at a lower temperature than welding but requires
preheating the base materials to create an effective joint.
 Welding runs at higher temperatures to melt both filler material
and workpiece together. It results in a stronger bond, with some
changes to the mechanical properties of the metal from heating
and cooling.
Soldering works well with the following base metals:
 Gold
 Silver
 Iron
 Brass
 Copper
 Aluminium
 Steel
 Titanium

While some of these metals can easily be soft-soldered, harder metals

may require filler materials with a higher melting point to be joined.
Soldering Tools:
 Soldering irons are hand tools that heat the solder above its melting

temperatures. They offer a wide variety of sizes, which is great for different

applications. The tip of the iron has different types and sizes that suit a variety

of projects.

 Soldering guns are employed when higher temperatures require more power. A

soldering gun heats quicker and offers better flexibility as it can be operated in

confined spaces, heavy electrical connections, and metal works.

 Soldering stations are multipurpose devices that have everything covered for

minor projects. They are more durable than regular soldering irons due to them

being equipped with sensors, fuses, alerts and temperature regulation.

Solders:
Lead-based solder: Most soldering projects are typically
performed using lead solder consisting of a 60-40 tin-to-lead
ratio. This solder melts in a range of 180 to 190°C and is usually
the best choice for soldering electrical connections.

Lead-free solder: As a way to mitigate the use of harmful

elements, lead-free solders were developed. These usually
come as solder wire and are composed of metals with higher
melting points: tin, copper, bismuth, silver, brass, indium, and
Flux core solder: These filler metals come as paste or soldering
wires that contain a flux solder core. The flux releases a
protective layer around the workpiece as it is consumed, which
achieves cleaner electronic connections and better wetting
properties.
Flux: Rosin flux (alternatively called passive flux) is used for
electronics as it leaves a residue that doesn’t lead to corrosion.
Acid flux: solders contain aggressive properties, which are
effective in removing the oxides of the metal surface. This leads
to stronger and cleaner metal joints compared to rosin.
 The type of flux can be broken down into two groups
depending on its application. No-clean flux is made with
natural rosin or other synthetic materials, requiring no
post-cleanup, while water-soluble flux contains water-
soluble resin that is easily removed by rinsing.
 Heating Methods
While the concept of soldering is fairly simple, there are
different heating methods that depend on the application or
project. Primitive methods involve a fire heating element
through butane, but this has now evolved into more advanced
techniques.
Laser: Commonly used in delicate electronics, lasers at 30-50
watts can accurately create a soldered joint while preventing
heat in the surrounding area. It is commonly used on circuit
boards where the components are compact.
Induction: Copper coils induce heat to the solder by using an oscillating

high-frequency alternating current. Induction allows for an even

application of thermal energy to heat solder, being a great application to

cylinders and pipes, minimizing holes and maintaining uniformity.

Resistance: This soldering form generates heat by applying an electrical

current to the solder and soldering iron. Heat is generated in a small

space and it dissipates quickly, reducing the risk of damaging

components.

Infrared: This method uses infrared (IR) light as a mode of heat transfer

to the targeted area. It only takes a few seconds, reducing the heat
 Types of Soldering
There are three soldering types that are used at varying temperature levels that

result in different joint strengths:

 Soft soldering (90 °C – 450 °C): The solder melts alloys containing lead that has a

low melting point. With a lower melting point, this soldering type minimises the

thermal stress wherein the base metals are subjected.

 Hard soldering (above 450 °C): Brass and silver are usually hard soldered, with

the use of a flame via blowtorch to melt the filler metal. Hard soldering has

better mechanical strength than soft soldering, which applies to crafting

jewellery and some machining operations.

 Brazing (above 450 °C): Brazing uses metals with a much higher melting point

compared to hard and soft soldering. It produces the strongest result, which is
Advantages of Soldering:
1. Soldering is operated at lower temperatures compared
to common welding methods.
2. Most metals and non-metals can be soldered.

