How to solder plastic correctly

Plastic Welding Equipment

01.11.2018

Plastic welding is a reliable way to assemble pipes or sheets at the molecular level. A seam of a homogeneous structure is obtained using heating equipment - welding machines. Working with them does not require any special skills.

Learning how to weld plastic yourself is easy. It is more difficult to choose a tool that is suitable for work at home. When choosing, the pros and cons of each are taken into account. Expert advice can be useful.

Not all types of plastics can be hot-joined, only those that do not shrink when heated.

Types of plastic that can be welded

Not all types of plastic retain their properties when melted and then cooled. It is impossible to weld plastic that is afraid of heat. These types of polymer materials are called thermosets. They are flammable, when heated they begin to smoke, and at high temperatures they burn and char.

Only thermoplastics are welded well, the most common of which are PVC (polyvinyl chloride), polyethylene and polypropylene. Other types of heated plastics are usually glued or mounted on a lathing. This:

• nylon;
• polyvinyl acetate;
• polycarbonate;
• polyethylene terephthalate;
• polystyrene

The welding process is possible if the parts are made of homogeneous plastic. The format does not play a special role. The parts can be joined over the entire thickness or through a third of the layer; with a smaller seam, the adhesion of the parts is considered unreliable. Pipe products are often installed with an overlap. This connection has a large adhesion area.

Plastic welding methods and equipment

Several methods are used for soldering plastic at home.

1. Contact welding for plastic is the most convenient. Does not require filler material. The simplest of them is a household soldering iron with an operating voltage of 220 volts with a special nozzle instead of a tip; it provides a large heating area. The contact method is considered universal; it connects polypropylene and polyethylene of various densities, shapes and thicknesses. The essence of the process is heating the seam area to 260°C and then joining the parts by butting or overlapping. There are three types of equipment for welding plastics: 1) when the heating element acts on the entire thickness of the part (for sheet and pipe plastic); 2) the heating zone is limited (overlapping sheets); 3) the inner and outer parts of the elements being connected are simultaneously heated (socket joint).
2. Construction hair dryer, also known as a heat gun, with attachments

   Connecting parts with hot air using a heat gun or a heat gun allows you to use a filler rod; it is supplied manually. The principle of operation of the equipment is simple: air from the electric heater is forced by a fan through a narrow opening into the heating zone.

   The polymer melts and a seam is formed. A hairdryer with a nozzle is more convenient than a pistol; the rod is tucked into the nozzle, and the left hand is freed. For home use, a heat gun or hair dryer with a power of 1.5 or 2 kW is often purchased. It heats the air from +180°C to +260°C, models are equipped with thermostats.

3. Joining parts with an extruder involves feeding molten polymer into the area where the parts are joined. This method is the simplest and most reliable; after welding, an even seam bead is formed.

Manual extruder for plastic welding

Extruders are available in two types:

• non-contact, when the supplied mass must be leveled with a special roller;
• contact, when a soft polymer is fed with force.

The adjustment is carried out taking into account the type of polymer and the thickness of the filler rod.

Technology of welding plastics with a hairdryer or heat gun

The method is used for products of any configuration. A hairdryer can be used to install pipes, bumpers, swimming pools, flooring and much more.

A plastic welding hairdryer can be used to join any thermoplastics. The gun is more often used to join parts with overlaps: the space between them is heated, after which the seam is compacted and rolled with a roller.

They also connect parts using a hair dryer; when the products are joined end-to-end, a filler rod is fed into the seam area - it is directed over the joint or into it.

Now about the nozzles, a construction hair dryer for rod welding simultaneously heats the edges and the filler material. Hair dryer attachments are divided into types:

• fixing ones press the surfaces to be welded before welding;
• slotted ones are convenient for welding roofing materials;
• forming ones are used for rods thicker than 4 mm.

The technology for making a seam involves pre-processing the edges: they are cleaned and degreased. Edges thicker than 2 mm are first chamfered to make room for laying the rod. When joining thin plastics, the rod is fed directly into the gap between the parts.

It must be taken into account that with the use of filler material a convex weld is formed. If necessary, excess polymer is cut off. To form an even connection, it is necessary to maintain a distance between the hair dryer and the parts being connected.

The speed of the hair dryer is adjusted so that the rod and edges have time to warm up, but do not melt too much. There should be no edge deformation.

Extruder welding technology for plastics

Of all the hot methods, the most economical and convenient is the connection of plastic elements with a contact extruder, when the molten mass fed into the joint is pressed by a guide nozzle. This method is used for parts with thick walls. The extruder feeds already softened material. With this method:

• energy consumption decreases;
• heat transfer improves;
• there is no need to use clamping devices;
• it is easier to control the quality of the seam.

Main stages of the technological process:

1. Heating the welded edges to a state of viscosity with a heated mass;
2. Docking by hand force or special devices;
3. Natural cooling of the connected parts (they cannot be moved until they have completely hardened).

Selection of welding rods

The filler material is selected according to the type of plastic being welded. It is indicated in the labeling. Polypropylene filler rods are available in different sections: triangular, round. If the parts are fastened at right angles, it is better to choose a triangular rod. They vary in color. Black and gray are in great demand. Polyethylene rods for welding plastic are softer than polypropylene rods, the melting point is lower (from +160°C).

