EXERCISE 1

Welding of Plastics
Review

A review of welding of plastics

Vinitha S
Government college of Technology, Coimbatore.

ARTICLE INFO AB STRACT

Keywords:

Welding technologies This review synthesizes recent

advancements in welding technologies for
Thermoplastic composites
metallic and polymeric materials,
Aluminum alloys examining key developments in friction-

Process optimization based, ultrasonic, and thermal welding

methods. The analysis covers process
Infrared thermography
innovations for aluminum alloys,
Multi-material joining thermoplastic composites, and multi-
material joints, focusing on energy
efficiency, distortion control, and quality
assessment techniques like infrared
thermography. Key findings highlight
optimized parameters, mechanical
performance, and industrial applications
across aerospace, automotive, and medical
sectors, while identifying future research
directions in smart manufacturing and
sustainable joining solutions.

1
1.INTRODUCTION:

In response to the growing industrial demand for lightweight, high-strength and sustainable materials,
the field of welding technology for plastics and composite materials has undergone significant
transformation. Traditional joining methods, such as adhesive bonding and mechanical fastening
often suffer from limitations including high energy consumption, residual stress accumulation and
material degradation. Consequently, researchers and manufacturers have shifted focus toward
advanced welding techniques capable of delivering enhanced efficiency, structural integrity and
process adaptability.

Recent developments have explored innovative welding processes across a wide range of polymeric
and composite materials. Notably, friction stir spot welding (FSSW) has been applied to polylactic
acid (PLA) sheets for improved joint strength and minimal thermal degradation [1], while fusion
bonding techniques have been extensively studied for thermoplastic composites to optimize
interfacial adhesion [2]. Rotary friction welding (RFW) and ultrasonic plastic welding have also
shown promise in enhancing weld performance for various thermoplastics and fiber-reinforced
polymers [4]-[6]. Moreover, hot gas welding remains a viable technique for joining large
thermoplastic components particularly in infrastructure and piping applications [7].

The adoption of non-contact temperature monitoring methods such as infrared thermography has
further advanced quality assurance practices in plastics welding. Rojek et al. demonstrated its
effectiveness for assessing thermal distribution and weld integrity in butt fusion, socket fusion and
infrared welding methods [26]. Accurate thermal profiling is essential for ensuring proper molecular
diffusion and preventing weld defects.

Additionally, modern research has expanded into joining dissimilar materials and improving weld
properties through techniques such as ultrasonic welding of aluminum to carbon fiber-reinforced
thermoplastics (CFRTPs) [14], frequency-dependent ultrasonic welding analysis [15], and laser
transmission welding for micro-scale plastic components [16]. These techniques are particularly
relevant in industries such as aerospace and automotive, where structural performance and material
compatibility are paramount.

Complementary research has also examined the mechanical and thermal phenomena during welding
including plastic strain formation in aluminum alloys [9], the development of energy-efficient
polymer welding strategies [10] and the application of severe plastic deformation to enhance weld
strength [12] [24]. Furthermore, numerical modeling efforts have provided insights into distortion

2
control and process optimization for friction stir welding (FSW) and other thermo-mechanical
methods [3] [17].

This literature review synthesizes these advancements to provide a comprehensive overview of the
state-of-the-art in plastic and composite welding technologies. It categorizes findings by material
systems—such as PLA, thermoplastic composites, aluminum alloys and CFRTPs—and welding
techniques including FSSW, RFW, ultrasonic welding, hot gas welding, laser welding and hybrid
methods. The review highlights both the current capabilities and emerging directions in the pursuit of
efficient, reliable and scalable joining technologies for modern manufacturing systems.

2.CORE AND TRADITIONAL WELDING TECHNIQUES

2.1 HOT GAS WELDING OF THERMOPLASTICS

Haque et al. [7] reviewed hot gas welding, an external heating method using gas streams (air,
nitrogen, CO₂) to soften thermoplastics like PVC, polyethylene, and polypropylene. Key
parameters include temperature (220–300°C for PVC), gas composition, and filler rod
compatibility. While effective for repairing tanks and automotive parts, challenges include
weaker weld beads compared to parent material, necessitating further optimization [7].

2.2 ULTRASONIC PLASTIC WELDING SYSTEMS

Tsujino et al. [5] designed a 94 kHz ultrasonic longitudinal

vibration system (Fig 1) for plastic welding, achieving a
maximum vibration velocity of 3.3 m/s and weld strength
exceeding 580 N for polyurethane sheets. The system’s high-
frequency operation reduces required vibration velocities
compared to lower-frequency systems (27 kHz, 40 kHz),
enhancing efficiency. Hongoh et al. [6] further demonstrated
that a 67 kHz system operating at fundamental and higher-
resonance frequencies (up to 93 kHz) triples weld strength
compared to single-frequency operation. These findings
highlight the advantages of high-frequency ultrasonic welding
for precision applications.

Fig.1. Ultrasonic plastic welding system

3
2.3 FUSION BONDING OF THERMOPLASTIC COMPOSITES

Yousefpour et al. [2] reviewed fusion bonding techniques for thermoplastic composites,
emphasizing their advantages over adhesive bonding and mechanical fastening. The process
involves heating the interface to a viscous state, enabling polymer chain interdiffusion.
Methods include friction welding (linear vibration, spin, and friction stir welding), thermal
welding (hot tool, laser, and hot gas welding), and electromagnetic welding (induction,
resistance, and dielectric welding). Aerospace applications benefit from fusion bonding’s high
strength-to-weight ratio and repairability. However, challenges remain in optimizing
processing temperatures and pressures for high-performance composites [2].

2.4 FRICTION STIR SPOT WELDING (FSSW) OF PLA SHEETS WITH NON-
METALLIC TOOLS

Liu et al. [1] investigated FSSW of polylactic acid (PLA) sheets using non-metallic tools,
addressing challenges like warpage and insufficient heat generation with conventional steel
tools. Their study examined rotating speeds (600–1000 RPM), dwell times (15–45s), and
temperature effects on weld formation. Results showed that higher speeds and longer dwell
times increased the stir zone width (WSZ) due to enhanced material softening. The bonding
factor (product of temperature and dwell time) correlated with WSZ, resembling diffusion
bonding mechanisms. Microscopic analysis confirmed effective stirring and deformation at
the joint interface, demonstrating the feasibility of non-metallic tools for PLA welding [1].

2.5 FRICTION WELDING OF SPD ALUMINUM ALLOYS

The study by Sahin et al. [24] demonstrated significant advancements in aluminum joining
through the combination of severe plastic deformation (SPD) and friction welding techniques.
Their research on 5083 aluminum alloys revealed that a single pass of equal channel angular
pressing (ECAP) could refine grain structures from 50-100 μm to 0.5-2 μm, resulting in a
remarkable 37.7% increase in tensile strength (from 305 MPa to 420 MPa). The optimized
friction welding parameters established in this work included a friction pressure of 35 MPa
maintained for 3 seconds, followed by an upset pressure of 90 MPa applied for 15 seconds.
These parameters proved particularly effective, with welded joints maintaining 90-95% of the
enhanced base material strength. Microstructural analysis showed that while some
recrystallization occurred in the weld zone, hardness values remained 15-20% higher than in
non-SPD material, confirming the stability of the improved grain structure during the welding
thermal cycle. This combined SPD-friction welding approach offers a cost-effective solution

4
for high-strength aluminum components in transportation applications, particularly where
weight reduction and structural integrity are paramount concerns.

