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Identifying Plastics for Fabrication and Repair

2/15/2019

 
Picture
It's important to identify the plastic you're welding as only like plastics can be joined. The simplest way is by performing a burn test.  

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Why Your Hot Air Tool Needs Airflow

11/20/2018

 
​Inside every Leister hot air tool is a heating element composed of a ceramic honeycomb supported resistance wire filament (See below). Electric resistance wire heaters work on the principle that when electrical current passes through a conductor heat is generated, and the amount of heat generated is related to the resistance of the conductor. 
Leister ElementFigure 1: Leister Heating Element
Some resistance wire heaters are able to function without airflow because they have been designed in such a way that they will not reach temperatures above their safe operating limits. Examples include: a toaster, some ovens, wrap heaters, some space heaters, etc.
​
However, Leister heaters are designed to operate at very high temperatures—most are designed to heat airflows up to 650°C, and some up to 900°C—and as a result require airflow at all times. To reach these high air temperatures, the heating element must be capable of reaching even higher temperatures. Without adequate airflow, the element will heat up unchecked and will exceed safe limits, leading to the destruction of the element. 


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Extrusion Welding PVC: Why You Need a Specialized Tool

8/21/2018

 
When PVC is melted or burned, it emits hydrogen chloride (HCl) fumes. At room temperature HCl is a colorless gas, although it will form white fumes of hydrochloric acid upon contact with atmospheric water vapor. When welding PVC the work area should be well ventilated, either naturally or through a forced air system.
​
PVC should only be used with an extrusion welder that specifies compatibility with the material. Components that will be exposed to PVC plastic or HCl fumes in these extruders should either be made with different materials or have a corrosion resistant coating. Using PVC with any extrusion welder without specified compatibility will result in signification corrosion to the internal components in contact with the plastic and fumes (see photos below). In the photos, the corrosion damage to the extruder screw is evident. This costly repair was completed in the STANMECH Service Centre and required the replacement of the extruder screw, extruder tube, and extruder nozzle. The damage could have been avoided by using a tool designed for use with PVC. ​​

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Why you Can’t Measure Air Temperature with a Laser IR Gun and a Simple, Effective Alternative

7/18/2018

 
While Laser IR Thermometers are an extremely common tool, they are entirely ineffective for measuring the outlet temperature of an air heater. To understand why, we must first understand how this tool works. Laser IR Thermometers measure the surface temperature of an object by measuring the thermal energy emitted by the target. Knowing the amount of thermal energy discharged and the emissivity of an object’s surface, the object's temperature can be determined by the device.

When measuring a heater’s output air temperature, the largest issue with these tools is that they measure surface temperatures. As the heated air is transparent, the measurement will always be the surface temperature of a nozzle or a component of the heater housing; and frequently it will be an exterior surface. These items will always be cooler than the heated air, often by a significantly larger margin than the user would expect. To accurately measure the output temperature of an air heater you must measure air temperature and laser IR thermometers are incapable of doing so.

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How-to Video: Easy repair of plastic boxes and containers

6/27/2018

 
​Repairing plastic boxes or containers is an issue in many industries. Repairing rather than replacing helps save money and is better for the environment. In this video we show you how easy it can be to repair a container if you follow the appropriate steps.

Welding Parameters for Extrusion Welding Plastics

4/20/2018

 

Based on DVS 2207-4

Welding Process Materials Abbreviations Material Temperature °C 1 Hot Gas Temperature °C 2 Hot Gas Volume Flow l/min 3 Welding Speed mm/min 5
Extrusion Welding (WE) High-density polyethylene PE-HD 4 210 - 230 210 - 300 300 300
Polypropylene, Types 1, 2, 3 PP-H; PP-B; PP-R 210 - 240 210 - 300 300 300
Unplasticised polyvinyl chloride PVC-U 190 - 200 330 - 360 300 300
Impact resistant polyvinyl chloride PVC-HI 170 - 180 280 - 340 300 300
Chlorinated polyvinyl chloride PVC-C 195 - 205 300 - 360 300 300
Polyvinylidene fluoride PVDF 240 - 260 280 - 350 300 300
Polyamide 6 6 PA 6 280 315 300 300
Polycarbonate 6 PC 270 315 270 300
Acrylonitrile butadiene styrene 6 ABS 265 300 150 300
Polystirene 6 PS 245 280 300 300
Polypropylen Athylen Propylen Terpolymer 6 PP-EPDM 200 - 230 200 - 290 300 300
Polyurethane (Thermoplast) 6 7 PUR 180 260 - 300 300 300
1) Measured with an insert thermometer at the exrudate outlet of the hand extruder.
2) Measured 5mm in the nozzle, in the centre of the nozzle opening.
3) Drawn-in cold air volume at the ambient pressure.
4) PE 63, PE 80, PE 100
5) Depending on the preheating
6) LEISTER empiric parameters
7) Welding rod has to be pre-dryed

Please note:
The indicated welding parameter may vary depending on the ambient temperature and the material configuration. Test welds need to be done and the parameter aligned accordingly! Leister takes no responsibility for poor quality welding!

