High Purity Systems

Welding and Inspection Seminar

Presented by:Roger GovaertAsahi/America Inc.

Welding Techniques

Socket Fusion

Butt Fusion

IR Fusion

HPF (Electrofusion), BCF & SIB

Socket Fusion

Align/Prepare Material

Insert and Heat

Join and Cool

Heater

InsertsCoupling

Material

Socket FusionLimitations

Can not be Visually Inspected from OutsideExcessive internal Cracks and CrevicesRepeatability is limitedLimited Size Ranges

Butt Fusion Theory

TIME

PRES

SUR

E

Initial Melt Pressure

Heat Soak Time & Pressure Change Over

Ramp Up Pressure

Cool Down Time

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 FusionLimitations

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

IR Fusion Theory

TIME

PRES

SUR

E

Heat Soak (Pressure of Clamps on Heater, Not Material)

Change Over

Ramp Up Pressure

Cool Down 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 inWeld Zone

Failure mode: COLD JOINT

No Materialin Weld Zone

Melt Flow IndexDefinition

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 IndexImportance 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 ResinMelt Flow Indexes for Purad by Asahi/America

Pipes 1010/0001 MFI = 4 - 7 g/10minFittings (2-1/2” - 12”) 1008/0001 MFI = 22-27 g/10minFittings (1/2” - 2”) 1009/0001 MFI = 12-16 g/10min

GF PVDF ResinMelt Flow Indexes for Sygef®

Pipes Kynar 740®

MFI = 2 - 2.5 g/10minFittings (1/2” - 9”) Solef® 1008/0001 MFI = 22-27 g/10min

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

AlignmentEnvironmentIncorrect ParametersImproper PlaningImproper 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

b1 b2

IR Weld Inspection Uniformity

Symptom: Non-uniform welding beadCause: Non-angular joining surfaces resulting in diversely built-up welding beads locally or all along the weld length, caused by improper planing or inconsistent heatingAcceptable variation of the beads = b1 0.5 x b2

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 FusionPolyPure & PP Inspection / Bead Size

2019181716151413121110987654 321 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Bea

d Si

ze (b

) mm

Wall Thickness (S) mm

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

IR Fusion UF2000 Semi-Automated Welders

UF2000-1 1/2” - 2” UF2000-2 2 1/2” - 10”

IR Fusion UF2000 Semi-Automated Welders

Programmed ParametersComputer Monitored

PressureSemi-Automated ProcessIntegrated PrinterReliable Welds

IR Fusion SP Automated Welders

SP-110 1/2” - 4” SP-250 2 1/2” - 10”

IR Fusion SP Automated Welders

Automated Fusion ProcessTouch Screen OperationControls and Monitors:

Welding ParametersHeatingJoining Force and Time

Computer MemoryEngineered 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 Coupling

Align Material

Insert Balloon

Scan Size Code

Complete Weld

HPF Fusion Result

HPF Fusion Weld Time Comparison

0

200

400

600

800

1000

1200

1/ 2" 3/ 4" 1" 1 1/ 4" 1 1/ 2" 2"

HPFwithBalloonHPFWithoutBalloonBCF

HPF Fusion Labor Comparison

Size Pipe Fittings WeldCount

½” 200’ 25 37

1’ 1000’ 75 136

1 ½” 500’ 50 81

2” 1500’ 75 166

Total Amount of Welds = 420Total Amount of Welds = 420

HPF Fusion Labor Comparison Cont.

Welding Time Time Savings (hours)

Size HPFWith

Balloon

HPFWithoutBalloon

BCF Timesavings

withballoon

TimeSavingswithoutballoon

½” 4.1 .93 6.75 3 61” 23 7.9 31 8 23

1 ½” 18 6.75 24 6 172” 45 16 48 3 32

Total 90.1 32 109.75 20 78

IR Fusion Sample QA Log

Date:Operator:Machine Type:Machine SN#:Coupon Material PVDF PP PPn E-CTFE PFA

Size½” (20mm)¾” (25mm)1” (32mm)

1 ¼” (40mm)1 ½” (50mm)

2” (63mm)3” (90mm)

4” (110mm)

Inspector:Print Name Signature Date

Place WeldCoupon Labels

Here

HP SystemsThank You