PRODUCTS FASTENINGS & ADHESIVES
EPOXY-BASED TIN SOLDER REPLACEMENT INTRODUCED
New from Henkel is TEROSON EP 5020 TR, a 2-component, epoxy-based tin solder replacement for rebuilding metal surfaces such as vehicle shells or car bodies made from steel or
aluminium. According to the company, it is also ideal for the final modelling of repulled dents on difficult-to-reach/rebuild areas or welded joints. This new addition is both lead- and tin-free, making it
substantially more sustainable and environmentally responsible than the traditional method. Another benefit is that it is cold-applied so, for applications that do not require welding, there is no need to remove fire-risk items such as airbags, plastics, fabrics and fuel tanks. It can also be safely used on metal frames containing electric cables. Of further benefit, where appropriate, cure speed can be
accelerated by applying heat. Fast and easy to use, TEROSON EP 5020 TR has excellent sag-resistance, has an open time of ten minutes and is easily sandable after 2.5 hours, typically with P150 grade sandpaper. As the product is free from solvents, there is no risk of shrinkage and it causes no damage to existing cataphoretic paint or indeed, any painted areas, cavity conservation or seam sealing. Supplied in a 175ml cartridge, TEROSON EP 5020 TR can be
applied via a LOCTITE manual piston gun or any commercially available alternative that is pneumatically, electrically or manually actuated.
Henkel
www.henkel-adhesives.co.uk ULTRASONIC TECHNOLOGY: A SAFE JOINING SOLUTION
Although using ultrasonic technology as a method for joining metals or plastics may mean higher investment costs initially, when compared to other processes it is very often more economic in the long term. Depending on the area and height of the weld, welding times typically range from 0.2 to two seconds. Not only is no heat-up or cool-down time required, but different alloys with variable material thickness can be joined together, and the majority of natural oxide layers have very little impact on the weldability of the joints. Aluminium can also be easily welded with ultrasonic technology. Compared to other metal welding processes, the parts which are
component and the joining zone is compatible with the ultrasonic process. The various quality control options also contribute to reducing costs.
Connection between copper cable and MAK terminal welded using ultrasonics
being joined do not become as hot, ensuring they never meet their melting point; and no structural changes occur in the boundary layer. The process is also very energy efficient, and the tooling costs
associated with the ultrasonic process are straightforward. Ultrasonic welding is therefore an inexpensive joining method
for the majority of thermoplastics and non-ferrous metals such as aluminium, copper, brass and nickel. However, failure to pay attention to having a suitable design for the part in question can result in extensive adaptations and loss of the financial benefits. Telsonic therefore recommends involving an ultrasonic specialist at an early stage of the design phase, in order to ensure that the design of the
10 MAY 2020 | DESIGN SOLUTIONS
Feedback is provided for each part regarding quality-relevant variables such as total energy, maximum output, welding time, absolute or differential part thickness, etc. The intelligent process control unit that is used by the system can detect problems based on defined tolerance ranges, such as missing or incompletely formed contours, the use of an incorrect number of wires, missing strands, changes to material hardness and thickness, or even the complete absence of parts in the tool. Of additional benefit, ultrasonic welding systems are environmentally friendly and relatively simple to use – a one-day
training course is usually sufficient. Ultrasonic joining technology for
plastics and metals is now widespread in the automotive industry, since it actively supports weight reduction, energy efficiency and electromobility. It is suitable for virtually any lightweight material and is also used for the on-board power supplies of high-current applications in electric vehicles, where copper is increasingly being replaced by aluminium to save weight. Short cycle times, selective energy supply, flexibility in use and a high degree of process reliability are other criteria said to characterise ultrasonic welding technology.
Telsonic UK
www.telsonic.com MOULDED-IN INSERTS FOR PLASTICS ASSEMBLIES LAUNCHED
SPIROL has introduced a new, high-performance, series of Moulded-In Inserts for plastics assemblies. The rugged design of the Series 63 Through Hole Inserts and Series 65 Blind End Inserts consists of multiple bands of helical knurls to maximize torque resistance, balanced with radial undercuts to achieve high pull-out (tensile) force. These Moulded-In Inserts are designed to be placed in the mould cavity prior to plastic injection, and offer exceptional performance due to unrestricted plastic flow into the retention features on the outside diameter of the Inserts. These lightweight, lead-free, Threaded Inserts for Plastics are manufactured from
2024 grade aluminium which provides the best combination of strength, corrosion resistance, machinability and cost. The Series 63 and Series 65 Moulded-In Inserts are lead free, 40% stronger than brass, and 1/3 the weight of the same Insert manufactured from brass. Standard metric thread sizes include M4, M5, M6, and M8, and standard inch threaded sizes include 8-32, 10-24, 1/4-20, and 5/16-18. SPIROL offers a comprehensive line of Inserts for Plastics including Press-In,
Self-Tapping, Heat / Ultrasonic and Moulded-In styles to accommodate specific performance and installation requirements. Learn more about SPIROL Inserts for Plastics, design guidelines for the plastic
components that use Inserts, proper installation methods and performance testing parameters in their full Inserts for Plastics design guide on the website.
SPIROL
www.SPIROL.com
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