A plastic product may be made of a variety of materials or components. It is necessary to combine the components with mechanical fasteners, adhesives and welding processes. In the three bonding methods, the welding process has the best effect, and the welding forms are various, and different welding processes can be used according to different materials, sizes and purposes.

机械固定件、粘合剂和焊接工艺均可将两种工程塑料接合。机械固定件可快速将两种部件连接，但接缝的防漏功能较差，局部应力也会使聚合物材料之间脱离。

Two kinds of engineering plastics can be joined by mechanical fixture, adhesive and welding technology. Mechanical fasteners can quickly connect two components, but the joint leakage prevention function is poor, local stress will also separate polymer materials.

粘合剂可提供良好的特性，形成防漏功能优良的接缝，可是，粘合剂处理难度较大，固化速度慢。同时，采用粘合剂粘合时，接缝准备和表面清洁度要求较高。

The adhesive can provide good characteristics and form a good seam with anti leakage function, but the adhesive treatment is difficult and the curing speed is slow. At the same time, with adhesive bonding, joint preparation and surface cleanliness requirements are higher.

焊接可产生粘合稳固的接缝，其机械特性接近于母体材料。塑料焊接仅限于热塑性聚合物，原因在于热塑性材料可通过加热而软化。热固性聚合物在硬化之后，无法通过加热而软化。与金属相比，热塑性聚合物焊接所需的热量较少。

Welding can produce bonded and stable joints, whose mechanical properties are close to the parent material. Plastic welding is limited to thermoplastic polymers because the thermoplastic material can be softened by heating. Thermosetting polymers can not be softened by heating after hardening. Compared to metals, thermoplastic polymers require less heat to weld.

塑料焊接工艺可分为两类：

Plastic welding process can be divided into two categories:

A）机械移动式焊接工艺：超声焊接、摩擦焊接和振动焊接。

A) mechanical mobile welding process: ultrasonic welding, friction welding and vibration welding.

B）外部加热式焊接工艺：热板焊接、热气焊接和植入焊接。

B) external heating welding process: hot plate welding, hot gas welding and implantation welding.

超声波焊接

Ultrasonic welding

超声焊接法通过机械高频振动而形成接缝。待装配的部件加压夹持于振荡焊头和固定焊头之间，然后与接触面呈直角，接受频率为20～40KHz的超声振动。交替式高频应力在接缝界面处产生热量，从而形成优质的焊接。用于这一工艺的工具十分昂贵，因此，适宜在生产量较大时采用。

Ultrasonic welding forms joints by mechanical high frequency vibration. If the assembly part is clamped between the pressure oscillation welding head and fixed welding head, and a right angle with the contact surface is accepted, the frequency of 20 ~ 40KHz of ultrasonic vibration. Alternating high frequency stress generates heat at the joint interface, resulting in high quality welding. The tool used in this process is very expensive, so it is suitable to be used when the production is large.

此焊接法仅适用于焊接长度不超过数厘米的小型部件。应用领域包括在多头机上焊接医疗器材所用的阀门和筛检程序、盒体、汽车部件、吸尘器外壳等。

This welding method is only suitable for small parts with a length of not more than several centimeters. Applications include welding of valves and screening procedures for medical equipment, boxes, automotive components, vacuum cleaners, etc. on multiple heads.

摩擦焊接

friction welding

热塑性塑料摩擦焊接（也称为“旋转焊接”）与金属焊接的原理相同。在这种焊接工艺中，将一片基材固定，另一片基材以受控的角速度旋转。当部件压合在一起时，摩擦热导致聚合物熔融，冷却后即形成焊接。主要焊接参数包括：旋转速度、摩擦压力、锻压压力、焊接时间和熔化长度。

Thermoplastic friction welding (also referred to as rotary welding) is the same as metal welding. In this welding process, a substrate is fixed, and the other substrate rotates at a controlled angular velocity. When the components are pressed together,zengchouji.75ix.comchengmo.75ix.comchujinji.75ix.com zhusaibeng.75ix.comshuiban.75ix.comguaniji.75ix.com the frictional heat causes the polymer to melt and the weld is formed after cooling. The main welding parameters include rotational speed, friction pressure, forging pressure, welding time and melting length.

摩擦焊接能产生优良的焊接质量，焊接工艺简单，重复性强。但也由于其工艺简单，所以仅适合于至少有一个部件是圆形且不需要角度对齐的应用领域。

Friction welding can produce excellent welding quality, welding process is simple, repeatability is strong. However, due to its simple process, it is only suitable for applications where at least one component is round and does not require angle alignment.