Filler materials are used at ambient temperatures above +15°C. In the cold they lose their plasticity and become brittle.

When choosing an additive, you need to pay attention to the melting point of the rod or rods. It is acceptable to use slightly different polymers if they are similar in their plasticity regime. It is important that the filler material fits well into the extruder and matches the diameter of the loading hole and outlet nozzle. For manual extruders, rods or rods from 2 to 7 mm are used.

Conclusion

Household equipment is used for welding plastics. It is designed for 200 volts and a frequency of 50 Hz. It is better not to purchase industrial devices. The easiest device to use is an extruder. To assemble home water pipes, use a soldering iron with special attachments.

Source: https://svarkaprosto.ru/tehnologii/oborudovanie-dlya-svarki-plastmass

How to properly solder plastic pipes with a soldering iron

Manufacturers of materials for laying utility networks offer a wide selection of modern solutions that have replaced traditional ones. In particular, this applies to pipes for installation in a house or apartment of a water supply system, a hot water supply branch, a radiator and floor heating system.

To lay or repair a local pipeline made of polymer pipes (polyvinyl chloride, polypropylene), you need a special tool and some skill in working with it.

Soldering plastic pipes is not a complex job, but it is important to understand the technology and take into account a number of points in order to get a reliable and durable result.

Tool for soldering plastic pipes

Pipe soldering machine

In everyday life, a special device is used, designed to connect a polymer pipe to the corresponding fitting or coupling. The maximum permissible pipe diameter that a home craftsman can handle is 63 mm. Larger diameter pipes are mostly butt welded using professional equipment.

A soldering tool for home use is a unit equipped with a stand, the working part of which is heated to a predetermined temperature. The heating element (sole) is equipped with holes for installing nozzles of various diameters (from 16 to 32 mm).

Apparatus for soldering plastic pipes

The devices differ in design:

• xiphoid;
• cylindrical.

There is no fundamental difference which one to use for soldering plastic pipes with your own hands. In any case, strictly following the instructions will help you get the desired result.

Secrets of high-quality soldering

Soldering of pipes should be carried out in a room with a positive temperature, and the colder the air, the more time it will take to warm up plastic or metal-plastic parts for a tight and durable connection.

Secrets of high-quality soldering

To avoid common mistakes when installing heating or water supply pipes, pay attention to the following recommendations:

• The power of a household tool should be 1200 W.
• The device for home use is designed to work with pipes with a diameter of up to 32 mm; in other cases, you need to use a professional soldering iron.
• Before you start soldering, warm up the device for at least 5–10 minutes so that the working part with nozzles warms up to the specified parameters.
• Having soldered the pipeline elements together, do not twist them or move the seam so as not to damage its integrity. It is only permissible to carefully straighten the distortions, otherwise the seam will leak under load.
• Do not squeeze the parts together too much. Since the melted plastic will be pressed inward and reduce the bore diameter of the fitting, which will worsen the operating parameters of the system.
• Do not leave gaps between the edge of the pipe and the inside of the fitting. Such a connection will leak under pressure.
• Be sure to allow the soldered area to cool completely before applying stress.
• After each soldering operation, clean the nozzles from traces of melted plastic. This will prevent the appearance of carbon deposits, as well as damage to elements that need to be soldered.
• Clean the nozzles using a flat wooden stick. This will protect the Teflon coating from damage. Metal objects cannot be used, as scratches will render the nozzle unusable, and the plastic will stick to it and burn.

Attention! Before you begin installing the pipeline, watch the detailed video instructions and practice on unnecessary scraps of plastic pipes.

Security measures

It is important not only to know how to solder plastic pipes, but also to follow safety precautions when working with power tools so as not to get burned or injured.

It is important to use protective gloves

1. When working, be sure to wear protective gloves.
2. Pay attention to the cleanliness of the floor and dustiness of the room. Dirt trapped in the molten plastic impairs the quality of the weld and makes the joint unsightly.
3. The soldering unit must be placed on a horizontal, flat surface.
4. During the entire working process, the unit is not de-energized.
5. You can start welding elements only after the soldering iron has completely warmed up. In modern models, the indicator switched off indicates that the operating mode has been reached.

   Using an old device, wait about 20 minutes from the moment you turn it on.

Work progress

Let's take a closer look at how to properly solder plastic pipes at home. At the preliminary stage, you need to prepare all the necessary tools:

• tape measure and marker;
• needle file or file;
• fine grain sandpaper;
• pipe cutter;
• sharp mounting knife;
• soldering iron for welding plastic.

You will also need a rag and alcohol (or other degreasing agent) to treat the surfaces to be soldered.

Preparing elements

The pipes are cut to the required length using a special pipe cutter or a sharp mounting knife. Make sure that the cut is strictly perpendicular, otherwise you will not be able to make a tight connection.

Using a Shaver

Next you need to process the edge of the pipe. It is advisable to use a special tool - a shaver, but in its absence it is enough to use a mounting knife (used to remove burrs), after which the edge of an ordinary pipe made of propylene or fiberglass reinforced needs to be processed until smooth using a needle file and fine-grained sandpaper.