3. ADVANCED AND EMERGING TECHNOLOGIES

3.1 ULTRASONIC WELDING OF METAL-THERMOPLASTIC JOINTS

Dal Conte and Villegas [14] made significant contributions to understanding ultrasonic plastic
welding (USPW) for aluminum-CF/PA6 composites in automotive applications. Their work
demonstrated that successful joining relies on two primary mechanisms: mechanical
interlocking of molten polymer into aluminum surface asperities and adsorption forces at the
interface. The study systematically evaluated various surface treatments, finding that laser-
structured aluminum (using Polygon mode patterning) achieved lap shear strengths
comparable to adhesive bonding while offering faster processing times. A critical insight was
the importance of positioning aluminum as the bottom substrate with an insulating Kapton
interlayer to prevent premature heat dissipation. These findings have important implications
for lightweight vehicle design, where reduced joining weight and improved recyclability are
paramount concerns.

Fig.2 Ultrasonic welding of aluminium to CF/PA6 composites through mechanical

interlocking and adsorption forces

3.2 ULTRASONIC WELDING OF CFRTPS

Al Mahmoud et al. [25] presented a comprehensive review of ultrasonic welding

advancements for Carbon Fiber-Reinforced Thermoplastics (CFRTPS), highlighting its
emergence as a preferred joining method for composite materials. Their analysis revealed that
modern ultrasonic welding systems can achieve complete joints in remarkably short cycle
times of 2-5 seconds while maintaining joint strengths at 70-80% of the base material
properties. The development of specialized energy directors using materials like
polyetherimide has significantly improved weld quality by optimizing energy concentration
5
at the joint interface. The introduction of novel resins such as Elium®, which enables room-
temperature curing, has further enhanced processing efficiency. Comparative studies cited in
the review demonstrated that ultrasonic welding outperforms alternative methods like friction
stir welding and adhesive bonding in terms of both processing speed (up to 50% faster) and
energy efficiency (40-50% lower consumption). These characteristics make ultrasonic
welding particularly valuable for aerospace and medical applications where clean, precise,
and rapid joining of complex composite components is essential. The technology has been
successfully implemented in manufacturing structural brackets for automotive applications,
access panels for aerospace systems, and various prosthetic devices in the medical field.

3.3 SEVERE PLASTIC DEFORMATION ENHANCED WELDING

Sahin's research [12] on friction welding of SPD-processed 5083 aluminum demonstrated

remarkable improvements in joint performance. Equal Channel Angular Pressing (ECAP)
pretreatment increased base material tensile strength from 305 MPa to 420 MPa, with welded
joints maintaining these enhanced properties when optimal parameters were used (35 MPa
friction pressure, 90 MPa upset pressure). Microstructural analysis revealed that while some
recrystallization occurred in the weld zone, the overall grain refinement benefits of SPD were
largely preserved. This approach shows particular promise for high-performance applications
where joint strength must match or exceed base material properties.

Material Condition Tensile Strength (MPa) Hardness (HV) Grain Size (μm)

As-received 305 85 50-100

1-pass ECAP 420 120 0.5-2

Welded ECAP 390-410 110 1-5 (weld zone)

Table 2: Mechanical properties of SPD-processed vs conventional aluminum welds [12]

3.4 PLASTIC DEFORMATION JOINING TECHNOLOGIES

Mori et al. [19] provided a comprehensive classification of plastic deformation joining

processes. Their work highlighted cold welding's requirement for significant surface
deformation (50-90% reduction) to enable metallic bonding. In friction-based processes,
rotational speeds of 1000-3000 RPM typically generate sufficient frictional heat for quality
joints. For mechanical joining, self-pierce riveting demonstrated 20-30% higher fatigue life

6
compared to spot welding in automotive assemblies. Recent innovations in electromagnetic
forming [19] show promise for tubular joints, where magnetic pressures exceeding 200 MPa
can create interference fits without thermal distortion. However, the review identified
standardization of mechanical joint quality assessment as a critical research gap.

3.5 FREQUENCY EFFECTS IN ULTRASONIC PLASTIC WELDING

Tsujino et al. [15] conducted a comprehensive investigation of frequency-dependent welding

characteristics across the 27-180 kHz range. Their research revealed that higher frequency
systems (94-180 kHz) provide superior weld strength at lower vibration velocities compared
to conventional 27-40 kHz systems (Fig). Temperature measurements showed localized
heating exceeding 330°C.

Fig 3. Frequency effects on weld strength

3.6 THERMOPLASTIC WELDING INNOVATIONS

Sivakumar et al. [21] developed a plastic welding torch system operating at 300-500°C,
achieving 85-95% of base material strength. Patel's work [22] on induction heating revealed
cross-ply laminates showed 200× greater energy absorption than unidirectional layups.For
friction stir welding, Leitão et al. [23] established fundamental differences in AA5083-H111
and AA6082-T6 weldability (Fig. 2).The AA6082's dynamic precipitation behavior facilitated
better material flow, producing larger nugget zones under identical parameters.

Fig 4. Residual stress distribution in multi-pass weld

7
3.7 ADVANCED PLASTIC WELDING TECHNOLOGIES

Haque and Siddiqui's comprehensive review [13] documented significant progress in plastic
welding methods, particularly for PVC and other thermoplastics. Hot gas welding emerged as
a versatile, low-cost option achieving 11.25 MPa tensile strength in optimized conditions
(200-600°C, proper filler selection). The study also highlighted growing adoption of
ultrasonic welding for precision applications and ongoing development of specialized friction
variants (orbital, angular) for complex geometries. As shown in Figure 4, each plastic
welding method exhibits distinct temperature and pressure profiles that must be carefully
matched to material properties and joint requirements.

4. MODELING, STRESS, AND MATERIAL BEHAVIOUR

4.1 THERMO-ELASTIC-PLASTIC MODELING FOR WELDING DISTORTION

Mollicone et al. [3] developed finite-element (FE) models to simulate welding-induced

distortions in thin metallic structures. Their study compared 2D and 3D models, analyzing
angular deformation and residual stresses. Simplified analytical models, such as the Thermal
Contraction Strain (TCS) algorithm, provided reasonable predictions for single-run welds,
while 3D FE models offered higher accuracy at greater computational cost. The findings are
critical for aerospace and shipbuilding industries, where distortion control is essential [3].

4.2 PLASTIC STRAIN FORMATION IN ALUMINUM WELDING

Johnson's investigation [9] of gas tungsten-arc welded Al-Mg alloys provided fundamental
insights into strain development mechanisms using advanced moiré fringe analysis. The study
revealed that welding parameters significantly influence strain patterns, with higher travel
speeds (200-800 mm/min) producing more concentrated strain distributions near the weld
centerline. As shown in Figure 1, shear strains predominated in two distinct orientations
relative to the weld bead, while transverse compressive strains indicated substantial plastic
deformation. The research established that thermal gradient asymmetry creates distinct plastic
flow patterns around the weld pool with steeper gradients ahead of the arc driving
compressive flow. These findings enable better prediction and control of welding-induced
distortion particularly for thin-section aerospace components where dimensional precision is
critical.

8
 Strain Plastic Flow
Parameter Range Dominant Strain Type
Concentration Pattern

Current: 105-250A Shear

Moderate to high Radial expansion
(parallel/perpendicular)

Speed: 200-800
Increases with speed Compressive (transverse) Rearward shift
mm/min

Table 1: Effect of welding parameters on strain characteristics in Al-Mg alloys [9]4.3

RESIDUAL STRESS ANALYSIS IN CRITICAL WELDS

Ogawa et al. [20] advanced understanding of residual stress evolution through combined
experimental and computational analysis. Their 3D thermal-elastic-plastic FEM approach
accurately predicted stress concentrations at J-groove weld toes (Figure 1) revealing axial
stress variations up to 300 MPa around nozzle circumferences.

Method Resolution Computational Cost Key Advantage

2D Axisymmetric FEM Low Moderate Rapid screening

Accurate local
3D Thermal-elastic-plastic FEM High Intensive
stresses

Table 5: Comparison of residual stress prediction methods [20]

The research demonstrated that semi-circle balanced welding sequences reduced peak
residual stresses by 15-20% compared to continuous deposition.