振动焊接

Vibration welding

振动焊接也称为线性摩擦焊接。两件热塑性部件在适当的压力、频率和振幅下相互摩擦，直到产生足够的热量使聚合物熔融为止。振动停止后，部件彼此对齐，熔化的聚合物固化后形成焊接。振动焊接类似于旋转焊接，区别在于运动为直线运动而非旋转运动。这一焊接法十分快速，振动频率一般为100～240Hz，振幅为1毫米～5毫米。

Vibration welding is also called linear friction welding. The two thermoplastic components rub against each other at proper pressure, frequency and amplitude until they produce enough heat to melt the polymer. After the vibration stops, the components align with each other and the molten polymer is solidified and welded. Vibration welding is similar to rotary welding. The difference is that the motion is linear motion rather than rotary motion. This welding method is very fast, the vibration frequency is generally 100 ~ 240Hz, the amplitude is 1 millimeters to 5 millimeters.

此焊接工艺的主要优点在于能高速焊接大型复杂线性部件。其它优点还包括：能同时焊接多个部件，焊接工具简单，几乎能焊接所有热塑性材料包括注塑部件、挤塑部件、吹塑部件、热成型部件、发泡部件和冲压部件，主要用于汽车和家用电器行业。

The main advantage of this welding process is the ability to weld large complex linear components at high speed. Other advantages include: welding several parts, welding tools simple, almost all thermoplastic materials including injection molding parts, extrusion parts, blow molding parts, heat molding parts, foaming parts and stamping parts welding, mainly used for automobile and household appliances industry.

Dukane推出的两款振动焊接设备VWB3500（965mm×455mm）及VWB3700（1320mm×610mm），适用于焊接以玻璃充填及高效性塑料制成的汽车、家电及医疗设备部件。电磁振动头特别耐用，由于没有支承面，因此无须润滑。焊接头经过优化设计，可容纳高频的重型工具，所以焊接时间较短。

The two vibration welding equipment VWB3500 (965mm x 455mm) and VWB3700 (1320mm x 610mm) introduced by Dukane are suitable for welding automobiles, household appliances and medical equipment parts made of glass filling and high effective plastics. Electromagnetic vibration head is very durable, because there is no supporting surface, so it is not necessary to lubricate. The welding head is optimized to accommodate high frequency heavy tools, so the welding time is short.

线性换能器可由控制器编程，确保升降台保持的精准高度、减速点、焊接开始时间及距离。设定快速，利用自动调校功能可自动找出焊接头的共振频率。其它标准特色还包括：距离焊接、时间焊接、可编程振幅、多重设定及三级密码保护。

The linear transducer can be programmed by the controller to ensure the precise height, the deceleration point, the welding starting time and the distance of the lifting table. Setting fast, using automatic adjustment function can automatically find the resonance frequency of welding head. Other standard features include distance welding, time soldering, programmable amplitude, multiple settings, and three level cryptographic protection.

振动焊接尤其适合热塑性材料，包括无定形树脂如ABS/PC、PVC、PMMA及PES；半结晶树脂如HDPE、PA、PP、TPO。Dukane的焊接机可接合汽车部件，例如进气歧管、仪表板、尾灯及保险杠等；航空用途如HVAC管、内饰灯及储存箱；家电则有洗碗机的泵及喷水臂、洗涤剂的喷洒器及吸尘机外壳。

Vibration welding is especially suitable for thermoplastic materials, including amorphous resins such as ABS/PC, PVC, PMMA and PES; semi crystalline resins such as HDPE, PA, PP, TPO. The welding machine Dukane engageable auto parts, such as intake manifold, dashboard, taillights and bumpers; aerospace applications such as HVAC tube, interior lights and appliances, storage box; spraying device and vacuum cleaner and water pump shell, the dishwasher detergent arm.

热板焊接

Hot plate welding

对于塑料接合来说，热板焊接是最简单的批量生产技术。高温热板夹于待接缝的表面之间，直到软化为止。此时，将热板抽出，两表面在受控压力之下贴合，保持一段特定的时间后合在一起。然后，让熔融表面冷却，形成焊接。焊接工具或加热组件配有内置电热器，以避免塑料粘连于焊接工具上。

For plastic bonding, hot plate welding is the simplest batch production technology. The hot plate is sandwiched between the surfaces of the joint to be softened until it is softened. At this time, the hot plate out, two surface under controlled pressure, to maintain a certain period of time after together. Then, molten surfaces are cooled and welded. Welding tools or heating components are equipped with built-in electric heaters to avoid plastic adhesion on the welding tools.

温度一般介于180℃～230℃之间，具体根据待焊接材料的厚度和类型而定。这种焊接方法常用于焊接供气、供水、污水、排水塑料管及化工行业所用塑料管的端头；将加油管和接头焊接于汽车用吹塑油箱上。

The temperature is generally between 180 and 230 degrees, depending on the thickness and type of the material to be welded. The welding method is usually used for welding gas supply, water supply, sewage, drainage plastic pipes and the end of plastic pipes used in chemical industry; welding the refueling pipes and joints to the blow tank for automobiles.

多种日常用品都采用这一焊接工艺，例如：吸尘

A variety of daily necessities are used in this welding process, such as: vacuuming