Important! For an aluminum-reinforced PVC pipe, it is recommended to remove the top layer of polymer and the foil layer at the edge to improve the quality of the connection.

After making sure that the smoothness of the treated edge is almost as good as the inside of a fitting purchased in a store, you can begin to solder the elements, having previously degreased the surfaces to be joined with alcohol.

Soldering technology

Let's look at how to use a soldering iron and what temperature mode you need to choose for different types of plastic pipes. Do-it-yourself installation of a polymer pipeline is carried out in several stages:

1. The soldering unit is securely fixed to the platform and installed on the working part of the nozzle of a suitable diameter.
2. The electric soldering iron is turned on after setting the required temperature. To solder polypropylene parts to each other, the working part must be heated to 260°C; when welding PVC products, heating to 220°C is required.
3. After the apparatus has warmed up, the fitting and the prepared edge of the pipe are put on the nozzles and the parts are heated for several seconds (the exact heating time is indicated in the table below, it depends on the diameter of the elements).
4. After waiting the required time, the parts are carefully joined together and left to cool completely. All other elements of the pipeline are fastened in the same way.

The depth of welding of the pipe corresponds to the parameters of the inside of the fitting - nozzles on the soldering iron ensure heating of the elements to the same depth to ensure maximum contact of surfaces for better adhesion.

Soldering process technology

The method of connecting polymer pipes using temperature welding is quite simple if you master the skill of accurately connecting heated elements and know how to solder the parts. Once the pipe is inserted into the fitting, it is not moved or rotated so that the heated polymer can form a monolith. If the joint is moved before the material hardens, the polymer will bunch up and the joint will depressurize.

Checking the connection quality

Testing the tightness of connections begins after all the joints have been installed and have had time to cool. To do this, water is poured into the finished system and the pipeline is inspected to identify leaks. Before adding water, let the installed system stand for at least an hour at normal room temperature, and if the air in the room is cooler, then the pre-test pause should last at least 2-3 hours.

If leaky joints are found, it is necessary to drain the water from the system and reinstall the pipeline section by installing new fittings and taking a piece of pipe of the appropriate length. An attempt to somehow seal a leaky connection or solder it using an electric soldering iron is doomed to failure in advance. Installation of a polymer pipeline requires strict adherence to technology.

An example of a quality connection

At the end of the repair work, the tightness of the system is checked again by pouring water into it. If we are talking about a heating system, the pipeline will undergo a real check only after heating the coolant in the boiler, at elevated temperatures and pressure.

Soldering plastic with your own hands

Many motorcyclists and motorists have to deal with the fact that the plastic parts of their vehicles (most often bumpers) receive some damage and lose their former appearance.

But instead of buying a new spare part, you can restore the old one yourself by soldering. Soldering plastic is not that difficult.

Necessary tool

In this case, the following soldering tools can be used:

• an ordinary 100-watt soldering iron,
• hair dryer (also called a heat gun),
• Soldering Station.

The capabilities and operating principle of a conventional soldering iron are familiar to almost every home craftsman. Such a soldering apparatus may have a straight or curved tip.

The hot-melt gun solders plastic by supplying heated air. The heating temperature ranges from +80 to +600 ℃, it can be continuously adjusted.

As a rule, models of soldering guns are equipped with a large number of attachments that make this tool as convenient and efficient as possible.

The nozzles help direct the air to the desired area and create the required angle of inclination. High-quality hair dryers for soldering plastic have a power of at least 1600 watts.

The soldering station combines a regular soldering iron and a hot-melt gun for plastic. Such a unit is capable of solving many problems. Temperature adjustment and a huge number of attachments allow you to carefully solder plastic, as well as other materials.

Types of plastics

In order to successfully repair a car element, it is worth determining in advance what kind of plastic it is made of. All plastics can be divided into hard and soft. In particular, fiberglass plastics that do not have any markings are considered soft.

Hard types of plastics can have different markings, for example, ABS, GF30, PAG6. The markings are visible if you look from the back of the vehicle part. Polypropylene (PP marking) is considered the most durable.

Quite often, vehicle owners require soldering of ABS plastic, since it is from this material that the bumpers of cars of many well-known brands are made.

Use of a soldering iron

Let's assume that the plastic bumper of a car is seriously damaged and needs to be repaired by soldering. How to do it?

To make it easier to solder the structure, it must be removed from the car. It also doesn’t hurt to look at the labeling in advance. Most likely, the part will be made of ABS plastic.

Then you should clean the surface of the bumper from dirt, remove paint and varnish residues. Additionally, the entire plastic part must be degreased. Next, you need to connect all the fragments of the bumper together.

For such a connection, it is important to use clamps or staples. But this must be done carefully so that they do not penetrate through the car plastic.

Soldering plastic with a standard soldering iron should begin from the inside of the car bumper . To do this, one of its edges is securely fixed, and special plastic electrodes are laid along the future seam (although the name “electrodes” in this case is very arbitrary).

At the next stage, a soldering iron for soldering plastic melts the electrode material, and it fills all the recesses of the crack. This operation must be repeated as many times as stitches need to be made, that is, it all depends on the initial number of defects and damage.

Now you need to wait for the molten mass (characteristic bubbles appear on it) to cool a little - this will take about five minutes. Then you need to smooth out the seams on the plastic.