5. ENERGY EFFICIENCY AND SUSTAINABILITY

5.1 THERMOGRAPHIC TECHNIQUES IN PLASTICS WELDING

5.1.2 Principles and Methodology

Rojek et al. [26] introduced a detailed thermographic assessment protocol employing mid-
wave infrared (MWIR) cameras within a spectral range of 3–5 μm and a thermal sensitivity
of less than 0.03°C. Their methodology encompassed several critical steps, beginning with
calibration procedures to ensure precise temperature measurements using blackbody
reference sources.

9
They also addressed emissivity variations by compensating for the differing surface
properties of various thermoplastic materials. Furthermore, the protocol incorporated real-
time monitoring, capturing thermal profiles at a frame rate of 60 Hz during welding cycles.
The study highlighted that with proper calibration, temperature measurement accuracy could
be maintained within a margin of ±1.5°C for welding surfaces with temperatures ranging
from 180 to 320°C [26].

5.1.2 Applications to Specific Welding Processes

5.1.2.1 Butt Fusion Welding:

The research revealed that non-uniform temperature distribution during the heating phase
directly correlated with weld line defects. Thermography identified temperature variations as
small as 2-3°C across heating tool surfaces, enabling early detection of faulty heating
elements before production use [26].

5.1.2.2 Socket Fusion Welding:

For socket joints, thermographic analysis showed that improper heat penetration depth caused
by incorrect heating times could be visually identified through characteristic thermal gradient
patterns. Optimal welding parameters produced consistent radial temperature distributions
with less than 5% variation [26].

5.1.2.3. Infrared Welding:

The study found infrared welding exhibited the most complex thermal profiles due to varying
material absorption characteristics. Thermography enabled visualization of hot spots caused
by uneven radiation absorption, particularly in glass-filled composites [26].

Fig 5. Butt fusion welding Fig 6. Socket fusion welding Fig 7. Infrared Welding

10
5.2 Quality Assessment and Defect Detection

5.2.1. Process Monitoring Capabilities

Rojek et al. [26] established several key quality indicators detectable through thermographic
monitoring:

1. Heating tool temperature uniformity (<5% variation ideal)

2. Proper heat soak time based on thermal diffusion rates

3. Cooling rate consistency during joint solidification

4. Presence of cold spots indicating poor contact or contamination

5.3 Energy Efficiency In Rotary Friction Welding (RFW) Of HDPE Pipes

Hamade et al. [4] compared RFW with conventional fusion butt welding for HDPE pipes,
highlighting RFW’s superior energy efficiency. RFW’s four-phase process (solid friction,
unsteady-state friction, steady-state melting, and solidification) reduces energy consumption
by focusing heat generation at the interface. Experimental results showed that RFW
consumes one-tenth of the energy required for fusion welding while maintaining weld quality.
The study advocates for RFW as a sustainable alternative in industrial pipe joining
applications [4].

5.4 ENERGY-EFFICIENT POLYMER WELDING METHODS

The comparative study by Hamade et al. [10] demonstrated significant advantages of rotary
friction welding (RFW) over conventional fusion methods for HDPE pipe joining (Fig7).
RFW' s four-phase process achieved equivalent joint strength while reducing energy
consumption by 90% through localized heat generation at the interface. As illustrated in
Figure 2, the mechanical energy conversion in RFW occurs more efficiently than the thermal
conduction/convection processes of fusion welding. Experimental results showed that optimal
parameter combinations (particularly rotational speed and axial pressure) could produce high-
quality welds in under 10 seconds, compared to several minutes for fusion methods. This
research positions RFW as a sustainable solution for pipeline systems, with potential
applications in chemical processing and water infrastructure where energy efficiency and
joint reliability are paramount.

11
 Fig 8. Energy efficient polymer welding methods

6. SAFETY, MONITORING, AND MANUFACTURING SYSTEMS

6.1 SAFETY MEASURES IN PLASTIC WELDING

Levchenko et al. [8] outlined critical safety protocols, including proper gas cylinder
storage, ventilation for toxic fumes (e.g., PVC vapors), and protective gear (gloves,
goggles). The study emphasizes training programs and equipment maintenance to prevent
hazards like fires and suffocation from nitrogen or oxygen use [8].

6.2 RECONFIGURABLE MANUFACTURING SYSTEMS

Mehrabi's foundational work [11] on Reconfigurable Manufacturing Systems (RMS)

established a framework for adaptable welding operations. RMS principles address the
limitations of both dedicated systems (inflexible) and flexible systems (costly) through
modular design and rapid reconfiguration capabilities. Key features include:

• Hardware/software modularity for component interchangeability

• Convertibility between product families

• Integrated diagnostics for quality control

These characteristics prove particularly valuable for welding operations requiring frequent
adaptation to new materials or joint configurations. Figure 3 illustrates how RMS architecture
supports seamless transitions between different welding processes within a single production
environment.

12
6.3 COMPARATIVE ANALYSIS AND INDUSTRIAL APPLICATIONS

When comparing these two advanced welding technologies, distinct but complementary
advantages emerge. SPD-enhanced friction welding excels in creating high-strength metallic
joints for load-bearing structural components in automotive and aerospace applications. In
contrast, ultrasonic welding provides superior solutions for joining complex thermoplastic
composite parts where weight reduction and production speed are critical factors. Industrial
implementation data shows that while SPD-friction welding typically requires 20-30 second
cycle times, the resulting joints often demonstrate near-parent material strength, making them
ideal for safety-critical components. Ultrasonic welding's faster 2-5 second cycle times better
suit high-volume production environments when joining smaller composite parts. Both
technologies address the growing industry need for reliable joining methods that can
accommodate the increasing use of advanced materials in modern manufacturing while
overcoming traditional limitations associated with thermal distortion or adhesive bonding.

6.4 COMPARATIVE ANALYSIS AND FUTURE DIRECTIONS

The reviewed studies collectively demonstrate that modern welding technologies are evolving
along several critical axes: energy efficiency, material performance and process flexibility.
RFW [10] and SPD-enhanced methods [12] show promise for sustainable high-performance
joining, while RMS principles [11] enable system-level adaptability. Future research should
prioritize:

1. AI-driven parameter optimization for complex material combinations

2. Hybrid processes combining multiple energy sources

3. Closed-loop control systems integrating real-time monitoring

4. Expanded material databases for emerging alloys and polymers

6.5 PROCESS TECHNOLOGIES AND APPLICATIONS

6.5.1 Ultrasonic Welding of Metal-Thermoplastic Joints

Dal Conte and Villegas [14] demonstrated that ultrasonic welding successfully joins
aluminum to CF/PA6 composites through mechanical interlocking and adsorption forces (Fig.
1). Their work showed laser-structured aluminum surfaces (Polygon mode) achieved 20 MPa
lap shear strength - comparable to adhesive bonding but with faster processing. The study
established optimal parameters using 20 kHz frequency with Kapton interlayer insulation.

13
Treatment Method Ra (μm) LSS (MPa) Process Time

As-received 0.8 8.2 -

Sandblasting 3.5 12.1 45 s

Laser structuring 15.2 19.8 30 s

Plasma treatment 1.2 10.3 60 s

Table 3: Performance of surface treatments in ultrasonic welding [14]

6.5.2 Frequency Optimization in Ultrasonic Welding

Tsujino et al. [15] compared welding across 27-180 kHz frequencies, finding 94-180 kHz
systems provided superior strength at lower energy inputs (Fig. 2). High-frequency welding
(94 kHz) achieved 18 MPa strength in polypropylene at 30% lower energy than conventional
27 kHz systems, with more localized heating (330°C peak at interface).

