Fabrication

Plastic Fabrication

Finding the right plastic welding equipment can be a real challenge. When looking to find plastic welding equipment to fit your need it is crucial that you know its application. Although there is a fitting solution for all plastic welding requests, some welding tools are not suitable for certain kinds of plastic materials. Simply put: If you know the material, the working area, the kind of assembly, your choice of plastic welder will be much easier. Plasgroup can help you every step of the way.

Which Plastic?

Today’s markets are flooded with an infinite number of plastic materials and blends. In such an environment trying to recognize the plastic’s family is not easy, but it is very important that you do. All plastics are different to each other in behavior and in chemical structure. The type of plastic welding rod used will make the difference between a strong weld and poor weld quality.



Commonly available plastic materials can be recognized by four simple identification tests. Most testing labs offer plastic identification as a service or you can try the following tests yourself.

Plastic Identification Tests


This test though is not very accurate it helps to give you an insight in to what plastic you might be working with. Some plastics like ABS or PVC are harder and some are softer like PE and PP.

To check whether it is a hard or a soft type of plastic, scratch on its surface with your fingernail. If you see a scratch mark then it is not a hard plastic like ABS, PVC. So what you are looking at is something like PE, PP, PTFE or another similar softer material.

Because of the dissimilar weights and surface hardness of different types of plastics, each type, sound different when a piece of it is dropped on the floor. However, it is hard to determine an exact identification this way.

Take a solid piece of the material and drop it on the floor from a height of about 5-10 inches (or 10–25 cm). You will hear specific tones. A trained ear can detect slight differences in a plastic’s tone. This method is often used to determine the plastics family.

Different plastic materials have a different weight that can be higher or lower than the weight of water.

Take a sample piece of the plastic and drop it in to a glass of water at room temperature. Observe its behaviour. Except for PE and PP all other plastics will sink.

This method is the most accurate test you can do by yourself. Different plastic material reacts differently when burning. For this test you should have prior knowledge as to how different types of plastics behave and smell while burning. If possible, keep samples of plastic materials that you already know to compare with the unknown plastic.

Go to an open place with fresh air, scrape off a sample of the plastic you want to test and burn it. Observe the reaction, flame or no flame, colour of flame, carbon above the flame, etc. Then after killing the flame smell the smoke for familiar odours. PE produces a Blue/Yellow flame, smokes, and smells like paraffin (candle). PP produces a Blue/Yellow flame, drips, and smells diesel like. Avoid the use of matches to light the fire to prevent the smell of sulphur getting in the way.

The combined results of these four tests should help you identify the plastic material you are working with. After getting to know your plastic you can start the plastic welding process.

Acrylic (PMMA)
Burns with a yellow, blue in the bottom and clear flame. Smells aromatically. Does not extinguish itself.

Welding: Ultra – sonic welding. Hot air welding.

Acrylonitrile butadiene styrene (ABS)
Burns with a sooting, orange flame. Smells like rubber. Does not extinguish itself.

Welding: Heating plate. Hot air welding. Ultra – sonic welding.

Polyacetal (POM)
Burns with a clear blue flame .

Welding: Heating plate. Hot air welding with nitrogen. Ultra – sonic welding.

Polyamide (PA)
Burns with a yellow, blue in the bottom and sooting flame. Melts and makes foam. Harsh smell like formic acid. Does extinguish itself

Welding: Heating plate. Friction welding.

Polycarbonate (PC)
Burns with a sooting, yellow flame and glowing ashes. Smells sweet. Partially extinguishes itself.

Welding: All welding metods.

Polyethylene (PE)
Burns with a clear flame, blue bottom, yellow top, drips and smells like stearin. Does not extinguish itself.

Welding: Heating plate. Hot air welding. Friction welding .

Heating plate temperature: PE 80: 200°C to 220°C

Heating plate temperature: PE 100: 220°C (Quickly change-over time)

Polypropylene (PP)
Burns with a clear flame, blue bottom, yellow top, drips a lot. Smells like oil or wax. Does not extinguish itself.

Welding: Heating plate. Hot air welding. Friction welding .

Heating plate temperature: 210°C +/- 10°C

Polystyrene (PS)
Burns with a sooting, orange flame. Does not extinguish itself.

Welding: Heating plate. Hot air welding. Ultra – sonic welding.