In principle, any blunt object can be used for this procedure. In hard-to-reach places, the surface can be smoothed and leveled with gloved hands. Complete hardening of the seams will occur in a few hours. At this point, the soldering of the auto plastic can be considered complete.

Using a hair dryer

Soldering automotive plastic is done a little differently if a heat gun (hair dryer) is used. Here you will need special welding rods (essentially, this is solder for soldering plastic).

You can purchase them in specialized stores or even make them yourself. The main thing is that they are similar to the material being welded. One of the ends of the rod is sharpened and then inserted into the corresponding hole in the nozzle of the heat gun.

The hair dryer should be moved slowly along the crack being repaired; the filler rod should be inclined towards the workpiece at an angle of approximately 45°. If a plastic part has shattered into separate pieces, then soldering it with a hairdryer is carried out in two passes.

First, the pieces or fragments are fastened together with short stitches (seams). And only after this the final reliable soldering is made. When the material has cooled, the surface of the part is puttied and sanded, preparing for painting.

To repair the plastic of a motorcycle, all kinds of elements of its external design, you can use soldering using approximately the same technology as in the case of repairing a car bumper. Moreover, motorcycle panels are usually made of the same ABS plastic.

Source: https://trubyisantehnika.ru/%D0%BA%D0%B0%D0%BA-%D1%81%D0%BF%D0%B0%D1%8F%D1%82%D1%8C-%D0 %BF%D0%BB%D0%B0%D1%81%D1%82%D0%B8%D0%BA.html

Secrets of soldering auto plastic

Many motorcyclists and motorists have to deal with the fact that the plastic parts of their vehicles (most often bumpers) receive some damage and lose their former appearance.

But instead of buying a new spare part, you can restore the old one yourself by soldering. Soldering plastic is not that difficult.

Reinforcing mesh

Also, home craftsmen can use in their work such a device as a reinforcing mesh for soldering hard plastic.

It is needed to ensure that the final result is stronger and more durable. This mesh is placed on the inside of the structures.

Then, using a soldering iron or hair dryer, it is heated and, in this state, pressed into the plastic using a screwdriver. The mesh should become a kind of frame that holds and strengthens the part.

Excess plastic resulting from reinforcement can be removed using a grinding machine or an ordinary knife. If you work carefully on the outside, traces of cracks and breaks will not be visible even close up.

Source: https://svaring.com/soldering/tehnologii/pajka-plastika

Soldering plastic at home - Metalworker's Guide

Many motorcyclists and motorists have to deal with the fact that the plastic parts of their vehicles (most often bumpers) receive some damage and lose their former appearance.

But instead of buying a new spare part, you can restore the old one yourself by soldering. Soldering plastic is not that difficult.

How to choose a soldering iron for soldering plastic?

In case of an accident, bumpers take the main load. The part is damaged and therefore needs to be repaired. To do this, use a special soldering iron for plastic. With its help, you can level the surface, eliminate cracks and connect broken elements.

Requirements for soldering irons for plastic

The main characteristic of such devices is power. For efficient and comfortable work, it is recommended to use a device with at least 100 W. If you use a soldering iron of lower power, the plastic will not melt. When choosing thermal hair dryers, you need to pay attention to devices from 1600 W.

Another requirement is the heating speed of the soldering tip. For processing plastic elements, it is recommended to select options that heat up in 7-10 seconds. For domestic use, you can take equipment with prolonged heating, but for professional activities this will be associated with some inconveniences.

Tool types

The modern market offers several types of tools for working with plastic parts. Among them:

1. Devices with standard configuration . This tool can have a curved or straight soldering rod. Most often it is used to connect broken plastic elements. Standard models create strong seams due to high temperature exposure and can work at different angles.
2. Thermal gun . The equipment is designed to correct the deformation of parts and solder them. The soldering gun is equipped with temperature control, which expands its scope of application. This bumper repair kit may include additional attachments that simplify and speed up the work.
3. Hot air station for soldering . This tool is universal. It combines a hot air gun and a standard soldering iron. Additional attachments may be sold with it.

What to look for when choosing

When choosing a soldering iron, you must take into account that it is designed to heat plastic. In this case, you should pay attention to several characteristics. First, the equipment must have optimal power, otherwise the plastic will not melt. The optimal indicator is at least 100 W.

Secondly, a soldering iron for car bumpers should have a convenient design. The user should not experience any discomfort when working with it. In addition, you need to choose a reliable unit from a trusted manufacturer.

Experts recommend giving preference to models equipped with wooden handles. This material does not heat up and does not lose its performance properties for a long time under the influence of high temperatures.