6.5.3 Laser Transmission Welding Advances

sHumbe et al. [16] reviewed laser welding variants, showing contour welding's suitability for
3D geometries and quasi-simultaneous welding's balance of speed-flexibility. For micro-
components, Haberstroh [18] demonstrated polycarbonate's superior performance over POM
due to better light transmission, achieving 30 MPa strength in medical devices.

Comparative Analysis

Energy
Technique Materials Strength Speed
Efficiency

Ultrasonic [14] Al-CF/PA6 20 MPa Fast Medium

High-freq USPW [15] Plastics 18 MPa Very Fast High

Laser [16] Thermoplastics 30 MPa Medium Medium

FSW [17] Full

Metals Slow High
parent

Table 4: Comparison of advanced welding techniques

14
6.5.4 Numerical Modeling of FSW

Nandan et al. [17] developed a 3D model for stainless steel FSW, predicting:

• Asymmetric temperature profiles (1518 K peak)

• Strain rates >130 s⁻¹ near tool

• Material flow patterns (Fig 9)

Fig 9. Material flow in FSW

24.CONCLUSION:

This literature review highlights significant advancements in welding technologies for

plastics, composites, and metallic materials, emphasizing improved efficiency, sustainability,
and joint performance. Key developments include non-metallic FSSW tools for reduced PLA
warpage [13], high-strength fusion bonding for aerospace composites [13], and energy-
efficient RFW and ultrasonic welding as alternatives to conventional methods [10], [25].
Innovations such as SPD-enhanced friction welding for aluminum alloys [24] and ultrasonic
welding for CFRTPs [25] address critical challenges in modern manufacturing, enabling
high-strength and rapid joining. Additionally, plastic deformation methods [19] and advanced
modeling techniques [20] provide distortion-free solutions and residual stress management,
while thermoplastic welding innovations [21]–[23] expand lightweight structure applications.

Future research should focus on hybrid process development, digital monitoring for quality
control, and sustainability improvements to further enhance these joining methods. The
integration of these technologies with Industry 4.0 systems will drive smart manufacturing,
supporting next-generation applications in aerospace, automotive, and medical industries.
Continued advancements in material-specific strategies, parameter optimization, and

15
automation will be crucial for expanding the applicability and performance of welding
technologies in multi-material joining.

25.REFERENCES:

[1] C. T. Liu, S. H. Xu, H. G. Shen, and Y. [9] L. Johnson, "Formation of Plastic

P. Chang, "Preliminary Study on Friction Strains During Welding of Aluminum
Stir Spot Welding of Plastic Sheets with Alloys," J. Mater. Process. Technol., vol.
Non-Metallic Tools," Journal of Materials 285, 2020.
Processing Technology, 2021. [10] R. F. Hamade et al., "Rotary Friction
[2] A. Yousefpour, M. Hojjati, and J.-P. Welding versus Fusion Butt Welding of
Immarigeon, "Fusion Bonding/Welding of Plastic Pipes," J. Clean. Prod., vol. 279,
Thermoplastic Composites," Journal of 2021.
Thermoplastic Composite Materials, 2004. [11] M. G. Mehrabi et al., "Reconfigurable
[3] P. Mollicone, D. Camilleri, T. G. F. Manufacturing Systems," CIRP Ann., vol.
Gray, and T. Comlekci, "Simple Thermo- 49, no. 2, 2000.
Elastic-Plastic Models for Welding [12] M. Sahin et al., "Joining of SPD
Distortion Simulation," Journal of Aluminum with Friction Welding," Mater.
Materials Engineering and Performance, Des., vol. 146, 2018.
2006. [13] M. S. Haque and M. A. Siddiqui,
[4] R. F. Hamade, T. R. Andari, A. H. "Plastic Welding: Important Facts," Int. J.
Ammouri, and I. S. Jawahir, "Rotary Adv. Manuf. Technol., vol. 103, 2019.
Friction Welding versus Fusion Butt
[14] U. F. Dal Conte et al., J. Mater.
Welding of Plastic Pipes – Feasibility and
Process. Technol., vol. 302, 2022.
Energy Perspective," Journal of Cleaner
Production, 2020. [15] J. Tsujino et al., Ultrasonics, vol. 118,
[5] J. Tsujino et al., "Configuration of a 2022.
30-mm-diameter 94 kHz Ultrasonic [16] A. B. Humbe et al., Opt. Laser
Longitudinal Vibration System for Plastic Technol., vol. 153, 2022.
Welding," Ultrasonics, 2022. [17] R. Nandan et al., Acta Mater., vol.
[6] M. Hongoh et al., "Welding 206, 2021.
Characteristics of 67 kHz Ultrasonic [18] E. Haberstroh et al., J. Polym. Eng.,
Plastic Welding System Using vol. 41, no. 3, 2021.
Fundamental and Higher-Resonance-
[19] K. Mori et al., "Joining by Plastic
Frequency Vibrations," Journal of
Deformation," CIRP Annals, vol. 62, no. 2,
Ultrasonics, 2021.
2013.
[7] Md. S. Haque, M. Kumar, and A.
[20] K. Ogawa et al., "Welding Residual
Khan, "Hot Gas Welding of Plastic:
Stresses in Penetration
Fundamentals &
Nozzles," International Journal of
Importance," International Journal of
Pressure Vessels and Piping, vol. 196,
Advanced Manufacturing Technology,
2022.
2019.
[21] N. Sivakumar et al., "Plastic Welding
[8] O. Levchenko et al., "Basic Safety
Torch Design," Journal of Manufacturing
Measures During Plastic Welding," Safety
Processes, vol. 68, 2021.
Science, 2023.
[22] A. Patel, "Finite Element EM
Analyses of Induction Heating," MSc
16
Thesis, TU Delft, 2020. FIGURE SOURCES:
[23] C. Leitão et al., "FSW of AA5083 and
Fig.1. Ultrasonic plastic welding system
AA6082," Materials & Design, vol. 183,
2019. Fig.2Ultrasonic welding of aluminium to
[24] M. Sahin, H. E. Akata, and K. Ozel, CF/PA6 composites through mechanical
"An Experimental Study on Joining of interlocking and adsorption forces
Severe Plastic Deformed Aluminium
Materials with Friction Welding Fig 3. Frequency effects on weld strength
Method," Journal of Materials Processing Fig 4. Residual stress distribution in multi-
Technology, vol. 271, pp. 148-157, 2019.
pass weld
[25] Z. Al Mahmoud et al., "Recent
Developments in Ultrasonic Welding of Fig 5. Butt fusion welding
Similar and Dissimilar Joints of Carbon
Fiber-Reinforced Thermoplastics With and Fig 6. Socket fusion welding
Without Interlayer," Composites Part B:
Fig 7. Infrared Welding
Engineering, vol. 230, p. 109450, 2022.
[26] M. Rojek, J. Stabik, G. Muzia, Fig 8. Energy efficient polymer welding
“Thermography in plastics welding methods
processes assessment”
Fig 9. Material flow in FSW

**All the above images are AI generated**

17
AI PLAGIARISM REPORT:

18
PLAGIARISM REPORT:

19
ANNEXURE:

The above QR code includes:

1. Literature review papers

2. Plagiarism report
3. AI plagiarism report

20
 EXERCISE 2

Industrial Visit Report: Roots Industries India

Introduction
Industrial visits play a vital role in enhancing practical understanding and exposure to real-
time operations in manufacturing industries. As part of our curriculum, we visited Roots
Industries India Pvt. Ltd., Automotive Division, located in Coimbatore. This report
presents the observations made during the visit, focusing on the workflow, processes
involved, and the organization of departments.

