New method of infrared welding MM modern plastic Kubota Research Associates (KRA, a US research and development company) has developed an advanced method for infrared penetration (TTIR) welding of sensitive plastic parts. The emerging company's P-wave TTIR device is capable of producing multi-color (multi-wavelength) infrared energy instead of the monochromatic (single-wavelength) infrared energy used in laser welding. Mr. Masnori Kubota, President of KRA, stated that P-waves provide a new way to weld transparent, translucent and colored parts and films, and that it can weld a wide range of engineering plastics. Like laser welding, P-waves focus infrared energy on the area between the infrared transparency and the infrared absorbing portion, causing the interface to partially melt. This melting, combined with the applied pressure, bonds the parts together. However, Kubota said that P-wave is a more precise, more tolerant and less expensive welding method than infrared laser welding. KRA believes that their technology outperforms infrared laser welding in welding films used in electronics, automotive and medical components, fuel cells and bio-liquid bags, as well as certain composite parts. Surface defects (ablation) of parts are greatly reduced. It is said that the use of KRA technology in conjunction with the corresponding wavelength transducers allows for precise guidance of infrared energy so that high temperature polymers such as fluoropolymers and polyetheretherketone (PEEK) are the first to be used. The TTIR welding has become obedient. How P waves work John Long, chief technology officer of KRA, said the power of the P-wave devices offered is 300 and 500W. The system includes an infrared lamp (halogen, helium or metal halide) as well as a patented optical focusing device and KRA's proprietary wavelength transducer. The device produces an unconventional solder joint with a diameter of approximately 5 mm, and a robotic raster scanner can be used to expand the weld area. KRA's infrared lamps and optics produce a filtered, bandwidth-conducting, cone-shaped beam that precisely and deeply illuminates the infrared energy in the solder interface area, making local precision soldering possible. The patented optical component focuses the infrared beam to such an extent that it can penetrate deeper into the plastic part than the laser energy, while reducing damage to the surface of the part. Mr. Long said that in most cases, P-wave soldering is most effective with wavelength transducers. The transducer is a plastic film, strip or die cutting device made of an infrared absorbing material that is placed on or over the part being welded. The transducer focuses the infrared beam energy onto the soldering interface like a lens, increasing the energy flow density by 300%, thereby accelerating the melting rate of the soldered area. The transducer can be designed according to the shape of the welded joint, which will facilitate the welding of 2D or 3D joints. This equipment can weld films, sheets, cloths, sheets, tubes and molded parts. Wavelength transducers can weld natural (infrared transparent) materials into bags and containers, such as polyethylene blood and biological fluid bags. These flexible containers can replace the PVC bags currently in use, thereby avoiding the risk of toxic gases when incinerating these vinyl bags. The P-wave device can also weld non-woven bags and medical wraps made with DuPont's Tyvek film. Another use is in fluoropolymer bags used in biological and environmental sampling procedures. KRA wavelength transducers can greatly increase the absorption of infrared light, allowing a wider range of materials to be soldered than other methods. In addition to polystyrene, polyethylene, polypropylene and other polyolefins, the materials that can be welded include most fluoropolymers and polyetheretherketone (PEEK), polyether-imide (PEI, GE). Ultem grade), polyimide, ultra high molecular weight polyethylene, polycarbonate, nylon, glycol resin, polyvinyl chloride, TPO and other TPE polymers. According to KRA, its 300W system has been used by a US medical device manufacturer, but the company declined to agree. The device is used for the welding of polypropylene, polyethylene, ABS and polycarbonate medical devices because no residue is produced after welding. KRA says P-wave devices are not as expensive as infrared lasers or ultrasound systems. The price of basic P-wave equipment hardware is about $20,000, which is half to one-third cheaper than infrared laser equipment. It is said that equipment costs are also very low. The infrared head weighs less than 4 pounds and can be easily installed on automated production lines. The KRA system also does not require shielding to protect the operator. Infrared transparent parts with various colors can be welded successfully. Solve the problem of 3R (recycling, refilling, maintenance) The P-wave system can also be riveted together by means of a proprietary, and at the same time, the parts can be disassembled later. Alternatively, the fasteners may be infrared