Best models

A soldering iron for repairing plastic parts is an expensive device, which is explained by its technical characteristics and operating features. There are several of the most reliable and effective devices on the domestic market:

1. Steinel . This brand produces a whole repair kit, which includes a heat gun. The device has a power of 2.3 kW. With its help, plastic can be heated to a temperature of 650°C. Sold in a durable polymer case with additional accessories (electrodes, extension cord, etc.) and attachments.
2. RT-2003 from Intertool . This device is great for processing thin plastic materials.
3. Teroson . A convenient kit for repairing plastic parts, which contains a heat gun. Additionally, the device comes with attachments and accessories, including mixers, replaceable cartridges and reinforcement materials.
4. Neiko . This tool is professional and made in China. Its power is 1600 W. Additionally, a special roller and attachments are supplied with it. Precisely selected components can ensure fast and simple operation. The advantage of Neico is that you do not need to purchase auxiliary materials for it.
5. Stapler . Budget class model with a power of 100 W. The seams are created using special staples, which is why the tool got its name.
6. Lukey . This is a cheap Chinese model. It is perfect for beginners and home use.

It is necessary to choose a tool taking into account your goals and financial budget.

Application area

In most cases, a soldering iron is used in car repair shops for processing plastic elements. They are used to repair bumpers, mirror structures, interiors, torpedoes, body kits, etc.

In addition, this device makes it possible to quickly and easily repair broken plastic parts on motorcycles, ATVs and bicycles, boats and yachts.

In a private home, a soldering tip for plastic is useful for repairing pipes, polymer frames of greenhouses and greenhouses.

How the tool works

The surface to be treated must first be lubricated with a degreasing compound and sanded. This will make it possible to achieve the highest quality docking. Using a standard soldering iron model, you simply melt the edges of the element, then fix them to each other and expose them to temperature. If the operation was performed correctly, a strong seam will appear at the junction of the plastic parts.

Treatment with a hot air gun is carried out using a similar principle. A targeted flow of hot air ensures the transition of the polymer into a liquid state. If you are leveling defects, you need to wait until the car bumper softens and becomes plastic. Only after this can you manipulate it. If the ends of the parts melt, they must immediately be tightly connected to each other and held until completely solidified.

When working with a soldering iron, you must follow the following rules:

1. To make the tool heat up faster, it is recommended to clean its tip with fine-grained sandpaper. After prolonged use of the equipment, more thorough cleaning is necessary.
2. A broken soldering tip can be replaced with a nail or steel wire.
3. To extend the life of the tool, you need to let the transformer cool down when using it.
4. When processing highly deformed plastic elements, it is better to use a special electrode. When heated, the material will fill all existing defects.
5. Processing must begin with the internal surfaces. This will allow you to set the optimal heating level. If the temperature is not suitable, the defect on the wrong side will be invisible.
6. When reinforcing plastic with mesh or staples, metal inclusions must be lubricated with anti-corrosion agents.

By following these recommendations, you can achieve the highest quality fastening of plastic bumper parts.

Source: https://electrod.biz/payka/kak-vybrat-payalnik-dlya-pajki-plastika.html

How to solder plastic at home

Often we need to glue a broken or cracked plastic product - from the temple of glasses to the bumper of a car. It may also be necessary to glue a hook in the bathroom or a holder for a garden sprayer. The essence of the gluing process is to dissolve the surface layer of two workpieces and form from this solution a layer of plastic common to both parts. After hardening, the parts form a single whole, or, as they say, “glue tightly together.”

Determining the type of plastic

In order to reliably glue plastic, you first need to find out what kind of plastic the object is made of. Knowing the plastic, you can choose the most suitable adhesive for it.

All manufacturers put recycling symbols on their plastic products - this is the well-known Recycling Triangle - a triangle with arrows on the sides, symbolizing the reuse of materials.

The triangle contains numbers from one to seven. Often the numbers are supplemented by an abbreviation. These designations are used to determine the type of plastic.

What does the marking on plastic mean?

• PET low density polyethylene or polyethylene terephthalate. It is mainly used for packaging or packaging food products. Available in the form of film, bags or transparent containers for liquid and bulk goods, as well as drinks.
• HDPE compacted low pressure polyethylene. Used for the production of shrink film and packaging bags.
• V (PVC) polyvinyl chloride is a non-food plastic used for the manufacture of strong and durable items, such as household buckets, metal-plastic window frames, and linoleum.
• LDPE Low density polyethylene of high pressure. Used in the production of bottles for drinks and dairy products, packaging bags, toys, cold water pipes.
• PP polypropylene. Plastic is not chemically active, heat-resistant (up to 150 °C), and is most widely used in the production of medical goods, heat-resistant dishes and household utensils, toys, pipes and fittings for hot water, and much more.

Source: https://moy-instrument.ru/masteru/kak-spayat-plastik-v-domashnih-usloviyah.html

How to solder plastic pipes correctly? — Prof Pipes

Manufacturers of materials for laying utility networks offer a wide selection of modern solutions that have replaced traditional ones. In particular, this applies to pipes for installation in a house or apartment of a water supply system, a hot water supply branch, a radiator and floor heating system.

To lay or repair a local pipeline made of polymer pipes (polyvinyl chloride, polypropylene), you need a special tool and some skill in working with it.

Soldering plastic pipes is not a complex job, but it is important to understand the technology and take into account a number of points in order to get a reliable and durable result.

Tool for soldering plastic pipes

Electrodes for soldering plastic and bumpers: rods and rods for welding on plastic

Any repair that is performed when using an electrode for soldering plastic products is considered high quality. Thanks to their use, the welding is strong, almost like solid plastic, and sometimes looks even better than the factory specifications provided by the manufacturer.