Company Overview
Roots Industries India Pvt. Ltd. is one of the flagship companies of the Roots Group,
established in 1970. It is a reputed manufacturer of automotive components such as horns,
electrical parts, and other electro-mechanical devices. The company’s automotive division
primarily focuses on producing a wide range of automotive horns, electronic horns, and
electro-pneumatic signaling devices that are supplied to various automobile manufacturers
both in India and abroad.
• ISO/TS 16949 and ISO 14001 certified
• Global supplier to OEMs like Tata, Ashok Leyland, Maruti Suzuki, and export
markets
• Integration of automation and lean manufacturing techniques

Workflow and Processes

a. Overall Workflow Description
The overall production workflow of the automotive division follows a streamlined Make-to-
Order (MTO) and Make-to-Stock (MTS) hybrid model. The general workflow is as
follows:
1. Design and R&D: Product design based on customer requirements and standards.
2. Raw Material Procurement: Sourcing of steel, plastics, and electronic components.
3. Component Manufacturing: Pressing, molding, and machining of parts.
4. Sub-Assembly and Assembly: Combination of mechanical and electronic parts.
5. Testing and Quality Control: 100% functional testing for performance and
durability.
6. Packaging and Dispatch: Products packed and dispatched to OEMs and dealers.
21
b. Department-wise Process Description
1. Press Shop
The press shop utilizes hydraulic and mechanical presses to shape horn diaphragms and other
metal components. Progressive dies are employed to perform multiple operations in a single
stroke, enhancing production efficiency and reducing cycle time.
2. Plastic Injection Molding
This section features high-precision molding machines that manufacture plastic casings and
various internal parts of the horn. The most commonly used materials include ABS and
nylon, chosen for their strength, durability, and moldability.
3. Electroplating & Surface Treatment
To enhance corrosion resistance, components undergo a series of surface treatments including
degreasing, pickling, zinc plating, and painting. These processes ensure long-term durability
and a high-quality finish for exposed parts.
4. Sub-Assembly Department
In this department, coils are wound and soldered using automated machines for precision and
consistency. The diaphragm, contact points, and casings are assembled step-by-step, ensuring
proper alignment and fit before moving to the final assembly.
5. Final Assembly
The horn body is assembled using custom-designed fixtures and tools to ensure uniformity
across all units. Screws and rivets are tightened with torque-controlled equipment to meet
product standards and prevent assembly-related defects.
6. Testing and Quality Assurance
Each horn undergoes a thorough testing process to verify sound frequency, decibel levels,
operating voltage, and current. Mechanical durability is also tested through life cycle testing.
In addition, random sampling and Statistical Process Control (SPC) methods are applied to
monitor and maintain quality.
7. Packing and Dispatch
Finished products are labeled with QR codes for traceability and are packed in bulk for
efficient storage. Once packed, they are stored in a designated warehouse area, ready for
dispatch to distribution centers or customers.

Observations and Learnings

• The use of automation and robotics in the assembly lines increases productivity and
consistency.
• Roots emphasizes quality control with 100% product testing.
• Lean manufacturing and Kaizen principles are actively followed.
• Employees undergo continuous training for skill development.
• Safety protocols and 5S workplace organization are strictly enforced.
• Energy-efficient and environmentally friendly practices such as waste segregation and
water recycling are implemented.

22
Conclusion
The visit to Roots Industries India Pvt. Ltd. – Automotive Division provided valuable insights
into the manufacturing processes of automotive horns and electro-mechanical devices. The
company’s focus on quality, safety, and innovation was evident in every department. This
industrial exposure helped bridge the gap between academic learning and industrial practices,
and highlighted the importance of process integration, lean manufacturing, and continual
improvement in a competitive manufacturing environment.

23
 EXERCISE 3

Energy Efficiency and Management Report – Roots Industries

India Ltd., Coimbatore.

Introduction
This report presents the findings of an energy audit conducted at Roots Industries India Pvt.
Ltd., Automotive Division, Coimbatore. The purpose of the audit is to evaluate current
energy usage, identify potential areas of energy wastage, and recommend measures for
improving energy efficiency across the plant. As industrial energy costs are rising,
minimizing energy losses is vital for cost reduction and environmental sustainability.

Energy Consumption Overview

Roots Industries utilizes energy primarily in the form of:
• Electricity: Supplied by TANGEDCO and supported by captive solar power.
• Compressed Air: For pneumatic tools and equipment.
• Diesel: Used for backup power via DG sets.
• Thermal Energy: Minor usage in surface treatment and curing ovens.

Key Consumption Areas:

Department Energy Type Approx. Share

Assembly Line Electricity 25%

Press Shop Electricity 20%

Injection Molding Electricity 30%

Surface Treatment Electricity & Thermal 15%

Utilities (Lighting, HVAC, Air Compressors) Electricity 10%

Identification of Energy Wastage Areas

1. Idle Running of Equipment
Energy is wasted when machines are left powered ON during non-production hours.
Additionally, air compressors are often found running at low loads for extended periods,
consuming significant energy without delivering effective output.

24
2. Lighting Inefficiencies
Some sections of the facility still use conventional tube lights instead of energy-efficient LED
lighting. Furthermore, due to inadequate sensor integration, lights remain ON even during
daylight hours, leading to unnecessary energy consumption.
3. Compressed Air Leakage
Leaks in pneumatic lines are audible in various areas, indicating significant energy loss. This
issue is compounded by the lack of routine maintenance and absence of systematic leak
detection and repair audits.
4. Motor and Drive Inefficiency
Outdated motors, particularly IE1 class models, are still operating in areas like the press shop
and utility pumps. Moreover, several heavy-load motors have not been equipped with
Variable Frequency Drives (VFDs), resulting in inefficient energy usage.
5. Thermal Losses
Significant thermal energy is lost in the surface treatment area due to uninsulated pipelines
and the habit of leaving oven doors open. These practices not only reduce energy efficiency
but also affect the consistency of heating processes.

Recommendations for Energy Savings

Recommendation Estimated Saving (%) Priority

Replace all tube lights with LED fixtures 40–60% (lighting) High

Install VFDs on motors above 5 HP 15–30% (motor load) Medium

Conduct regular air leak detection and repair 10–20% (compressed air) High

Introduce machine idle-time auto shutoff 5–10% (overall) High

Upgrade motors to IE3 efficiency class 8–15% (motor section) Medium

Insulate thermal pipelines 10–12% (thermal) Medium

Install motion sensors in low-traffic areas 25–30% (lighting) Medium

Energy Recovery Opportunities

1. Waste Heat Recovery System (WHRS)
o Install WHRS for ovens and air compressors to preheat process water or
ambient air.
2. Solar Energy Expansion
o Expand rooftop solar installation to reduce dependency on grid power.

25
 3. Regenerative Braking in Assembly Line Conveyors
o Utilize kinetic energy recovery in motorized conveyor systems.
4. Rainwater Harvesting for Cooling Towers
o Reduce pump energy consumption for water handling.

Cost-Benefit Analysis
Estimated Investment (₹ Annual Saving (₹ Payback
Initiative
Lakhs) Lakhs) Period

LED Lighting Retrofit 3.5 1.8 < 2 Years

VFD Installation (10

6.0 2.5 ~2.4 Years
units)

Air Leak Audit &

1.2 1.0 ~1.2 Years
Rectification

Motor Efficiency Upgrade

5.0 1.5 ~3.3 Years
(IE3)

WHR System for Ovens 8.0 3.0 ~2.6 Years

Conclusion
The energy audit of Roots Industries Automotive Division identified multiple opportunities to
optimize energy use and reduce costs. By implementing the suggested energy conservation
measures (ECMs), the company can potentially reduce overall energy consumption by 15–
20% annually, significantly cutting operational costs and lowering the carbon footprint.
Adoption of automation, energy-efficient equipment, and proactive maintenance will further
reinforce the company’s commitment to sustainable manufacturing.

26
 EXERCISE 4

Process Improvement Report – Roots Industries India Ltd.,

Coimbatore

Introduction
In a highly competitive manufacturing environment, continuous improvement in productivity
is essential for maintaining quality, reducing operational costs, and meeting delivery
commitments. This report evaluates the existing processes in the automotive division of
Roots Industries India Pvt. Ltd., Coimbatore, and identifies areas where minor but
effective modifications can significantly improve productivity without investing in new
machinery.