Welding Parameters for Hand Welding Plastics

4/20/2018

 

Based on DVS 2207-3

Welding Process Materials Abbreviations Hot Gas Temperature °C 1 Hot Gas Volume Flow l/min 2 Welding Speed mm/min 3 Welding Force (N) with wire Ø3 mm Welding Force (N) with wire Ø4 mm
Free Hand Welding (WF) High-density polyethylene PE-HD 4 300 - 320 40 - 50 70 - 90 8 - 10 20 - 25
Polypropylene, Types 1, 2, 3 PP-H; PP-B; PP-R 305 - 315 40 - 50 60 - 85 8 - 10 20 - 25
Unplasticised polyvinyl chloride PVC-U 330 - 350 40 - 50 110 - 170 8 - 10 20 - 25
Chlorinated polyvinyl chloride PVC-C 340 - 360 40 - 50 55 - 85 15 - 20 20 - 25
Polyvinylidene fluoride PVDF 350 - 370 40 - 50 45 - 50 15 - 20 25 - 30
Acrylonitrile butadiene styrene ABS 6 350 N/A N/A N/A N/A
Polycarbonate PC 6 350 N/A N/A N/A N/A
Polyamide PA 6 400 N/A N/A N/A N/A
Polybutylene terephthalate PBT 6 350 N/A N/A N/A N/A
Low-density polyethylene PE-LD 6 270 N/A N/A N/A N/A
Polyurethane PUR (Thermoplast) 6 300 N/A N/A N/A N/A
XENOY XENOY PC/PBTB 6 350 N/A N/A N/A N/A
Plasticised polyvinyl chloride PVC-P 6 350 N/A N/A N/A N/A
Polyethylene terephthalate glycol-modified PETG 6 200 - 215 N/A N/A N/A N/A
Draw/Speed Welding (WZ) Polyvinyl chloride PE-HD 300 - 340 45 - 55 250 - 350 15 - 20 25 - 35
Polypropylene, Types 1, 2, 3 PP-H; PP-B; PP-R 300 - 340 45 - 55 250 - 350 15 - 20 25 - 35
Unplasticised polyvinyl chloride PVC-U 350 - 370 45 - 55 250 - 350 15 - 20 25 - 35
Chlorinated polyvinyl chloride PVC-C 370 - 390 45 - 55 180 - 220 15 - 25 30 - 35
Polyvinylidene fluoride PVDF 365 - 385 45 - 55 200 - 250 15 - 25 30 - 35
Ethylene Chloro Tri Fluoro Ethylene E/CTFE 5 350 - 380 5 50 - 60 5 220 - 250 10 - 15 N/A
Fluorinated ethylene propylene FEP 380 - 390 50 - 60 60 - 80 10 - 15 N/A
Tetrafluorethylen Perfluormethylvinylether MFA 395 - 405 50 - 60 60 - 80 10 - 15 N/A
Perfluoroalkoxy alkanes PFA 400 - 410 50 - 60 70 10 - 15 N/A
1) Measured 5mm in the nozzle, in the centre of the nozzle opening.
2) Drawn-in cold air volume at the ambient pressure.
3) Depending on the welding filler material diameter and the welding groove geometry.
4) PE 63, PE 80, PE 100
5) Nitrogene recommended
6) LEISTER empiric parameters

Please note:
The indicated welding parameter may vary depending on the ambient temperature and the material configuration. Test welds need to be done and the parameter aligned accordingly! STANMECH takes no responsibility for poor quality welding!

WELDPLAST vs. FUSION – What’s the difference between these Leister extrusion welders?

2/13/2018

 

WELDPLAST Series

Lesiter WELDPLAST S2
  • Closed-loop system: closed-loop control of plast and air temperature
  • Less welding experience required
  • Integrated display and temperature probe
  • Precise temperature independent of environmental factors or quality of voltage source
  • Greater process reliability
  • DVS-compliant

FUSION Series

Leister FUSION 3C
  • Open-loop system: open-loop control of plast and air temperature
  • More welding experience required
  • Neither display nor temperature probe
  • Output temperature depends on environmental factors and voltage source

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How Screw Extruders Work

9/27/2017

 
We've written previously about the Advantages of a Screw Extruder for Extrusion Plastic Welding. In a screw-based extruder, the turning screw grinds up the welding rod as it passes through the barrel. Both the mechanical energy of the turning screw and heat introduced along the extrusion barrel plasticize the incoming material. The barrel can be heated either with hot air or with a coil heater. 

Screw Extruder with Hot Air Heating (e.g., FUSION)

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Principle of Screw Extruders with Hot Air Heating

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How-To: Weld Plastics with an Extrusion Welder

6/27/2017

 
  1. Make sure an extrusion welder is right for the project.
  2. Learn about the advantages of a screw extruder.
  3. Read about recognizing if your tool is electrically certified for use in Canada.
  4. Identify your plastics and ensure the base material and welding rod are the same. See our article and this convenient flow chart. 
  5. Learn about the 3 parameters for plastic welding.
  6. Find the correct welding temperature for your project.
  7. Pick the right welding shoe for your extrusion welding project.
  8. Make sure to do some test welds!
  9. Prepare the plastics for welding.
  10. Directions for using an extrusion welder
  11. How-To Video: Using a Leister FUSION Extrusion Welder
  12. How-To Video: Using a Leister WELDPLAST Extrusion Welder
  13. Common extrusion weld defects and their causes.
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