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PLASTIC WELDING: Inspection and Testing of Plastic Welds
I just assume that everybody who produces something will do so to the best of his or her ability. I sure hope
this is the way everybody works. But how can we be sure about the actual quality of work our employees or we
have done? For example, a nice looking weld does not necessarily mean a strong weld. Many things come
together to make a quality weld.
If you have been welding for a number of years and are not familiar with the basic principles of plastic
welding, problems always occur. Maybe you do not realize it because none of your customers complain.
Perhaps an occasional client would come back with more business if the welding job was done better. You may
think, "My welds are great," maybe they look awesome, but as I mentioned, this is not an indication of a good
weld. An expert may be able to see the difference between a good weld and a bad weld just by looking at it.
But this is still difficult.
Unfortunately, plastic welding is not something you can learn just by doing. If you start plastic welding, I
highly recommend taking a course from someone who knows plastic welding. If you read my articles, you
know that it takes some work before you can call a weld a quality weld.
While all my previous articles focused on "how" to produce a quality plastic weld, this article will concentrate
on the created weld. While it is always good practice to check the produced welds to be sure that the job was
done right, it is not always necessary to check every weld. You and your customer have to decide which welds
need to be checked and which ones do not.
I will try to keep my explanation as simple as I can while filling you in on the some of the processes of plastic
weld tests. It would be too much to explain all the different testing processes in detail, so I will limit my
explanations to the four most common testing methods and their basics.
What is the purpose of the manufactured part? Water tight, pressure resistant, display, etc.
But testing begins before the welding job starts. If it will be necessary to test the welds for a project, the tester
needs to be qualified. If the worker has no or only limited experience in plastic welding, the welds will
probably not hold up to the testing procedures.
There are different ways to test a plastic weld. There are non-destructive and destructive methods. Which
method is appropriate is dependent on the requirements for the finished product and the agreement between the
fabricator and the customer.
Non-destructive test methods can be done by visual inspection of the weld bead in order to check its
dimensions and appearances (undercuts and cleanliness etc., see Volume 22, Number 2, March/April 2001).
There are also leak/pressure tests and ultrasonic testing methods. These tests allow examination of the finished
parts without making separate welds.
The most common destructive test methods are the technological bend test, the tensile strength test and the
tensile impact test. For these tests, special testing equipment is required. If you do not want to purchase or
cannot afford this equipment, you can contact testing laboratories. These facilities, some specialize in plastics,
will perform the required tests and provide you with the results. You need to supply the tester with your
customer requirements and sample welds. If you own the testing equipment yourself, you need an operator who
knows how to use the testing machinery. Keep in mind that the customer may require that an independent
laboratory do the testing.
Regardless of the testing method, it should be performed approximately 24 hours after the last weld is
completed. This will ensure that the molecular structure in the welded areas has had adequate time to set.
Leak/Pressure Test
When you build a tank or a pipe system, you want it to hold the liquid for a long time. You can pressure test the
container to check the welds. To do this, you have to seal the tank or pipe section. Maybe a spout is built into
the tank already or you can use one built into the lid. Now the part has to be filled with water. A hose, attached
to a pressure device with a gauge, is then secured to the spout. A predetermined pressure is then applied. In
order to perform the test correctly, you need to know what level of pressure will be necessary. This information
should be specified on the drawings or by the customer.
The tested part will need to hold the pressure for a fixed time. If the pressure holds, you can be sure the welds
are watertight and meet the customer’s expectations. If not, you must find the leak and fix the problem. This
can be hard, because it is difficult to see the leak area. You might be able to see where the water comes out, but
this does not automatically mean that this is the leakage point. Liquids can travel a long way when it comes to
leaks. This testing process would be considered a non-destructive test.
More common are destructive test methods. What we seek are the ‘yield point’ and/or break.
The yield point is the moment when the internal molecular structure of the weld or material weakens for the
first time. This is usually not visible, but test machines (see following sketches) can measure it. Some materials
are very flexible or very rigid and do not show a yield point at all. With these materials, you test for a break
situation.
A variety of destructive testing methods are available, but most common are the following:
This test is the least common in the group. The test piece is held in a clamping device. A hammer-like
pendulum hits the weld area with a certain, specified force. This force can be seen on an impact-measuring
gauge. The system is hooked up to a computer with a program to determine the test result.
