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As a result of growing potential for high performance applications, parts made of HDPE materials is gaining greater interest for industry. Hence, the studies on joining of HDPE has got much significance. In this work, resistance welding of HDPE sheets was performed focusing on the governing set of parameters, current, pressure and time. Design of experiment (DOE) is done using full factorial design. The Analysis of Variance (ANOVA) was done with shear strength of weld as main parameter with the assistance of MINITAB software. Optimum parameters were identified in the study were medium level parameters produced good strength and better finished welded samples. Microstructure taken through Scanning electron microscopy (SEM) was supportive for this observation as there was a uniform flow of HDPE material without any void around the implant SS mesh for the best weld condition. The Finite element (FE) modeling of the resistance welding process was also performed using ANSYS to predict the thermal distributions occurring during the process depending on different levels of current and time inputs.

Investigations on Joining of High Density Poly Ethylene Sheets using Resistance Welding Technique