Polysulfone (PSU)
Does extinguish itself.

Welding: Heating plate. Hot air welding. Friction welding . Ultra – sonic welding.

Polyvinylchloride (PVC)
Burns with a very sooting, yellow flame, which is green at the edges. White smoke and smells like hydrochloric acid. Does extinguish itself

Welding: All welding methods.

Polyvinylidene fluoride (PVDF)
Does extinguish itself. By heating over 380°C. toxic fumes are released.

Welding: Heating plate. Hot air welding. Friction welding . Ultra – sonic welding.

Heating plate temperature: 240°C +/- 8°C

Our Fabrication Process

Built Locally

  • 01

    PLASGROUP is proudly Australian owned and operated where practical gives preference to and supports Australian suppliers of raw materials for use in our products.

  • 02

    PLASGROUP has grown to include a comprehensive range of plastic welding equipment,

  • 03

    PLASGROUP predominatly sources from German manufacturers who source and build locally, thus ensuring German quality and strenght built in.

  • 04

    If there is an application that requires a specific polymer or a custom colour or shape that is not listed in our standard welding rod range, feel free to contact us and we will be only too happy to assist you in getting you fabricating with your own cost effective alternative.

Hüerner Butt Welders

  • 01

    Hürner butt-welding technologies, that’s getting the most out of butt welding.

  • 02

    From 160 mm (including reducers down to 40 mm) through 1200 mm, the comprehensive product line offers machines for any work environment

  • 03

    Fully manual butt welding, manual welding with report generation by way of an add-on report generation system or an on-board report generator.

  • 04

    CNC welding with automatic report generation and with or without Hürner Distance Control (HDC), i.e. Hürner’s welding/melting road and carriage movement sensor.

Control quality

  • 01

    HÜRNER SPG 2000 and SPG 2000 Basic Report Generation Units for fast, accurate monitoring and recording of weld values under DVS and other national standards (WIS, INSTA, etc.).

  • 02

    The Report Generation Units SPG 2000 and SPG 2000 Basic can be universally used with any mechanically operated butt-welding machine and with all hydraulically operated machines from KWH Tech, as well as with various other makes.

  • 03

    With the SPG 2000 / SPG 2000 Basic, it is possible to capture all the data needed to evaluate the quality of a welding operation and to transfer them to a printer, a PC with the Hürner DataWork software installed, or to the internal micro-printer.

  • 04

    See below for full
    SPG 2000 Technical Specifications

SPG 2000 Technical Specifications
Input voltage 100V – 260V
Input frequency 40Hz – 80Hz
Weight approx. 4kg
Dimensions 24 x 200 x 250 mm
Box Protection IP 54
Technical
  • Easy to use with intuitive and structured user menus
  • Multilingual menus and reports
  • Film-protected alphanumeric keypad with welding process diagram
  • PC interface (RS232), printer (Centronics)
  • Report capacity: 1000 welding operations
  • LED-lit display, 4 rows, 20 characters each
  • Automatic auto-test after power-up
  • Report configuration customizable
  • Pressure sensor 100 bars or 250 bars, as selected
  • Temperature sensor PT100 or PT1000, as selected
  • LEDs to display welding progress
  • Scanning pen, handheld scanner
  • Micro-printer (SPG 2000 only)
Data Recorded
  • Machine type and machine ID
  • Cylinder
  • Sensors
  • Material
  • Diameter, wall thickness, nominal pressure
  • Angle (on workshop machines)
  • Incremental number and weld number
  • Commission number (32 characters)
  • Welder ID (ISO standard)
  • Date and time of day
  • Ambient temperature
  • Nominal and actual values of:
    • Drag pressure
    • Plate temperature (can be disabled)
    • Build-up pressure
    • Build-up time
    • Heat soaking pressure
    • Heat soaking time
    • Change-over delay
    • Joining pressure ramp
    • Joining pressure
    • Cooling time
Monitoring functions
  • Build-up pressure
  • Plate temperature
  • Heat soaking pressure
  • Heat soaking time
  • Ramp
  • Joining pressure
  • Cooling time
  • Power supply failure
  • Ambient temperature
  • Memory for reports
Traceability (SPG 2000 only)
  • Pipe codes (max. 40 characters, ISO)
  • Fitting code (26 characters, ISO)
  • Weather (DVS)
  • Additional data (max. 20 digits)