The Tensile Strength Tests
This, and the Technological Bend Test, are the most used testing methods. The Tensile Strength Test uses two
clamps to hold the testing strip. When secured, the testing strip will be pulled, with a specified force, apart. The
yield point and/or breaking point will be measured.
Technological Bend Test
The Technological Bend Test uses a ‘three-point-system’ consisting of two rollers and a ram or stamp to
perform the test. The rollers have a diameter of 50 mm or approx. 2". The distance between the two rollers, as
well as the thickness of the ram, are dependent on the material thickness.
This test measures the bending angle. Optimal would be a bending angle of 160º. This is the maximum that is
achievable, because at this point the sample will interfere with the stamp (ram). Once again, we are looking for
the yield point and/or breaking point.
You can use any of these methods to test plastic welds made by commercially available welding equipment
(injection, hot air/hot gas, extrusion, ultrasonic, hot plate, etc.).
This is intended to be a quick overview of the testing and inspection methods for welded plastic parts. Other
test methods exist and, ultimately, the best test method depends on the type of part or apparatus being
fabricated and its end use or application. Please contact me if you have questions about this article, plastic
welding, fabrication or injection welding. As we have covered the major highlights of thermoplastic welding
and joining in this series, we would now like to turn our focus to answering your questions and solving your
day-to-day welding problems. You can forward your questions or topics for future columns to me at
abramer@drader.com or contact the magazine.
For more information, click on the Author Biography link at the top of this page
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KOROSI
Pernahkah kalian melihat tumpukan kaleng bekas? Apa yang terjadi pada kaleng-kaleng tersebut
jika dibiarkan di tempat terbuka? Pasti kaleng tersebut akan berkarat. Ini berarti kaleng
mengalami korosi.
Korosi adalah reaksi redoks antara suatu logam dengan senyawa lain yang terdapat di lingkungannya
(misal air dan udara) dan menghasilkan senyawa yang tidak dikehendaki. Peristiwa korosi kita kenal
dengan istilah perkaratan. Korosi ini telah mengakibatkan kerugian bermilyar rupiah setiap tahunnya.
Biasanya logam yang paling banyak mengalami korosi adalah besi.
Korosi terjadi melalui reaksi redoks, di mana logam mengalami oksidasi, sedangkan oksigen
mengalami reduksi. Karat logam umumnya berupa oksida atau karbonat. Karat pada besi berupa zat
yang berwarna cokelat-merah dengan rumus kimia Fe2O3·xH2O. Oksida besi (karat) dapat
mengelupas, sehingga secara bertahap permukaan yang baru terbuka itu mengalami korosi. Berbeda
dengan aluminium, hasil korosi berupa Al2O3 membentuk lapisan yang melindungi lapisan logam dari
korosi selanjutnya. Hal ini dapat menerangkan mengapa panic dari besi lebih cepat rusak jika
dibiarkan, sedangkan panci dari aluminium lebih awet.
Korosi secara keseluruhan merupakan proses elektrokimia. Pada korosi besi, bagian tertentu dari besi
sebagai anode, di mana besi mengalami oksidasi.
Elektron yang dibebaskan dalam oksidasi akan mengalir ke bagian lain untuk mereduksi oksigen.
Ion besi(II) yang terbentuk pada anode akan teroksidasi membentuk besi(III) yang kemudian
membentuk senyawa oksida terhidrasi Fe2O3·xH2O yang disebut karat.
Korosi pada besi dapat dicegah dengan membuat besi menjadi baja tahan karat (stainless steel),
namun proses ini membutuhkan biaya yang mahal, sehingga tidak sesuai dengan kebanyakan
pengunaan besi
a. Pengecatan
Fungsi pengecatan adalah untuk melindungi besi kontak dengan air dan udara. Cat yang mengandung
timbal dan seng akan lebih melindungi besi terhadap korosi. Pengecatan harus sempurna karena jika
terdapat bagian yang tidak tertutup oleh cat, maka besi di bawah cat akan terkorosi. Pagar
bangunan dan jembatan biasanya dilindungi dari korosi dengan pengecatan.