Existing Process Overview

Roots Industries manufactures a wide range of automotive horns and electromechanical
components. The production line primarily includes:
1. Raw Material Handling and Storage
2. Press Shop Operations
3. Injection Molding
4. Sub-Assembly (Coil Winding, Contact Soldering)
5. Final Assembly
6. Quality Testing
7. Packing and Dispatch
Each department operates in a sequential layout, with manual or semi-automatic systems
connecting different stages. Material movement is mostly handled using trolleys, bins, and
manual pushcarts.

Identification of Improvement Areas

1. Press Shop to Assembly – Manual Transfer Delays
The movement of components from the press shop to the assembly area is done manually,
leading to frequent delays and idle time. The absence of conveyor systems or trolleys results
in inefficient material handling and impacts line flow.
2. Coil Winding Section – Poor Ergonomic Access
Operators in the coil winding area manually reach out to collect and stack components. This
not only slows down the process but also increases the risk of repetitive strain injuries due to
poor ergonomic setup.

27
3. Final Assembly Line – Inefficient Layout
The layout of the final assembly line requires workers to walk unnecessarily between
stations. This increases fatigue, reduces productive time, and indicates a need for better
workstation arrangement.
4. Packing Area – Unorganized Material Flow
In the packing section, the lack of proper bin organization disrupts workflow. This
disorganization results in time loss during sorting, packing, and movement of finished goods.
5. Sub-Assembly Storage – Inconsistent Labeling
Labeling in the sub-assembly storage area is inconsistent, making it difficult for workers to
quickly locate parts. This leads to delays during part picking and negatively affects assembly
line continuity.

Suggested Modifications
1. Addition of Roller Conveyors – Reducing Manual Effort
Installing gravity-based roller conveyors from the Press Shop to the Assembly area can
significantly reduce the need for manual handling of components. This change will not only
reduce physical strain on workers but also eliminate delays associated with manual transfer,
thereby streamlining the production flow.
2. Use of FIFO Racks – Improving Traceability and Access
Implementing First-In-First-Out (FIFO) flow racks in the Sub-Assembly and Packing areas
will help maintain organized part flow and ensure that older components are used first. This
setup improves inventory management, enhances traceability, and enables quicker access to
required parts.
3. Re-layout of Assembly Stations – Enhancing Ergonomics
Rearranging tools and component storage to be closer to each workstation using ergonomic
principles will reduce unnecessary movement by operators. This modification minimizes
motion waste, improves productivity, and supports a more comfortable working environment.
4. Tugger Cart System for Material Movement – Standardizing Part Delivery
Introducing a tugger cart system with scheduled intervals between the stores and the shop
floor can standardize the material supply process. This method ensures timely and consistent
delivery of parts, reduces waiting time, and improves inventory control at the point of use.
5. Color-coded Bins and Shadow Boards – Applying 5S Principles
Using color-coded bins for parts and shadow boards for tools aligns with 5S methodology
and promotes visual control. These tools help in quick identification, better segregation, and
availability of required items, thus reducing search time and handling inefficiencies.

28
6. Visual Work Instructions with QR Codes – Reducing Operator Errors
Displaying digital or printed visual work instructions at each assembly station using QR
codes ensures that operators have easy access to updated and standardized process steps. This
not only reduces human errors but also supports quality consistency and faster onboarding of
new workers.

Expected Productivity Gains

Estimated Productivity Gain
Area Improvement Measure
(%)

Material Transfer Roller conveyors and tugger carts 8–12%

Assembly Layout Optimized workstation arrangement 5–7%

Storage &
FIFO racks and color-coded bins 6–10%
Retrieval

Operator Visual instructions and tool

4–6%
Efficiency organization

Overall productivity improvement expected: 15–20%, based on cumulative effect of the

small changes.

Conclusion
The analysis highlights that productivity improvements are achievable without investing
in new machinery, by making low-cost adjustments to material flow, storage, and
workstation layout. Implementing these minor modifications will lead to smoother workflow,
reduced operator fatigue, better space utilization, and overall efficiency enhancement in the
automotive division of Roots Industries.

29
 EXERCISE 5
INDUSTRIAL VISIT REPORT

Industry Name: KPR ENGINEERING WORKS

Type: MSME – Precision Machining Unit
Team Members:
• Vinitha S
• Sanjana R
• Princy Keerthana R

Aim:
To analyze and document the operational practices, productivity factors, and challenges faced
by KPR Engineering Works—an MSME specializing in precision machining—through
firsthand observation, with the objective of gaining insights into small-scale manufacturing
processes and identifying areas for improvement.

Objective of the Visit:

The purpose of this industrial visit was to explore and evaluate the factors contributing to the
success and challenges (failures) faced by a functioning MSME. Through direct observation
and interaction, we aimed to understand the operational, managerial, and economic realities
of a small-scale precision engineering unit.

Overview of the Industry:

KPR Engineering Works, founded by Mr. Ramesh, an ITI graduate, has been operational for
the past 12 years with a compact workforce of six employees. The firm specializes in
reconditioning and intricate machining of automotive engine components—primarily for two-
wheelers like Honda Dio and TVS XL.
Equipped with machines such as lathe, hydraulic press, bench drill, tool grinder, and air
compressor, the unit provides high-precision services to local auto garages.

30
Interaction & Insights:
During the visit, Mr. Ramesh provided an honest reflection of his entrepreneurial journey:
“I didn’t start this company to become famous—I started it to survive and succeed. Every
day is a learning curve.”

SUCCESS FACTORS IDENTIFIED:

Technical Skill: Years of hands-on experience allowed Mr. Ramesh to deliver consistent
quality.
Niche Focus: Specializing in rework of two-wheeler engine parts built a loyal customer base.
Cost Efficiency: Small team, optimized tools, and client-specific projects kept overheads
low.
Local Demand: Continuous inflow of work from neighborhood auto garages ensured
business continuity.

FAILURES & CHALLENGES FACED:

Rework Losses: Precision failures require complete rework, consuming time and increasing
cost.
“If it fails once, we pay twice—for the part and for the mistake,” he remarked.
Initial Capital Strain: Starting without external funding made scaling slow.
COVID-19 Impact: A complete halt during the pandemic caused financial setbacks and
temporary layoffs.

CONCLUSION:
The visit to KPR Engineering Works offered an in-depth look at the balancing act between
success and failure in a small-scale industrial setup. The unit’s success lies in skill,
consistency, and resilience, while its failures reveal the vulnerabilities of MSMEs to
operational errors and external disruptions.
“Success is when a customer returns with a new job. Failure is when the same job returns
again.”
In essence, the visit was a powerful reminder that entrepreneurial success is not about
avoiding failure, but learning to manage and grow through it.

31
Annexure:

The above QR code includes

1.Interview video

32
 EXERCISE 6

MARKET SURVEY ON ELECTRIC KETTLE

1. Introduction
In today’s fast-paced lifestyle, the demand for efficient and time-saving kitchen appliances
has grown significantly. Among these, electric kettles have become one of the most
commonly used household appliances for their convenience, speed, and versatility. They
provide an easy and quick method to boil water, prepare beverages, and even cook simple
meals—making them an essential part of modern kitchens, especially in urban households,
student accommodations, and workplaces.
This growing reliance on electric kettles is accompanied by heightened consumer awareness
regarding energy efficiency, safety features, design aesthetics, and smart capabilities. As a
result, the electric kettle market has seen rapid innovation, with manufacturers introducing
new features such as temperature control, auto shut-off, keep-warm functions, and eco-
friendly materials to cater to evolving user preferences.
The primary objective of this market survey is to evaluate consumer awareness, ownership
patterns, usage frequency, satisfaction levels, and purchasing behavior with respect to electric
kettles. The study also aims to uncover consumer expectations, common issues encountered,
and preferences related to brand, design, capacity, and functional features. By surveying a
diverse group of respondents across age groups, income levels, and regions, this report
presents a detailed analysis of current market trends and user sentiments.
This survey is particularly relevant in the context of increasing demand for small home
appliances that combine performance with sustainability. The insights drawn from this study
are intended to help manufacturers, retailers, and marketers understand consumer needs more
accurately and adapt their products and strategies accordingly.
Ultimately, this report seeks to provide actionable recommendations for product
development, customer engagement, and innovation in the electric kettle segment, ensuring
better user satisfaction and increased market penetration.