transparent and the fasteners are soldered to a substrate that absorbs infrared light. KRA describes its fasteners as an alternative to adhesives, mechanical fasteners (screws and bolts) and hot piling. According to Kubota, they have a high bond strength and can reduce the number of joints by 50% compared to adhesives or mechanical fastening. This fastener can be quickly disassembled when it needs to be disassembled. A newly developed use is for a two-piece spliced ​​vehicle door panel that has been reported to increase door stiffness, reduce door weight and part count, making the door easier to service. KRA is investigating the use of its fastening system for the welding and sealing of removable covers for printer color cartridges. The cover is sturdy, leak-proof and durable; however, when the cartridge is used up, it can be removed without damage. Comparison between micro laser welding and micro TIG welding Comparing laser welding tool repair and micro TIG welding tool repair, we must consider the advantages and disadvantages of both. Each method has significant features that are appropriate for a particular repair application. Microlaser welding also has significant disadvantages in the welding process. The laser head is fixed and the laser head is used with the microscope to see the area being welded. This means that laser welding must control the workpiece compared to TIG torches. This is not only challenging, but also makes a lot of investment because each workpiece to be welded needs to be fixed. Because of this, laser welding is much slower than micro-TIG welding and is therefore much more expensive. As a result, the laser welder fixture is as expensive as the laser (usually more than $30,000 to $100,000) and its maintenance costs. Microscopic TIG welding The disadvantage of micro TIG welding is mainly because it requires much higher heat input than laser welding. The workpiece to be welded must be preheated to a specific temperature (depending on the type of steel), resulting in a longer post-heating process and cleaning process. Not only that, but the heat required for welding is also likely to deform the workpiece, especially for small, thin-walled and long, round workpieces. Micro-TIG welding is larger than the heat-affected zone of laser welding, which severely limits the ability of molders to mask welds on polished or textured surfaces. Both micro laser welding and micro TIG welding have obvious advantages and disadvantages. At the current state of the art, micro-laser welding is not feasible to replace micro-TIG welding, and the welds produced by micro-TIG welding are not comparable to the low-heat input of laser welding. Both methods have their own merits and should be the application of all well-equipped micro-welding plants. In the field of micro-welding, discussions about whether the rise of micro-laser welding will replace micro-TIG welding as the best method for repairing tools continues. On the one hand, laser manufacturers say that laser welding will replace microscopic TIG welding because of the excellent welding results of laser welding machines. On the other hand, if you ask most of the famous TIG welding plants, they will say that laser welding accounts for only a small part of their current workload (1% to 5%), so it is not worth investing in lasers. What is wrong? 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Mr. Kubota said that several uses of the adhesive bonding method currently seem to be able to use this method. He cited examples of printed circuit boards bonded with polyimide film, fuel cells bonded with fluoropolymers, and graphite or carbon fibers using polyetheretherketone and polyetherimide as binders. Composite material. Moreover, unlike existing methods, KRA's transducers are reusable and are not consumed during the welding process and do not enter the parts. Infrared laser welding uses a more expensive method, and one of the two welded parts needs to contain an infrared absorbing additive or coating.
Microlaser welding has obvious advantages in weld quality. The heat input of the laser during the welding process is very low, so the heat affected zone (HAZ) around the solder joint is also minimal. This is advantageous when repairing textured or polished surfaces, and there is no depression around the resulting weld, and almost no welds are visible after machining. In addition, the laser beam can enter the depth of the hole as long as this area allows a weld beam of at least about 15°.
Because microscopic TIG welding is a proven technology, it is a reasonable and economical method of repairing tools. Typical micro-TIG welding is performed by a micro-welder-controlled torch for virtually unlimited applications. TIG welding is much faster than laser welding for any size weld bead. The recess can be easily controlled within a few tenths of an inch, and the cost of the welding equipment and its maintenance is only a fraction of the laser welding. In general, the cost of repairing tools with microscopic TIG welding is lower as long as a reasonably priced microwelder is used.