3. A simple process makes it easy to learn.

4. The base metal isn’t melted in the process, unlike

welding techniques such as stick welding, fluxcored
welding, etc.
5. Soft soldering can be undone using a desoldering tool
Disadvantages of Soldering:
1. Weaker joints compared to other welding methods such
as MIG and TIG.
2. Soldering isn’t suitable at high temperatures, as the solder
has a low melting point.
3. Heavy metals aren’t suitable for soldering.
4. Melted solder might leave a toxic flux residue.
5. Improper heating may cause deformities or voids in the
solder.
 Applications
Electronics Industry: The most popular application of this
fusion process is electronics soldering, where wires are joined
and electronic components are fused to a circuit board. This
technique allows soldering components together with the
luxury of desoldering when needed.
Roofings: Soldering can be used in creating leak-proof
roofings wherein the galvanised steel is infused with solder.
The soldering iron tip is far broader when used in this
application compared to other uses.
Sections: Soldering is applied in the piping and plumbing industry as a
way to create joint sections. It is a straightforward process and a reliable
solution in sealing the connections in copper pipes, for example.
Art: Soldering can be used to create stained glass art, wire modelling,
sculptures, jewellery and other creative works.
Metalwork: The soldering material can be used to fill cavities and even
out rough surfaces. This process is practiced to fuse metal sheets, pipes
and other applications where metals don’t undergo high temperatures.
Automation: Technology allows us to automate the soldering process
through the use of programmed robots. Not only does it create precise
joints but it is also fast in production speed.
 Brazing
 Brazing is a process that joins two or more metal surfaces by letting
molten metal flow into the joint.
 The filler metal has a lower melting temperature than the parts to be
joined to keep the workpieces from melting.
 Although brazing is one of the oldest joining methods, it is still used today
for a good reason.
 Brazing joins metal surfaces together with a filler metal which has a low
melting point. The process uses capillary action wherein the homogenous
liquid flow of the filler material bonds with the base metals.
 A unique quality in the brazing process is that it keeps the mechanical
properties of the metals which are useful in applications such as silver
brazing or other similar metals.
Brazing Process:
 One of the most crucial steps in the metal joining process is the
cleaning of the base metal surfaces. Emery cloth or wire brush are
both great tools to remove contaminants.
 Having calculated joint gaps for the liquid filler metal to achieve
surface tension with the workpiece, the brazing operation begins
with properly positioning the assembly.
 A torch is normally used to slowly heat the workpiece’s metal surface
and filler metal into its brazing temperature. As the filler metal
liquefies, capillary action lets it pass through the tight spaces, thus
forming a bond between the surface of the base metals.
Materials:
These are the metals that are often joined by brazing:
 Aluminium
 Cast iron
 Magnesium
 Copper and copper alloys
 Silver
Filler metal requirements:
1. Once the molten flux and filler metal solidify, the brazed
joint should possess the expected mechanical properties.
2. Brazing temperatures must efficiently achieve a proper
liquid flow from the molten braze alloy into the joints.
3. Filler metals must achieve proper wetting conditions in
order to create strong bonds.
 Difference Between Brazing, Soldering & Welding
 Brazing uses capillary action to join different metal
surfaces. It makes use of a process called wetting, wherein
the base metals are bonded with a melted filler material.
The brazing filler metal has a melting point above 450 °C.
 Soldering uses filler metals that have a melting point
below 450 °C. Although soldering uses the same concept
as brazing, the main difference lies in their working
temperatures and thus in the strength of the created joint.
 Welding melts the workpieces in addition to the filler
metal. This allows the creation of stronger bonds than with
brazing. Processes such as TIG, MIG, and stick welding
operate at much higher temperatures.
 Braze welding is a type of MIG/MAG welding. The
difference lies in the melting point of the filler wires which
is significantly lower than the parent metal. The filler metal
is deposited in order to fill in the gaps via capillary action.
There is no significant fusion of the parent metals but it
may occur in a limited amount.
 Different Methods of Brazing
Brazing uses different heating methods to suit a variety of purposes
and applications. Heat can either be applied directly to a joint
(localized) or to the whole workpiece (diffuse heating).
Localised Heating Techniques:
 Torch brazing – Combusted fuel gas is formed by burning
acetylene, propane, or hydrogen with oxygen to heat and melt the
filler metal. Flux is required while using this technique in order to
protect the joint, which requires post-cleanup later on. Torch
brazing is mainly used for small production assemblies where metal
weight is unequal. The process is often performed with gas welding
equipment.
 Induction brazing – High-frequency alternating current is
supplied into a coil to achieve brazing temperature, which
heats the workpiece and melts the filler material.
 Resistance brazing – Heat is generated from the electrical
resistance of the brazing alloy, which is perfect for highly
conductive metals. This heating technique is best suited
for creating simple joints between metals.
Diffuse Heating Techniques:
 Furnace brazing – Gas firing or heating elements are used to bring the furnace