2. Objectives
The primary objectives of the Electric Kettle Market Survey are as follows. Each of these
objectives is designed to provide a comprehensive understanding of consumer behavior,
preferences, and expectations related to the usage and purchasing of electric kettles.
• Examine Consumer Awareness:
Investigate how aware consumers are of electric kettles, their key features, and technological
advancements such as temperature control, auto shut-off, and energy efficiency. Determine
where consumers have learned about electric kettles—whether through online platforms, in-
store promotions, advertisements, peer recommendations, or social media.
• Understand Usage Patterns:
Analyze how frequently electric kettles are used and for what purposes—boiling water,
making tea/coffee, preparing instant foods, etc. Identify variations in usage patterns across

33
households, student accommodations, and workplaces. Evaluate how factors like household
size and lifestyle influence usage behavior.
• Measure Satisfaction Levels:
Record general satisfaction levels among users regarding their current electric kettle.
Evaluate performance aspects such as boiling speed, ease of use, design, noise level, energy
efficiency, safety features, and durability. Also, document common issues faced, such as
leakage, overheating, or slow heating times.
• Gather Feedback on Improvement Areas:
Identify the features consumers would like to see improved or added in electric kettles—such
as better insulation, quieter operation, faster boiling, ease of cleaning, or smart app control.
Gauge interest in advanced features like temperature presets, keep-warm functions, and eco-
friendly materials (e.g., BPA-free components).
• Market Trends and Potential for Upgrades:
Explore consumer willingness to upgrade their current electric kettle within the next 6–12
months. Understand the primary factors that drive purchase decisions, including price, brand
reputation, design, capacity, and technology features. Identify barriers to purchasing or
upgrading, such as price sensitivity, product complexity, or lack of awareness of new
features.
• Understand Consumer Demographics:
Collect and analyze demographic data such as age, gender, income level, education,
occupation, and region of residence. Use this data to segment the market and identify trends
in consumer behavior across different groups. Understand how demographic characteristics
influence preferences in kettle features, brands, and price ranges.

Analysis of Survey Results:

The responses render a good status on present-day market trends, consumer preference, and
major improvements needed on electric kettle. Following is the breakdown of the survey
results into major findings alongside relevant graphs to give a more visual portrayal.

1. Personal and Demographic Information

Age Group

• 18–25 years: 20%

• 26–35 years: 47%

• 36–50 years: 27%

• Above 50 years: 6%
Analysis: Most users fall within the 26–35 age group, suggesting that young working

34
 • professionals and small families form a major user base for electric kettles. This
aligns with the need for convenience and quick heating in busy routines.

Fig.1 Age group distribution of electric kettle users

2. Household and Purchase Design Dynamics

Purchase Decision Maker

• Self: 67%

• Spouse/Partner: 27%

• Other family members: 6%

Analysis: In two-thirds of cases, individuals made the purchase themselves,
highlighting a trend of independent decision-making, particularly among women and
working professionals.

3. Ownership and Usage Patterns

Fig.2 Ownership and usage patterns of electric kettle users

Usage Frequency

• Daily: 60%

35
 • Several times a week: 27%

• Weekly or less: 13%

• Analysis: The majority of users operate their kettles daily, showing that kettles are an
integral part of their daily routine—especially useful for quick tasks like making tea,
coffee, or boiling water.

4. Satisfaction and Experience

Fig. Satisfaction and experience of electric kettle users

Satisfaction Level

• Very Satisfied: 27%

• Satisfied/Moderate: 60%

• Not Satisfied: 13%

• Analysis: A majority (87%) of users report being satisfied or moderately satisfied

with their kettles, suggesting that the products generally meet expectations. However,
a relatively low "very satisfied" segment implies room for improvement, particularly
in feature set or build quality.

5. Future Intentions and Preferences

Fig. Interest in smart feature

36
Interest in Smart Features
• Maybe/Somewhat Interested: 60%

• Not Interested: 40%

Analysis: While smart features like mobile connectivity or programmable settings
aren't a priority, there's growing curiosity among younger users. This is a potential
market for future innovation if priced right,

6. Feature Importance and Product Attributes

Fig.6 Feature importance and product attributes

a. Auto Shut-off Feature

• Essential for Most (93%)

Analysis: Auto shut-off is the most valued feature among consumers. It enhances
both safety and convenience, making it a near-universal requirement. Manufacturers
should treat this as a non-negotiable inclusion.

b. Temperature Control

• Not Needed by Most (67%)

• Some Interest: Especially from younger or tech-savvy users

Analysis: Only a smaller segment currently values temperature control, often linked
with niche uses (milk boiling, green tea, etc.). However, its presence could attract
premium buyers or those looking to upgrade.

c. Keep-Warm Feature

• Generally Unnecessary (73%)

Analysis: The majority do not prioritize the keep-warm function. Since most users

37
 boil and use water immediately, this feature is often seen as a drain on energy or an
unnecessary extra.

d. Material Preference

• Stainless Steel: 47%

• Plastic: 27%

• Glass: 20%
Analysis: Stainless steel is the most preferred material due to durability and heat
retention. Some prefer glass for aesthetics, while plastic remains acceptable among
older or budget-conscious users.

e. Capacity Preference

• Popular Sizes: 1.2 to 1.5 litres

Analysis: These sizes reflect the ideal balance between household needs and
compact form. Large families lean towards 1.5 litres, while single users prefer 1.2
litres.

f. Cordless Preference

• Yes: 67%
Analysis: A clear majority prefer cordless designs for ease of movement and
convenience. This feature, though subtle, enhances usability and is increasingly
expected.

g. Cleaning Ease

• Important to Very Important: 80%

Analysis: Ease of cleaning is a major concern, especially among daily users. Users
have reported issues with narrow spouts or difficult-to-reach interiors. Manufacturers
should address this with wider openings or detachable lids.

h. Noise Concern

• Not a Major Concern: 87%

Analysis: Users are generally not bothered by noise during boiling, likely because the
operation is short and infrequent. Noise levels are not a deal-breaker in most cases.

38
i. Safety Issues

• No Major Issues Reported: Majority

• Analysis: Most users haven't faced critical safety problems, though design flaws like
hot exteriors or malfunctioning lids were mentioned. Addressing such pain points
could improve brand perception.

j. Value for Money

Rated Fair to High: 87%

Analysis: Most users feel they get good value for their money, especially within the ₹1,200–
₹2,000 range. Pricing continues to be a key driver of satisfaction.

k. Wishlist Features

• Commonly Desired:

o Temperature settings
o Milk boiling option
o Larger spouts or openings
Analysis: These reflect evolving needs and frustrations with current models.
Addressing them could provide an edge to innovative brands.
l. Dislikes and Past Problems
• Dislikes:

o Exterior gets too hot

o Steam leaks
• Past Problems:

o Faulty lids
o Switch-off malfunction
Analysis: While satisfaction remains generally high, recurring complaints
suggest room for quality improvements, especially in build design and heat
insulation.

