High Purity Systems

Welding and Inspection Seminar Presented by: Roger Govaert Asahi/America Inc.

Welding Techniques

Socket Fusion Butt Fusion IR Fusion HPF (Electrofusion), BCF & SIB

Socket Fusion

Heater Align/Prepare Material Coupling Insert and Heat Inserts Material Join and Cool

Socket Fusion

Limitations Can not be Visually Inspected from Outside Excessive internal Cracks and Crevices Repeatability is limited Limited Size Ranges

Butt Fusion

Theory Initial Melt Pressure Cool Down Time Ramp Up Pressure Heat Soak Time & Pressure TIME Change Over

Butt Fusion

Process Plane Material Align Material Apply Heat Join Material

Butt & IR Fusion

ASTM D 2657 “(B)ring the melted ends together immediately with sufficient force to form a uniform flash (bead)… This is the most critical part of the whole joining procedure. If the components are brought together with too much force, all molten material may be pushed out of the joint and cold material brought into contact forming a “cold” joint. If too little force is used, only the melt beads may be fused…”

Butt Fusion

Result

Cross Sectional View

Butt Fusion

Limitations Material in Contact with Heating Element *Possible Source of Contamination Smaller Crevice/Bead than Socket Fusion, but not small as possible

IR Fusion

Theory Heat Soak (Pressure of Clamps on Heater, Not Material) Cool Down Time Ramp Up Pressure Change Over TIME

IR Fusion

Theory Plane Material Align Material Apply Heat Join Material

IR Fusion

Result

Cross Sectional View

Butt & IR Fusion

Importance of Pressure Control

Normal Weld

Material in Weld Zone No Material in Weld Zone

Failure mode: COLD JOINT

Melt Flow Index

Definition

Melt Flow Index measures the rate of extrusion of molten resins, through a die of specified length and diameter, under prescribed conditions of temperature, load, and piston position in the barrel, as the timed measurement is being made.

ASTM D 1238

Melt Flow Index

Importance to Welding and Weld Inspection The melt flow index is measured to determine the flow behavior of thermoplastic materials. Different indexes within thermoplastic families and groupings display different welding characteristics.

The higher the index, the larger the bead under constant parameters

Solef

®

HP PVDF Resin

Melt Flow Indexes for Purad by Asahi/America Pipes 1010/0001  MFI = 4 - 7 g/10min Fittings (2-1/2” - 12”) 1008/0001  MFI = 22-27 g/10min Fittings (1/2” - 2”) 1009/0001  MFI = 12-16 g/10min

GF PVDF Resin

Melt Flow Indexes for Sygef ® Pipes Kynar 740 ®  MFI = 2 - 2.5 g/10min Fittings (1/2” - 9”) Solef ®  MFI = 22-27 g/10min 1008/0001

PolyPure

® Resin Melt Flow Index RA 130E random co-polymer natural polypropylene  Test Cond. 190/5, MFI = 0.5 g/10min   Test Cond. 230/2.16, MFI = 0.3 g/10min Test Cond. 230/5, MFI = 1.25 g/10min

IR Weld Inspection

Common Causes for Failure Alignment Environment Incorrect Parameters Improper Planing Improper Joining

IR Weld Inspection

Alignment Symptom: Joining Areas are offset by greater than 10% of wall thickness.

Cause: Misalignment, lack of alignment control or inspection

IR Weld Inspection

Misalignment Symptom: Angular Deviation Cause: - Faulty Alignment - Improper Planing - Improper Clamping

IR Weld Inspection

Environment, Heat or Parameters Symptom: Inconsistent Bead Size or Excessive Weld Notch intruding into joining area Cause: - Excessive Draft - Improper Heat - Wrong Weld Parameters

IR Weld Inspection

Uniformity Symptom: Non-uniform welding bead Cause: Non-angular joining surfaces resulting in diversely built-up welding beads locally or all along the weld length, caused by improper planing or inconsistent heating Acceptable variation of the beads = b 1  0.5 x b 2 b 1 b 2

IR Weld Inspection

Uniformity Symptom: Narrow, excessive welding bead. Excessive and sharp-edged welding bead locally or all along weld length or weld circumference. Cause: Inadequate welding parameters.

- Too much joining force or Too quick joining - Wrong Weld Parameters

IR Fusion

PolyPure & PP Inspection / Bead Size

Allowable bead size as measured on outside bead (recommendation - only)

6 5 4 3 2 1 20 19 18 17 16 15 14 13 12 11 10 9 8 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Wall Thickness (S) mm

IR Fusion

UF2000 Semi-Automated Welders UF2000-1 1/2” - 2” UF2000-2 2 1/2” - 10”

IR Fusion

UF2000 Semi-Automated Welders 

Programmed Parameters



Computer Monitored Pressure



Semi-Automated Process



Integrated Printer



Reliable Welds

IR Fusion

SP Automated Welders SP-110 1/2” - 4” SP-250 2 1/2” - 10”

IR Fusion

SP Automated Welders 

Automated Fusion Process



Touch Screen Operation



Controls and Monitors:



Welding Parameters



Heating



Joining Force and Time



Computer Memory



Engineered for PureBond®

IR Fusion

SP Automated Welders Touch Screen Control

IR Fusion

SP Automated Welders Weld Info Documentation

IR Fusion

SP Automated Welders Magnetic Clamps

IR Fusion

SP Automated Welders Quick & Easy Alignment Control

IR Fusion

SP Automated Welders Quality, Uniform Welds

HPF Fusion

Theory

HPF Fusion

Process Plane Material Insert Balloon Scan Size Code Insert Coupling Align Material Complete Weld

HPF Fusion

Result

HPF Fusion

Weld Time Comparison

1200 1000 800 600 400 200 0 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" HPF with Balloon HPF Without Balloon BCF

HPF Fusion

Labor Comparison Size ½” 1’ 1 ½” 2” Pipe 200’ 1000’ 500’ 1500’ Fittings 25 75 50 75 Weld Count 37 136 81 166

Total Amount of Welds = 420

HPF Fusion

Labor Comparison Cont.

Size

½” 1” 1 ½” 2” Total

HPF With Balloon

4.1

23 18 45 90.1

Welding Time HPF Without Balloon

.93

7.9

6.75

16 32

BCF

6.75

31 24 48 109.75

Time Savings (hours) Time savings with balloon

3 8 6 3 20

Time Savings without balloon

6 23 17 32 78

IR Fusion

Sample QA Log Date: Operator: Machine Type: Machine SN#: Coupon Material ½” (20mm) ¾” (25mm) 1” (32mm) 1 ¼” (40mm) 1 ½” (50mm) 2” (63mm) 3” (90mm) Size Inspector: Place Weld Here PVDF Print Name PP PPn E-CTFE PFA Signature Date

HP Systems

Thank You