An important quality when welding is the skillful placement of the strip by the master in such a way that the part is as efficient as possible and does not interfere with other spare parts of the equipment being repaired.

When might electrodes be needed for soldering plastic?

Almost all structures made of thermoplastic plastic can be repaired using flat electrodes.

For example, plastic electrodes are used for:

• bumper repair;
• body parts or decorative trims;
• headlight housings;
• various tanks and containers into which gasoline or other necessary liquid is poured;
• repair of parts in the car interior;
• other plastic products made from polypropylene.

Features of these electrodes

Flat electrodes are strips of different sizes, made from modified plastic through chemical and secondary processing. This material has high resistance to rupture or external damage, has good ductility, and high adhesion to many plastic copolymers.

Table of characteristics of plastics.

Strength may be low due to the characteristics of the material used in the production of plastic parts, as well as the active oxidation process if the temperature increases. The structure ages, which provokes early damage.

Many machine parts made of plastic, thermoplastic or polymer can retain their function when frequently melted. Thanks to this, most spare parts in a car can undergo a thermal process during repair work.

Some of the most popular types of plastic used in mechanical engineering are:

• polypropylene plastic electrode - used in repairing machines with plastic parts;
• polyethylene material;
• polyamide;
• styrene, acrylonitrile, copolymer-butadiene;
• polybutyl terephthalate.

Any experienced craftsman who has at least once soldered plastic using an electrode knows that these materials are repairable.

Advantages and disadvantages

Flat electrodes have a significant number of advantages and a small number of disadvantages. The only thing that can be attributed to the latter is that it is necessary to control the welding electrode for welding plastic so that it does not overheat and can hold the fastener for a long time.

The main advantages include the following aspects:

1. Electrodes are not limited in time, that is, they have no expiration date.
2. They have high strength due to the special structure of these parts.
   This can be seen when the bumper is damaged again; the crack does not appear at the seam site, but nearby on the plastic, which cannot be repaired.
3. The parts are easy to use.
   They are single component. To work with them, you only need to clean the surface and heat the flat electrode to the required melting temperature.
4. These parts also have good elasticity.
   Thanks to this property, the part can be placed in places where it is quite difficult to reach, and initial cunning fastenings of cracks that have appeared can be made.
5. When using flat planks, the quality of the repair will be high, and the result itself will last for a long time without any additional maintenance conditions.
6. In special situations, you can restore missing parts of the plastic using flat strips.
   This is done by laying one layer on top of another, forming the shape necessary for restoration.
7. The parts in question do not contain harmful substances that can harm health.
   However, you should not neglect the advice regarding timely ventilation of the room.
8. The cost of any type of planks is minimal.
   This allows the specialist to save an impressive amount, which allows him to spend money on more expensive parts. There is a discount for bulk purchases of parts. Each specialized store can have it individually.
9. The flat electrode covers most of the surface near the part where the seam needs to be welded.
   Thanks to this feature, the loads from the broken area are evenly distributed to the intact parts. This also gives extra strength to the mount.
10. If you follow the correct technology for the welding process and operation of the strips in question, then, with sufficient experience and skill of a specialist, you can significantly expand the capabilities, allowing you to maintain the original strength of the material.
11. There is also a ratio of the coefficients of thermal expansion of the material between the strip and the repaired part.

Overview of flat electrodes

There are several main types of electrodes used in the plastic soldering process. They are often designated by Latin letters: A, B and C. The classification of electrodes is divided only by thickness and width. The standard length is 200 millimeters.

The electrode of group “A” may include strips measuring 1x15. They are used for the front parts of the structure or internal seams of spare parts, where the thickness reaches 4 millimeters.

Flat electrodes of type “B” are available in welding rods in size 1.3x18 for repair work on bumpers. They can also be used to weld a crack or fracture located on the outside of a structure with a thickness of no more than 6 millimeters.

Electrodes of type “C” combine strips of dimensions 1.5x20. They can be used as reinforcing reinforcement for seams that bear increased load during operation of various spare parts. The wall thickness should not be more than 10 millimeters.

In addition to the listed operating methods, these types of soldering electrodes can be used to build up broken parts in plastic products or to patch up any resulting hole.

Thanks to this classification, you can quickly and accurately select the required strip for a specific wall size.

For example, a bumper can be repaired with a flat strip from group “A” or “B” only where the wall is no more than 3 millimeters. Otherwise, there is a risk of deforming the spare part when the surface cools down after the work has been completed.

How to work with flat electrodes?

If you have the task of welding several pieces of plastic together or carrying out repair work on a plastic product, soldering will be the easiest and cheapest option. For these purposes, you will need welding equipment and a flat electrode for it.

Rebuilt bumpers are some of the easiest parts to weld together.

In general, the operating principle is as follows:

1. It is necessary to warm up the welding equipment to the required temperature.
2. We prepare the plastic for the procedure, that is, we separate it from the entire structure, if possible, clean it with water and soap or detergent.
   Wipe dry.
3. Next, the plastic needs to be cleaned.
   This is done using sandpaper to smooth the surface.
4. Using foil wrapped around the edges of the plastic surface, protection is created so that the strips do not damage unnecessary parts.
   Check the fastening carefully.
5. We insert the bar into the already heated equipment.
   The parts will act as a guide line for the flow of hot air in the welding tool.
6. Slowly move the tip of the tool along the edge or attachment point to weld the plastic to each other.
   Movements must be stable and uniform.
7. Leave the plastic parts to cool for a few minutes.
8. Clean the resulting seam using sandpaper to a uniform consistency.

