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INFORMATION to USERS This Manuscript Has Been Reproduced INFORMATION TO USERS This manuscript has been reproduced from the microfilm master. UMI films the text directly from the original or copy submitted. Thus, some thesis and dissertation copies are in typewriter face, while others may be from any type of computer printer. The quality of this reproduction is dependent upon the quality of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleed through, substandard margins, and improper alignment can adversely affect reproduction. In the unlikely event that the author did not send UMI a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. Oversize materials (e.g., maps, drawings, charts) are reproduced by sectioning the original, beginning at the upper left-hand comer and continuing from left to right in equal sections with small overlaps. Each original is also photographed in one exposure and is included in reduced form at the back of the book. Photographs included in the original manuscript have been reproduced xerographically in this copy. Higher quality 6" x 9" black and white photographic prints are available for any photographs or illustrations appearing in this copy for an additional charge. Contact UMI directly to order. A Bell & Howell Information Company 300 North Z eeb Road. Ann Arbor. Ml 48106-1346 USA 313.'761-4700 800/521-0600 INFRARED HEATING AND WELDING OF THERMOPLASTICS AND COMPOSITES DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of the Ohio State University By Yang Shiau Chen, B.S., M.S. The Ohio State University 1995 Dissertation Committee Approved by Avraham Benatar Chon L. Tsai tjun\ Ly James Lee Adviser Welding Engineering Graduate Program DMI Number: 9544534 UMI Microform 9544534 Copyright 1995, by UMI Company. All rights reserved. This microform edition is protected against unauthorized copying under Title 17, United States Code. UMI 300 North Zeeb Road Ann Arbor, MI 48103 To God and My Parents I ACKNOWLEDGMENTS I wish to express my appreciation to my adviser Dr. Avraham Benatar, for helping me to develop this research. His guidance has been invaluable in my years at The Ohio State University. It was a great experience and an honor to work with someone who gave me the opportunity to get involved in the plastics joining field. I would also like to thank the members of my committee, Professor Chon L. Tsai, for his constant encouragement and guidance during the course of this study, and Professor James Lee, who gave me lots of advice on polymers and helped me use the equipment in the polymer laboratory in chemical engineering. I would like to thank Professor David A. Rigney for his suggestions and comments. Many thanks go to the National Science Foundation and Edison Welding Institute for financial assistance. Mr. Stefan N. Fodor deserves thanks for being a good friend during these difficult months of writing and rewriting. I also wish to thank Dr. K. Bolland for his friendship and for reviewing my dissertation. Special thanks go to my parents for their love and their faith in me during my education. Love and thanks also go to my wonderful wife, Pi Hsiang Kao for her unwavering love and support. Love my sweet sons, Anthony and Andrew. VITA October 13, 1960..................................Born in Taipei, Taiwan, R.O.C. 1985 .........................................................B.S., Mechanical Engineering, R.O.C. 1987 .........................................................M.S., Mechanical Engineering, R.O.C. 1987-1989 .............................................. Second Lieutenant, Chinese Army Corp, R.O.C. 1990.........................................................Graduate Research Associate, The Ohio State University FIELDS OF STUDY Major Fields: Welding Engineering Research in designing, manufacturing, and processing of polymer and polymeric composites, quantitative process modeling, simulation and control. IV TABLE OF CONTENTS DEDICATION..........................................................................................................................I ACKNOWLEDGMENT........................................................................................................II VITA...........................................................................................................................................Ill LIST OF FIGURES.................................................................................................................VIII LIST OF TABLES...................................................................................................................XVI CHAPTER PAGE I. INTRODUCTION....................................................................................................... 1 1.1 Introduction ............................................................................................................ 1 1.2 Description of IR Welding .................................................................................. 3 1.3 Mechanism and Application ofIR ..................................................................... 4 1.4 Literature Review .................................................................................................. 8 1.5 Objectives of This Work ..................................................................................... 10 II. IR WELDING SETUP.................................................................................................13 2.1 Introduction ............................................................................................................ 13 2.2 High Intensity IR Modules with Power Controller ...................................... 16 2.2.1 High intensity IR heater ................................................................................... 16 2.2.2 Power controller .............................................................................................. 18 2.3 Two Independent Air Cylinder Setups ........................................................... 18 2.4 A Process Controller System .............................................................................. 19 2.5 Lamp Cooling Setup............................................................................................ 20 2.6 Foundation and Fixture ....................................................................................... 20 III MODELING AND MEASUREMENT OF RADIATION FIELDS....................... 23 3.1 Introduction ........................................................................................................... 23 3.2 Lamp-U-Shape Reflector System...................................................................... 24 3.3 Mathematical Model of Radiation Field ........................................................... 27 3.3.1 Direction radiation ........................................................................................... 27 3.3.2 Indirect radiation .............................................................................................. 31 3.3.3 Total Radiation ................................................................................................. 37 v 3.4 Experimental Setup ............................................................................................ 38 3.5 Results and Discussion ...................................................................................... 39 3.6 Summary............................................................................................................... 42 IV. MODELING AND MEASUREMENT OF RADIANT ENERGY DISTRIBUTION....................................................................................................... 45 4.1 Introduction ......................................................................................................... 45 4.2 Parameter Estimates........................................................................................... 47 4.2.1 Effects of wavelength, output power, and applied voltage ................. 47 4.2.2 Effect of heating distance .............................................................................. 49 4.3 Normalization of Parameters .............................................................................. 53 4.3.1 Statistical independence of the applied voltage or dial scale ................. 55 4.3.2 Statistical independence of the heating position (X, Y, Z) ..................... 58 4.4 Discussion .............................................................................................................. 68 4.4.1 Effect of applied voltage ................................................................................ 68 4.4.2 Effect of the heating position (X, Y, Z) ...................................................... 69 4.5 Summary................................................................................................................ 70 V. HEAT TRANSFER MODELING OF IR WELDING........................................ 78 5.1 Introduction ........................... ;............................................................................... 78 5.2 Background ........................................................................................................... 79 5.3 Penetration Depth ................................................................................................. 82 5.4 Evaluation of Reflection Energy .......................................................................
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