to the desired temperature. The brazing filler metal is applied to the surfaces

to be joined and then the entire assembly is placed into the furnace and

brought to brazing temperature. Furnace brazing allows accuracy in

controlling the heating and cooling cycles of the metals. The process is often

performed in a vacuum to protect the braze alloy from atmospheric

conditions. This also negates the need for flux protection.

 Dip brazing – The workpiece or assembly is immersed in a bath of molten

filler metal (molten metal bath brazing) or molten salt (chemical bath dip

brazing). Brazing flux is applied to the parts to prevent oxidation. The

assembly can be removed once the molten brazing filler metal has solidified.
Advantages:

1. Can join dissimilar metals, unlike most welding

methods.

2. High production rates.

3. Consumes less power than welding.

4. Produces cleaner joints compared to most welding

processes.

5. Base metals don’t melt, keeping their shape and

Disadvantages:
1. Weaker results compared to welded joints.
2. Cannot join components operated at high temperatures.
3. Requires tight, uniform joint gaps to achieve capillary
action.
4. Unclean or contaminated metals may cause leaky joints.
 Welding of plastics
 Welding plastic is a process applicable in plastic part
fabrication for joining two compatible thermoplastics parts.
 It involves preparing the two thermoplastic parts, pressing
them together in the proposed joints, and heating them using
several heating techniques.
 Moreover, the heating technique used depends majorly on
the plastic material. For example, ultrasonic plastic welding is
commonly used for PVC because it does not involve direct
heating which leads to the emission of dangerous fumes by
the material.
 Continuous application of pressure during heating and
cooling forms a molecular bond between the two parts.
 Consequently, plastic welded joints are strong, unlike other
plastic joining processes such as adhesives and riveting.
 Plastic welding has been a widely used technique in
medicine, electronics, construction, etc.
3 Steps of Welding Plastics:
Step 1: Set up the working space and clean the plastic: The
first thing to do is to set up a workspace. The workplace needs
proper ventilation since most heating techniques emit
dangerous fumes. Aside from that, operators should wear
protective gear. Clean the thermoplastics to ensure a high
welded joint. Cleaning is achievable by washing with soap and
warm water and then drying the plastics with a clean, lint-free
cloth. Also, it’s suggested that you remove stains using liquid
solvents such as Methyl Ethyl Ketone (MEK), 80-frit sandpaper,
Step 2: Join the plastic: Clamp and tape the two plastic pieces
to form and hold the desired joint. Furthermore, place the
plastic pieces on a working bench and pin them using C-clamps.
The style of joining the plastic depends on the welding
technique. For example, ultrasonic welding is only suitable for
lap joints.
Step 3: Complete the weld: Fix the weld before cooling to deal
with issues such as smoothness. Allow the welded plastic to
cool for about 5 minutes or reach room temperature.
Furthermore, sand the welded joint after cooling or use other
Methods of Plastic Welding:
There are many plastic welding techniques based on the heating processes.

Below are the eight common techniques used in part manufacturing in the

plastic industry.

