A Presentation

on

“VIBRATION WELDING
Technology”
Classification Of Joining Methods
Classification Of Welding Methods For Thermoplastics
Vibration Welding
In vibration welding, also called linear friction welding, the surface to be joined
are rubbed against each other, under pressure, in an oscillatory manner as
schematically shown in figure. The resulting frictional work causes the
interfacial material to heat up and melt. Welding is then completed by allowing
the molten film to cool under pressure. The main process parameters are;

1.) Weld Frequency (n)

2.) Amplitude of the Vibratory Motion (a)
3.) Weld Pressure (P)
4.) Weld Time (T)
 Advantages of Vibration Welding

1. NO ADDITIONAL MATERIALS - Vibration welding uses no additional

materials such as fasteners, inserts, electromagnetic performs, adhesives or
solvents. Therefore, it is inherently lower in cost than methods, which do use
additional materials, and is less expensive to disassemble for recycling.

2. LOW SURFACE PREPARATION - Vibration welding is relatively

insensitive to poor surface preparation.

3. EASE OF ASSEMBLY - Vibration welding requires only the placement of the

two parts in the fixture of the vibration welder.
4. ENTRAPMENT OF OTHER PARTS - Additional parts can be
captured between the two parts to be vibration welded provided they
are located such that they do not interfere with the welding.

5. PERMANENCE - Vibration welding creates permanent assemblies

that cannot be reopened without damaging the parts. Owing to material
limitations, differences in thermal expansion and moisture absorption
are rarely of concern once the parts are welded. .

6. INTERNAL JOINTS - In some cases, internal walls can be vibration

welded provided they meet at the welding plane.

7. IMMEDIATE HANDLING – Assembled parts can proceed on to

other operations at once without waiting for parts to cool & for
adhesives o solvents to set.
8. ENERGY EFFICIENCY - Relative to other welding processes,
vibration welding is highly energy efficient. This also means that
there is no excess heat that must be removed from the workplace.

9. CLEAN ATMOSPHERE - Unlike adhesive and solvent joining

systems, no ventilation equipment is necessary for the removal of
toxic fumes.

10. HIGH PRODUCTION RATES - Depending on the application,

vibration welding is capable of production rates of 4 to 30 parts per
minute based on a single weldment per cycle and not taking into
account the part handling time which varies with each application.
Higher rates are possible if multiple parts are welded with each cycle.
11. PROCESS FREEDOM - Parts made from virtually all the thermoplastic
processes can be vibration welded.

12. LARGE PART CAPABILITY - Equipment is available that can weld parts
up to 1016 mm (40 in) by 2032 (80 in). A 1524 mm (60 in) automobile bumper
has been successfully vibration welded.

13. PRECISION CONTROL - Vibration welding permits precision control of

process variables.

14. QUICK CHANGEOVER - Vibration welding equipment can be quickly

changed from one job to the next.
 Disadvantages of Vibration Welding

1. SHAPE LIMITATIONS - There must be a flat, horizontal welding surface.

2. DAMAGE TO ELECTRONIC COMPONENTS - Vibrations can damage

some electronic components or their assemblies.

3. ALIGNMENT - Locating pins or other devices cannot be molded into the

part. Alignment between the two parts is set by the final resting place of the
two parts.
4. MATERIAL LIMITATIONS - Materials for vibration welding are
limited to compatible thermoplastics.

5. SOUND CONCERNS - The foghorn noise associated with vibration

welding (90 to 95 db) makes the use of sound enclosures commonplace.
These reduce the sound level to approximately 80 db.

6. EQUIPMENT COST - Vibration welders are more expensive than hot

plate welders and cost considerably more than ultrasonic welders or spin
welders, a consideration that tends to limit their use to applications,
which are too large or poorly configured for these techniques.
 Materials for Vibration Welding
It is very useful technique of welding for Crystalline
Thermoplastics. Apart from Crystalline Thermoplastic this is also
very useful technique for thermoplastic rubber and elastomers.

Applications Of Vibration Welding

1. All plastic automotive bumper

2. Welding of headlight, taillight & instrument panel assemblies
3. Assembling glass and particulate-filled polypropylene washer
and dishwasher pumps
Effect of Process Parameters on Weld Strength
Threshold Penetration

Threshold Penetration is most important from the point of view of

vibration welding. Generally Ƞᴛ(Threshold Penetration) is 0.25mm
(0.01 inch). When penetration is below the threshold value weld
strength appears to fall off and if penetration is above threshold value,
it provides higher strength.

where Ƞᴛ =Threshold Penetration

Ƞᴛ = 0.25 mm
Ƞғ= Penetration Thickness

One should ensure that in order to have better weld strength;

Ƞғ ≥ Ƞᴛ
 Effect of Pressure on Vibration Welding

Weld Pressure affects each polymer differently. Both the weld strength
and the ductility are relatively insensitive to the pressure P₀ in the range
of 0.9 to 6.9 MPa , but falls off at pressure of about 13.8 MPa.

Effect of Frequency on Vibration Welding

Weld frequency appears to have a significant effect on unfilled

resin. Weld strengths corresponding to those of the virgin unfilled
resin can only be achieved at high weld frequencies.
 Effect of Amplitude on Vibration Welding

Weld amplitude by itself does not affect the welding process; the
energy input into the process is determined by the product of the
amplitude and the frequency.
Thank you..