39
 Results and Discussion
1. Demographic Profile of Respondents

The respondents in the survey ranged in age from 22 to 47 years, representing a balanced
mix of male and female users. Occupations varied widely, including junior engineers,
school teachers, homemakers, auto mechanics, and students. This diversity suggests that
electric kettle usage cuts across professional and domestic domains. Most respondents
lived in nuclear households, typically comprising two to five members, indicating that
small to medium capacity kettles (1 to 1.5 litres) suit the typical user.

2. Household and Purchase Dynamics

A significant majority of the respondents were the primary decision-makers in their

households when it came to purchasing kitchen appliances. This trend was particularly
strong among single occupants and working individuals. In terms of shopping preferences,
younger users leaned toward online platforms such as Amazon and Flipkart due to
convenience and deals, while older users preferred offline retail stores like Big Bazaar or

local shops for the physical inspection of products. Most users allocated a budget of
₹1,000–₹2,000 for their purchase, but many showed willingness to upgrade to better
models costing up to ₹2,500, especially if they included advanced features.

3. Ownership and Usage Patterns

All respondents owned an electric kettle, and some had replaced their original unit due
to damage or product limitations. Daily usage was reported by a majority, with kettles
used primarily for boiling water, making tea or coffee, and even cooking eggs or instant
noodles. The average daily usage ranged between 2 to 5 cups. Most kettles in use were
less than two years old, showing growing and relatively recent adoption of this appliance
in households.

4. User Satisfaction and Experience

Satisfaction levels were generally high, with most respondents describing their experience
as "satisfied" or "very satisfied." Commonly appreciated features included fast boiling
time, ease of use, and compact design. However, a few users mentioned issues such as
steam leakage, hot exteriors, and improper lid fitting. Despite these minor complaints,
safety concerns were minimal, and most kettles were perceived as offering fair value for
money. The auto shut-off feature was highlighted as critical by nearly all users.

5. Future Purchase Intentions and Preferences

Nearly half of the respondents indicated interest in upgrading their current kettle if
better features were available at the same price point. Desired upgrades included
temperature control settings, larger spouts, and special modes for milk boiling. While
brand loyalty was not very strong, users were open to switching brands for better

40
 performance and design. Most were looking for a blend of affordability and advanced
features rather than sticking to specific brand names.

6. Feature Expectations and Product Attributes

Respondents emphasized the importance of practical features such as fast heating, auto
shut-off, cordless base, and easy-to-clean interiors. Stainless steel was the most preferred
material due to its durability and safety, though a few respondents showed a liking for
glass or BPA-free plastic for health and aesthetic reasons. Design appeal, though
secondary to functionality, was gaining importance, particularly among female users and
younger respondents. Energy efficiency and noise were not major concerns, while the
inclusion of smart features was met with lukewarm interest.

Conclusion
The survey on electric kettle usage among Tamil Nadu households provides valuable
insights into consumer behavior, preferences, and expectations. It is evident that electric
kettles have become an essential appliance across varied demographic segments, primarily
due to their convenience, speed, and multi-functionality. Most users are satisfied with their
current appliances, especially when key features like auto shut-off, fast boiling, and ease
of cleaning are present.

Price remains a crucial deciding factor, though many consumers are willing to invest more
if better features and improved safety are offered. While brand loyalty is moderate, the
demand for functionality, durability, and thoughtful design is growing. Preferences for
stainless steel material, cordless models, and compact capacities (1.2 to 1.5 litres)
dominate, reflecting practical needs of small to medium households.

Future intentions indicate an openness to upgrade kettles, especially if advanced features

such as temperature control, milk-boil modes, and improved ergonomics are made
available at affordable prices. Overall, there is a clear trend toward functional yet
affordable appliances, with a steady shift in consumer expectations toward smarter and
safer kitchen solutions.

This study underscores the need for manufacturers and marketers to focus on user-centric
design, quality assurance, and the integration of desirable features to meet the evolving
needs of a value-conscious yet aspirational market segment.

ANNEXURE:

The above QR code includes:

1.Questionarre Preparation
2.Sample answers

41
42
 EXERCISE 7
Mechanically Controlled Temperature-Regulated Electric Kettle

Aim:
To make a low-cost electric kettle that controls water temperature using only mechanical
parts like a thermostat and a dial, without using any electronic components.
Abstract:
This project presents a mechanically controlled electric kettle system that eliminates the need
for microcontrollers or digital sensors. Traditional electric kettles use thermostats and thermal
fuses, but this system enhances control by integrating a user-adjustable mechanical dial to
select desired temperature ranges. The kettle uses a bimetallic thermostat for automatic
temperature regulation and a thermal fuse for safety. The design provides a reliable, low-cost,
and electronics-free solution for precise water heating applications.

Introduction:
Electric kettles are common household appliances used for boiling water. Most modern
designs use electronic control systems involving microcontrollers, digital sensors, and
displays. However, such systems may be costly, prone to software failure, and difficult to
maintain in certain environments. This project explores a purely mechanical design using
proven thermal expansion principles and mechanical feedback to create a durable and precise
temperature-regulated kettle without any digital electronics.

Objective:
• To design and implement a temperature-controlled electric kettle using only
mechanical components
• To provide user-adjustable temperature control using a mechanical interface
• To enhance safety with passive protection mechanisms (thermal fuse and thermostat)
• To eliminate the use of microcontrollers and digital components for ease of
manufacturing and maintenance

System Overview:
Components Used:

Component Function

Senses and regulates water temperature by bending to

Bimetallic Thermostat
open/close the power circuit

Adjustable Mechanical Dial / Allows user to set target temperature by adjusting the
Cam Mechanism thermostat's tension or activation point

43
Component Function

Safety mechanism that cuts off power if overheating

Thermal Fuse (240°C)
occurs

Resistive Heating Element Converts electrical energy into heat to boil water

Optional analog indicator (spring-based or color-strip)

Mechanical Indicator
showing heating or ready status

On/Off Rocker Switch Manual control to start or stop heating

Kettle Body (Stainless

Encases all components and holds water
Steel/Glass)

Power Cord (220V/110V AC) Supplies power to the heating element

Circuit Diagram (Simplified Wiring Diagram):

less
Copy code
[AC Supply]
|
|
[Rocker Switch]
|
+---->[Thermal Fuse]----+
| |
| [Bimetallic Thermostat]
| |
+---->[Heating Element]+
|
[Neutral]
Note: The mechanical dial is mechanically connected to the thermostat to adjust its trip
temperature. No electronic circuit board is needed.
Working Principle:
1. The user turns the mechanical dial to select a temperature level (e.g., 70°C, 85°C, or
100°C).
2. This dial adjusts the bimetallic thermostat, changing the angle or contact pressure to
determine its trip point.

44
 3. When the kettle is switched ON, current flows through the thermal fuse, thermostat,
and heating element.
4. As water heats up, the bimetallic strip inside the thermostat bends due to heat.
Once the set temperature is reached, it opens the circuit, cutting power to the heating
element.
5. If the thermostat fails or temperature exceeds safety limits, the thermal fuse
permanently disconnects the circuit to prevent hazards.
6. An optional mechanical indicator (such as a spring-loaded pop-up or color-changing
disc) shows the user that the heating cycle is complete.

Advantages:
• Electronics-free operation
• Low-cost and simple design
• More durable in high-moisture or rugged environments
• Passive safety through thermal fuse and thermostat
• No programming, no software maintenance
• Energy-efficient due to automatic cutoff

45
Applications:
• Domestic electric kettles
• Travel kettles used in remote locations
• Industrial environments where electronics are not preferred
• Water heating systems in developing areas without access to repair tools
• Any context where simplicity, safety, and durability are prioritized
Conclusion:
This mechanically controlled electric kettle offers a reliable, precise, and cost-effective
alternative to digital systems. By using simple mechanical components such as a bimetallic
thermostat and cam-based adjustment dial, the design ensures long-term usability and safety.
It is especially suitable for applications where simplicity and robustness are crucial.

46