1. Ultrasonic Welding: Ultrasonic plastic welding uses mechanical

vibrations with high frequency (15 kHz to 40 kHz) and low amplitude to join

two plastic polymers. The mechanical vibration generates frictional heat,

which in turn melts the plastic polymers. Due to mechanical vibrations, a

molecular bond is formed between the plastic polymers. Therefore,

ultrasonic plastic welded joints are strong and of the highest quality.
Advantages of Ultrasonic Welding:

1. It has high throughputs and short turnaround times

2. It is highly safe because it does not heat the plastic

parts using direct heat

3. Its use of direct heat also makes it suitable for

materials like polyvinyl chloride, renown for producing
dangerous fumes on direct exposure to heat

4. It produces high quality welded joint, which improves

its aesthetic value
Disadvantages of Ultrasonic Welding:
1. The method is not suitable for thermoplastics with high
moisture content and hard/strong thermoplastics such as
polypropylene
2. The process is not ideal for thick materials such as
polypropylene because most ultrasonic machine transducers
have an output range between 100-150mm
3. Only suitable for joints that overlap each other. Other joints
such as a corner, butt, tee, and edge are incompatible
4. High lead time because of the number of tools and processes
required
2.Laser Welding:
Laser welding is a plastic welding process that involves using a
laser beam to thaw the plastic. However, the heat is kept
below the plastics’ evaporation temperature. Pressure is then
applied on thawing, and cooling occurs to strengthen the
welded joints. Laser welding is fast and occurs in different
ways. Hence the different types of plastic laser welding
processes: are hybrid, simultaneous, contour, and single pass.
However, the speed depends on the process, plastics, and
laser welding machine.
Advantages of Laser Welding:
1. It can heat the entire welding surface or a single spot.

2. It is highly accurate hence its use in the aerospace industry

3. Welding can occur at room temperature or under special

conditions

4. Suitable for welding plastics with complex designs

5. The welded joints have a high aesthetic value, i.e., a clean

appearance

6. It is a speedy process making it very popular in rapid

prototyping
Disadvantages of Laser Welding:
1. Not suitable for thickness plastics (above 0.5inches) so as
not to lead to bad welded joints
2. It can lead to welding porosity and brittleness
3. The initial cost of investment is high
Friction Welding:
Friction welding does not require a direct application of heat for the

welding to take place. Therefore, it is a common process for joining plastic

that does not require direct heat application. The process uses the

principle of friction to join the plastic material together.

It involves applying external pressure on both plastic materials by moving

or rotating them against each other. The movement produces friction,

generating heat that melts the plastics. After melting, there is an

application of uniformly increasing pressure force to both plastic

materials until a permanent joint form. There are two types of friction
• Continuous Induce Friction Welding: The procedure follows the
above procedure. However, the movement responsible for generating
the heat is from a rotor connected to a band brake. When the heat
generated is higher than the plastic temperature limit, the band
brake stops the rotor as the pressure increases until welding occurs.
• Inertia friction welding: It is similar to continuous induce friction
welding. However, the engine flywheel and shaft flywheel replace the
band brake. Although connected at the beginning of welding, the
flywheels separate when the friction/speed reaches the limit. The
shaft flywheel’s low moment of inertia makes it stop. Continuous
application of pressure force continues till the welded joint forms.
Advantages of Friction Welding:
1. Easy removal of oxides and contaminants present during
initial rubbing
2. Suitable for dissimilar plastic
3. No distortion and warping of material due to low heat
4. High welded joint quality
5. High welding speed
6. It is environmentally friendly
7. It does not require consumables and a special power
Disadvantages of Friction Welding:
1. Only suitable for round bars with the same cross-section
and angular and flat butt joints
2. It has a high initial cost of investment.
High Frequency Welding:

High-frequency welding involves welding plastic polymers using an

electromagnetic field (13–100 MHz). This generates heat inside the

material (it does not require direct heat application). The operator

applies pressure continuously to fuse the plastics until the weld form,

and heat removal occurs to cool the welded joint. This produces a strong

welded joint with similar or even better properties than the original

materials. HF welding is the most suitable plastic welding process for

dissimilar plastic materials. While useful in the plastic industry, it is only

compatible with a few materials. Common ones are polyvinyl chloride,

Advantages of High Frequency Welding:

1. Less effective splitting

2. Small thermal influence range

3. High welding speeds (around 100 to 120 m/min)

Disadvantages of High Frequency Welding:

4. It radiates a lot of heat

5. Depending on the machine, it has a small heating

range, i.e., the heating area
Vibration Welding:
Vibration welding involves rubbing the plastic part at a certain
frequency and amplitude. This leads to the generation of
frictional heat that melts the joint section and creates the
welded joint. There are two types of vibration welding:
 Linear Vibration Welding: It uses frictional heat generated
by moving one plastic part relative to the other at a given
displacement to melt the plastic parts’ joint. The process
continues at a constant pressure after the vibration stops
until the welded joint cools.
 Orbital Vibration Welding: It involves vibrating the upper
section of the plastic part in a continuous circular motion
in all directions. This generates heat that melts the plastic
part. The vibration stops reaching the melting point so the
welded joint can solidify.
Advantages of Vibration Welding:
1. It does not require any consumable
2. There is no need for surface preparation
3. It is highly efficient energy-wise
4. Suitable for welding thin plastic materials
5. Suitable for welding plastics with irregular shapes
Disadvantages of Vibration Welding:
1. The welding surface must be flat and horizontal
2. Limited compatible materials
3. Expensive equipment
Hot Plate Welding:

It involves heating a plate and using it to melt the

joining surface of two thermoplastics. After melting the
two halves, they are brought together and left for a
predetermined period so that a molecular, permanent,
and hermetic bond can form. Hot plate welding
requires extreme precision and control. It is suitable for
any thermoplastic material but more applicable for soft
and semi-crystalline thermoplastics, e.g., PP and PE.
Advantages of Hot Plate Welding:
1. Suitable for joining large plastics
2. It produces strong welded joints
3. It has a short cycle time depending on the time taken to
reach the plastic’s melting point

Disadvantages of Hot Plate Welding:

4. It is not suitable for welding thin plastics below 0.1 inch
5. The equipment requires a high level of maintenance
Hot Gas Welding:

Hot gas welding is used in thermoplastic fabrication and

involves using a hand-held welding gun that blows steam of
gas or air to heat plastic welding rods and polymers. The
plastic materials soften when heated above the melting
point, forming the welded joint. This then cools off to form
a solid welded joint.

The hot gas welding process is applicable in fabricating

containment vessels, pipework, heat exchangers, water
tanks, etc., made from similar plastic polymers.
Advantages of Hot Gas Welding:
1. The equipment is very portable
2. It doesn’t require electricity to operate
3. It doesn’t require any heavy-duty machinery
4. It doesn’t require much technical expertise
Disadvantages of Hot Gas Welding:
5. The heating rate is very slow, making the process slow
6. It is not suitable for thicker plastics.
Spin Welding:
Spin welding or rotational friction welding is a process used
for welding thermoplastic parts with rotationally symmetrical
joining surfaces. It involves rubbing the parts together (one
stationary) under pressure in a unidirectional circular motion.
This generates frictional heat that melts and bonds the
plastics. The welded joint then solidifies after cooling.
Advantages of Spin Welding:
1. It is a simple process and requires less technical expertise

2. It does not require consumables

3. It is highly energy efficient

4. Compatible with many thermoplastics

Disadvantages of Spin Welding:

5. One of the plastic parts to be welded must have a
symmetrical surface

6. It is expensive to set up.

 Applications of Plastic Welded Parts

Aeronautics: Aerospace plastics require permanent welding that is

accurate without comprising their properties. Therefore, the
process is suitable for making plastic welded parts such as interior
panels, holding tanks, and trays.

Agriculture: Plastic welded parts such as gaskets, PVC fencing,

tanks, and water & misting lines have wide applications in
agriculture.

Automotive: Automotive use plastic welding in joining plastics to

make grills, radiators, battery cases, wheel well liners, bumpers,
Marine: The process is also applicable in making boats, ballast
tanks, fish-holding wells, water-holding tanks, and other plastic
welded parts used in a marine environment. The marine
environment uses plastic due to its corrosion resistance and
other properties. However, plastic welded parts might be
assembled and welded together.
Plumbing: Plastic welding is very common in plumbing, where
it is applicable in making DWV pipes, drains, faucets, etc. Such
parts are produced singly and need assembling. Unlike other
plastic joining processes, welding is permanent, which is a