Essential Insights into the Plastic Welding Process

This edition of our Mechanical Engineering Newsletter is packed with fascinating updates and insights into the world of engineering and mechanics.

Today, we explore the versatile field of plastic welding and look closer at a metafluid with programmable properties developed by Harvard researchers.

Join us as we uncover these topics, offering technical depth and a glimpse into their future applications.

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INDUSTRY UPDATES

⚡️ UK explores world’s most powerful tidal turbine to unlock clean energy
The 242-foot (74 m) long tidal turbine is not at all like regular tidal stream turbines - it floats on the water

🔋 220kW force: HORSE kicks off production of powerful 1.2L hybrid turbo engines
HR12, a 3-cylinder turbocharged engine for plug-in hybrid-electric vehicles (PHEVs) that will help meet the growing demand for hybrid systems

🧱 Trash to tower: MIT engineers 3D-print LEGO-like glass bricks as tough as concrete
MIT builds multilayered glass bricks shaped like figure eights to explore the sustainable possibilities of circular construction

🛩️ Researchers to Create a Digital Library for Aircraft Parts
Researchers receive a grant to tackle the challenges of maintaining aging aircraft and aim to develop technologies that improve their sustainment. 

🚀 Electric Space Propulsion to Get Fusion Boost
Spacecraft engine FireStar Drive promises superior performance over other electric ion thruster systems by injecting a special element into its exhaust plume.

SPOTLIGHT

Plastic Welding Explained: Techniques and Industrial Applications

Plastic welding is an innovative fabrication process that joins thermoplastic materials using heat. It has become indispensable in various sectors, including automotive repairs, infrastructure building, and water tank and heat exchanger manufacturing. Unlike previous metal welding, plastic welding involves various techniques suited for different materials and applications, making it an adaptable and essential tool in modern manufacturing.

This process results in lightweight, high-quality joints, as it not only joins materials efficiently but also eliminates the need for fasteners or adhesives. Plastic welding methods include hot gas, ultrasonic, spin, and laser beam welding, each offering unique benefits. For example, hot gas welding uses a portable heat gun and plastic welding rods and doesn't require electricity, making it easier to carry around for various tasks.

Laser beam welding is known for its precision and speed. In this method, a concentrated heat source produces clean, strong welds with minimal post-weld processing. This method, however, requires significant initial investment and is not suitable for thick plastics. Ultrasonic welding, on the other hand, uses high-frequency vibrations to generate heat through friction, creating a bond without direct heat application. It is particularly effective for thin, low-moisture plastics but is limited to overlapping joint configurations.

Other notable techniques are spin welding and vibration welding. Spin welding uses rotational friction to generate heat and bond materials, which are ideal for circular plastic parts. Vibration welding, which can be either linear or orbital, involves moving one plastic part against another to create friction and heat, which is suitable for irregularly shaped plastics.

The most robust and large-scale plastic welding method is hot plate welding, in which a hot plate melts the contact surfaces of the plastics. After melting, the plastics are pressed together to form a strong bond as they cool, making this method ideal for larger parts. However, this technique requires regular maintenance of the welding equipment.

Safety should be given utmost importance in plastic welding despite its advantages over traditional methods. Proper ventilation and protective clothing are essential to protect against fumes and burns. Moreover, with the advent of software-operated processes, the precision and safety of plastic welding have significantly improved, minimizing risks and enhancing quality control.

MechTech Innovations

Harvard Unveils Revolutionary Programmable Metafluid

Harvard researchers pioneered a groundbreaking metafluid with programming properties that can reshape engineering. This innovative fluid, comprising small elastomer spheres suspended in silicon oil, can adjust its viscosity, opacity, and elasticity in response to changes in pressure.

This metafluid marks a departure from traditional, typically solid metamaterials. By utilizing a fluid medium, these materials can now adapt more seamlessly to varying shapes and applications, from acoustics to medical devices. The versatility of the metafluid's base allows it to be combined with various substances, from water and glycerol to air and glue, broadening its possible applications.

The metafluid's transformative aspect lies in its tiny spheres that buckle under pressure, dramatically altering the fluid’s characteristics. This capability enables the metafluid to transition between liquid and solid states or take on properties akin to gases, offering a new tool for industries requiring precise material control.

Potential applications for this metafluid are vast. It could revolutionize e-inks that change color under pressure, enhance hydraulic networks' safety, or improve robotic handling systems by providing built-in softness and control, eliminating the need for external mechanisms. As Harvard continues to explore the thermodynamic properties of their creation, the promise of metafluids looms large on the horizon of materials science, poised to offer customizable solutions across various industries.

BOOK RECOMMENDATIONS

🌆 The Works: Anatomy of a City by Kate Ascher 
This book provides an in-depth look at the infrastructure of modern cities. It offers mechanical engineers a detailed understanding of the complexity and diversity of essential public systems, from water pipes to power grids.

🧪 The Alchemy of Us: How Humans and Matter Transformed One Another by Ainissa Ramirez 
Ramirez explores how materials have shaped human culture and innovation. This book discusses the science of materials used in engineering, the societal impacts of technology, and the importance of diversity in innovation.

👩🏾‍💻 Invisible Women: Data Bias in a World Designed for Men by Caroline Criado Perez 
This book is a compelling examination of how most of the world has been designed based on male data, overlooking female requirements. It encourages engineers to think about inclusivity in design and engineering solutions.

☯️ Superior: The Return of Race Science by Angela Saini 
Saini's book is crucial for engineers to understand the dangerous history of scientific racism and the importance of ethical responsibility in technological development and application.

👩🏾‍🔬 The Bionic Woman: Technology, Feminism, and the Seventies Female Action Hero by Lauren Jade Thompson 
Lauren Thompson explores the intersection of technology, feminism, and pop culture through the lens of the iconic TV series, a unique way that engineers can examine how technology and media influence societal perceptions of gender and capability.