Bottom line

The flat electrode is divided into certain types to make it easier to use. Each type is used for a specific thickness, and before you start using the equipment to perform a particular task, you need to know all the intricacies of the electrodes.

Source: https://tutsvarka.ru/oborudovanie/elektrody-dlya-pajki-plastika

Soldering iron for plastic

Trouble may happen to your car on the road. A small collision or collision with a stationary obstacle can result in an ugly dent or tear appearing on the bumper or on the elements of the plastic body kit. Removing the bumper on a modern car means disassembling half the car, and this part costs a lot of money. Engineers have developed a device that allows you to repair plastic parts without dismantling them. A soldering iron for plastic saves owners a lot of time and money.

Soldering iron for plastic

Soldering iron for soldering plastic

The bumper is designed to protect the body from collisions and takes all impacts and damage. Traditional “tin” metal straightening, putty, painting is not suitable for this part of the body. For repairs you will need special equipment.

A soldering iron for plastic heats the damaged area to a certain temperature. Plastic can be heated to different degrees:

• Up to plasticity temperature. The material of the part becomes soft and flexible, its shape can be changed by hand. It is used to repair depressions, protrusions, warping and other deformations of a part without compromising its integrity.
• Up to melting point. The edges of the parts are melted and can be soldered into a single whole. Used in cases of plastic rupture.
• Up to destruction temperature. Not only the edge melts, but also large areas of the bumper material. Even if it was possible to form a seam, it will be fragile and short-lived. The repaired product will not be able to withstand operating loads.

Soldering the bumper

Soldering equipment is equipped with heating temperature control systems.

Types of soldering irons for soldering plastic bumpers

There are several types of soldering equipment for plastic products on the market:

• Ordinary. Powerful soldering iron for soldering plastic with a straight or curved tip. Designed for soldering broken and torn pieces of bumper. Such a device can reliably and permanently connect disparate fragments into a single whole.
• Thermal gun. It is used both for soldering parts and for straightening deformed areas. Equipped with a system for precise heating temperature control. This allows you to select operating parameters for each specific type of material, configuration and thickness of the bumper. The device comes with a wide range of attachments and accessories to facilitate soldering and straightening.
• Universal soldering station. A multi-tool combines several devices. Both a hair dryer and an electric soldering iron with a tip are connected to a common power supply. If necessary, they can be used either alternately or simultaneously to repair the most complex complex damage.

Hot air soldering station

Most stations and heat guns have a standard nozzle diameter, which allows you to use the nozzles apart from each other.

The principle of operation of a soldering iron

Before starting work, the surface must be cleaned of dirt and thoroughly degreased, the edges must be sanded.

When using a soldering iron, use the tip to melt the edges of the parts to be joined. Next, they need to be pressed together and fixed until they cool completely. It's best to press the edges together in advance and process them at the same time. After cooling, a weld is formed, connecting the two workpieces into a single whole.

When using a hairdryer, a stream of heated air is directed to the damaged area, uniformly heating it until the plasticity temperature is reached. Now you can give the softened plastic any desired shape. For welding, a slot nozzle is put on the hair dryer, which forms a narrow flat stream of heated air. This stream acts in the same way as a soldering iron tip.

Another type of repair is stapling. Staples are inserted into the soldering machine, they are heated and pressed into the material in such a way as to connect the parts of the bumper into a single whole, providing additional strength to the weld.

When repairing cracks, they should be cleaned and deepened to a depth of half a centimeter until a V-shaped groove is formed. Holes should be drilled at the ends of the crack to prevent further spread. Next, use a soldering iron to connect the edges until the crack disappears completely.

The seam should first be passed from the inside, the second pass is made from the front.

If the shape of the surface cannot be restored completely, pieces of fiberglass are glued to the problem areas. After restoring the shape and integrity of the bumper, it is painted in the same way as metal parts. A layer of primer is applied to the sanded and degreased surface, and after it dries, two layers of paint are applied. Polishing is used as a finishing touch.

Gun hair dryer

While working with a soldering iron, the material is leveled and redistributed by the tip. When working with a hair dryer, plastic filler rods are used, which are an analogue of solder when soldering or filler wire when welding.

Such rods are bought in stores or made independently by cutting up plastic waste. It is important to ensure that the rod is made of the same material as the product being repaired. The rod is sharpened on one side, and the other side is inserted into the retainer on the nozzle of the heat gun.

Soldering plastic with a hairdryer

The device is moved along the soldering line slowly, tilting the additive rod at an angle of 40-50°. To connect disparate fragments, soldering is performed in several passes. First you need to connect the fragments together with short seams, at the rate of one or two per side. Next, the resulting assembly is applied to the entire part of the bumper. If the contours coincide, solder along the contour. In the last pass, the fragments are finally soldered together.