Cromium Plating membuat bumper mobil tahan
karat
Besi adalah logam yang berasal dari bijih besi (tambang) yang banyak digunakan untuk kehidupan manusia
sehari-hari dari yang bermanfaat sampai dengan yang merusakkan. Dalam tabel periodik, besi mempunyai simbol
Fe dan nomor atom 26. Besi juga mempunyai nilai ekonomis yang tinggi.
Besi adalah logam yang paling banyak dan paling beragam penggunaannya. Hal itu karena beberapa hal,
diantaranya:
Salah satu kelemahan besi adalah mudah mengalami korosi. Korosi menimbulkan banyak kerugian karena
mengurangi umur pakai berbagai barang atau bangunan yang menggunakan besi atau baja. Sebenarnya korosi
dapat dicegah dengan mengubah besi menjadi baja tahan karat (stainless steel), akan tetapi proses ini terlalu
mahal untuk kebanyakan penggunaan besi.
Korosi besi memerlukan oksigen dan air. Berbagai jenis logam contohnya Zink dan Magnesium dapat
melindungi besi dari korosi. Cara-cara pencegahan korosi besi yang akan dibahas berikut ini didasarkan pada dua
sifat tersebut.
1. Pengecatan. Jembatan, pagar, dan railing biasanya dicat. Cat menghindarkan kontak dengan udara dan
air. Cat yang mengandung timbel dan zink (seng) akan lebih baik, karena keduanya melindungi besi
terhadap korosi.
2. Pelumuran dengan Oli atau Gemuk. Cara ini diterapkan untuk berbagai perkakas dan mesin. Oli dan
gemuk mencegah kontak dengan air.
3. Pembalutan dengan Plastik. Berbagai macam barang, misalnya rak piring dan keranjang sepeda dibalut
dengan plastik. Plastik mencegah kontak dengan udara dan air.
4. Tin Plating (pelapisan dengan timah). Kaleng-kaleng kemasan terbuat dari besi yang dilapisi dengan
timah. Pelapisan dilakukan secara elektrolisis, yang disebut tin plating. Timah tergolong logam yang tahan
karat. Akan tetapi, lapisan timah hanya melindungi besi selama lapisan itu utuh (tanpa cacat). Apabila
lapisan timah ada yang rusak, misalnya tergores, maka timah justru mendorong/mempercepat korosi besi.
Hal itu terjadi karena potensial reduksi besi lebih negatif daripada timah. Oleh karena itu, besi yang
dilapisi dengan timah akan membentuk suatu sel elektrokimia dengan besi sebagai anode. Dengan
demikian, timah mendorong korosi besi. Akan tetapi hal ini justru yang diharapkan, sehingga kaleng-
kaleng bekas cepat hancur.
5. Galvanisasi (pelapisan dengan Zink). Pipa besi, tiang telepon dan berbagai barang lain dilapisi dengan
zink. Berbeda dengan timah, zink dapat melindungi besi dari korosi sekalipun lapisannya tidak utuh. Hal
ini terjadi karena suatu mekanisme yang disebut perlindungan katode. Oleh karena potensial reduksi besi
lebih positif daripada zink, maka besi yang kontak dengan zink akan membentuk sel elektrokimia dengan
besi sebagai katode. Dengan demikian besi terlindungi dan zink yang mengalami oksidasi (berkarat).
Badan mobil-mobil baru pada umumnya telah digalvanisasi, sehingga tahan karat.
6. Cromium Plating (pelapisan dengan kromium). Besi atau baja juga dapat dilapisi dengan kromium untuk
memberi lapisan pelindung yang mengkilap, misalnya untuk bumper mobil. Cromium plating juga
dilakukan dengan elektrolisis. Sama seperti zink, kromium dapat memberi perlindungan sekalipun lapisan
kromium itu ada yang rusak.
7. Sacrificial Protection (pengorbanan anode). Magnesium adalah logam yang jauh lebih aktif (berarti lebih
mudah berkarat) daripada besi. Jika logam magnesium dikontakkan dengan besi, maka magnesium itu
akan berkarat tetapi besi tidak. Cara ini digunakan untuk melindungi pipa baja yang ditanam dalam tanah
atau badan kapal laut. Secara periodik, batang magnesium harus diganti.
WebElements.com – Iron
It's Elemental – Iron
The Most Tightly Bound Nuclei
Crystal structure of iron
Bursa besi