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Welding Tips

 

Co Name AxHAS THE WORLDS MOST TECHNOLOGICALLY ADVANCED ECO-FRIENDLY WELDABLE WEBBING TO MEET YOUR NEEDS

 

 

Welding tips for WeldTECH™   weldable webbing.

WeldTECH™   is 2nd generation weldable webbing that turns plastisol coated weldable webbing on its head. It welds up to 7 times faster or with up to 2 times the bond strength. It has a 23kn breaking strength, reworks back to its original bond strength and is New Zealand developed. You no longer have to work with plastisol which is detrimental to your health.

Our polymer coating absorbs heat very quickly and lets it go again quite slowly due to its thickness. Also our coating thickness tends to be thicker than Plastisol coated webbing. For these reasons it is easy to create shrinkage in the underlying polyester webbing because once the polymer is overheated it can heat the polyester webbing for longer time. For these reasons you need to weld it slightly differently. The heat absorbed by weldable webbing is a combination of time heating (traverse speed) and amount of heat applied (temperature) for hot air welding or for RF welding, welding time and power applied. If you are seeing shrinkage, you need to decrease the welding time or reduce the temperature / power.

For fast welds:

  • If you are using a crawler hot air welder, you are probably welding with a setting around 5. This product can weld multiples of times faster than that, so using the same heat setting you can comfortably set your traverse speed to 12. (common maximum speed). If you want to further improve shrinkage, you can now start reducing your temperature. Ideally you should determine the maximum speed you are comfortable welding at and then do a series of test welds at different temperates to determine when the weld delamination strength is to weak for your needs. Once you know where this drop off in weld performance is, you can adopt the temperature that best meets your needs, balancing speed, bond strength, and minimal shrinkage.
  • On a framed hot air welder you can start at the maximum temperature you are comfortable with and 12,000mm / minute traverse speed and go up from there in stages until the weld delamination strength is to weak for your needs. Once you know where this drop off in weld performance is, you can adopt the traverse speed that best meets your needs, balancing speed, bond strength, and minimal shrinkage. The quality of your heat source is very important to get fast welds. A heat source that can deliver large volumes of high temperature air over a wider area than just a knife edge (length of webbing) and over the full width of the webbing evenly is ideal. Adding shields to either side of the webbing will retain the side spilled hot air. It is also possible to weld either end of the run at slower speeds to gain the maximum bond strength and weld the bulk of the weld between the ends at a fast speed to save time. In this manner you can obtain the strongest welds with the fastest weld times. With our in house testing and overseas customers we have obtained weld traverse speeds of 34,000mm / minute.
  • On our in house RF welder which we use for quality assurance, we found that we could reduce the weld time to one seventh of what we would use for Plastisol. Your results will be much better than Plastisol, but may not reach one seventh the weld time. The performance improvement is very dependant of environmental conditions, your machine and bar length you use. Try starting at the maximum power you are comfortable with and weld at one half you usual weld time. Then do a series of welds at intervals, reducing the weld time 1 or 2 second(s) per interval. Once you know where the drop off in weld performance is, you can adopt the weld time that best meets your needs, balancing time, bond strength, and minimal shrinkage.

Like all polyester or nylon webbing or sheet products, shrinkage will occur with sufficient heat. Our customers have found that WeldTECH™   welded at higher speeds has the least shrinkage they have seen yet.

Most people do not believe how fast this product can weld. Go all out and run it as fast as your machines will make a good weld. Not only will you save time, but less toxin will be liberated from the plastisol sheet, and you will achieve the slimmest shrinkage results.

For strong welds:

WeldTECH™   produces a very strong weld with a high bond strength. Welding at 7 times faster on our RF welder produces a weld that requires 12kg to delaminate compared to 10kg for Plastisol. If you slow the weld down, putting more heat into it, the bond strength starts improving. At 3 times faster than Plastisol we get bond strengths resisting delamination of 20kg. Further increases in weld time can give results as high as 27kg depending on the environmental conditions and equipment, but watch for shrinkage. At 27kg, some PVC fabrics start delaminating instead of the WeldTECH™   webbing.

Look for the high initial resistance to delamination.

Plastisol is quite weak as far as plastics are concerned. Typically when you start to delaminate weldable webbing from PVC fabric, the plastisol snaps almost instantly and lets go of the polyester webbing it is bonded to. WeldTECH™   does something different. When you delaminate WeldTECH™   it stretches and orientates its molecules which is exactly how polypropylene packing tape or polyester yarn get there great strengths. Looking closely you will see our polymer form a peak lending strength to resist the delamination from 2 directions. This effect gives WeldTECH™   an even higher resistance to delamination. Once this peak of polymer succumbs to the load placed on it, the resistance to delamination figures mentioned above section take over. 

 

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