Technology for preparing plastic parts for soldering

First of all, you need to find out what kind of plastic the element to be repaired is made of. All of them are divided into two large groups:

• Solid. Marked with the symbols ABS, GF 15, GF 30, PAG.
• Soft. Usually not marked.

It is difficult to distinguish them by appearance without many years of experience. Therefore, it is worth looking for markings on the back of the bumper or body kit elements. The most durable plastic is polypropylene. Products made from it hold their shape well, have a good appearance and can be successfully repaired.

The preparation process consists of the following operations:

• Clean off dirt and remnants of old paintwork. Mechanical cleaning is accompanied by washing with a warm soapy solution.
• Degrease. Common organic solvents, such as white spirit, are suitable here. acetone, etc.
• Sand the soldering area with velvet sandpaper (P120). Large products are polished using a grinder.
• Blow with compressed air to remove sanding dust.

Plastic repair

Careful surface preparation allows you to achieve high quality work. A refurbished product may simply not be distinguishable from a new one.

Soldering plastic: tools, technology

Water and gas pipes made of plastic are quickly and confidently replacing their metal predecessors. And this is not surprising, because such communication elements are lightweight, reliable, and easy to install.

However, when installing plastic pipes, it is often necessary to create connections using thermal effects on the edges of the material. Let's find out how plastic soldering is done and what tools can be used for these purposes.

Soldering with a specialized welding machine

A soldering iron for plastic is a kind of “iron” that contains special holes for pipes of various diameters. The edges of the latter are placed in the appropriate openings, after which they are heated to melting temperature.

Soldering plastic using the machine is performed in the following sequence:

1. The evenly cut end of the pipe is inserted into the heating sleeve. The device is connected to the mains. The metal surfaces of the unit are heated to the required temperature. Next, the edges of the plastic pipes are melted.
2. After the material has softened, the pipes are abruptly removed from the connectors and connected to each other in fittings. In this case, a noticeable influx of molten material should form at the junction of the edges.
3. Before heat treatment of the edges of the next pipes, the welding machine is thoroughly cleaned of any remaining frozen material.

Soldering plastic with hot metal

The simplest, most accessible, but less reliable method for connecting elements of plastic products is thermal exposure using heated metal. In this case, it is enough to heat an iron plate or any other suitable tool. It is advisable to fix the latter in a vice, and then lean the edges of the parts against the hot surface. As soon as the melting of the necessary elements of the products occurs, they must be removed from the plate and firmly pressed together.

Before soldering plastic using this method, it is recommended to clean the surfaces of the parts to be joined from any contaminants that may interfere with the tight joining of the material. If materials are stained with oils, alcohol, acetone or white spirit should be used as degreasers.

Soldering using a gas torch

Do-it-yourself plastic soldering can be done with heated gas emanating from the burner nozzle. Nitrogen, carbon dioxide, and argon can serve as refueling here. The choice of the type of gaseous substance depends on the characteristics of the plastic that will be melted. As practice shows, the most durable connections using the thermal method of joining plastic parts can be obtained by heating the material with argon or nitrogen.

The presented soldering technology allows work to be performed with or without additives. In the first case, a plastic rod with a diameter of no more than 6 mm is used, the melting of which makes it possible to create a fairly thin, neat, but at the same time durable seam. The additive must be made of a material identical to the elements being connected.

When using a gas burner, the temperature at the outlet of the device nozzle must be maintained at least 50°C higher than the fluidity index of the material being processed.

The processing method is relevant not only when it is necessary to connect pipes, but also in cases where restoration of a car bumper, interior elements, and other parts is required. In such situations, a plastic solder mesh is often used, which is placed over the damaged areas and then filled with molten material.

Soldering hair dryer

A hot air gun is suitable for joining plastic elements. Here, the heating of the working surface is ensured by connecting the device to the electrical network.

The soldering dryer contains a mechanism that ensures uniform distribution of heated air on the surface of the workpiece. To ensure a high-quality tight connection of plastic elements, various nozzles are used during melting. Their size and shape are selected depending on the nature of the materials to be processed.

Soldering with chemical solvents

Connecting the edges of plastic parts using the presented method involves wetting the material with a solvent. After some time, the polymers begin to swell and acquire a viscous structure.

In conclusion, it is enough to join the elements and hold them under pressure for some time until the seam hardens. The connections gain strength after several hours.

To speed up the process, slight heating is allowed on the surface, which promotes accelerated evaporation of the solvent from the structure of the material.

Partially crystalline plastics are resistant to chemical solvents. Therefore, soldering using the presented method will be ineffective here. Most often, the method is used when it is necessary to process products made from amorphous thermoplastics.

The use of solvents is a relatively inexpensive way to process plastic parts. However, it is recommended to resort to it only in extreme cases when it is not possible to use a specialized tool. Because solvents are overwhelmingly toxic, and their fumes are harmful to health.

Finally

As a result, it is worth noting that it is better to solder plastic from the front and inside of the material, but only with a wall thickness of at least 5 mm. After the joints have hardened, the final finishing of the surfaces is carried out, which are sanded, puttied and prepared for painting. As you can see, soldering plastic is a completely doable task. The main thing is to have the necessary tools and act strictly according to the instructions.

Source: https://FB.ru/article/268275/payka-plastika-instrumentyi-tehnologiya