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High Purity Systems

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High Purity Systems. Welding and Inspection. Seminar. Presented by: Roger Govaert. Asahi/America Inc. Welding Techniques. Socket Fusion. Butt Fusion. IR Fusion. HPF ... – PowerPoint PPT presentation

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Title: High Purity Systems


1
High Purity Systems
  • Welding and Inspection
  • Seminar

Presented by Roger Govaert Asahi/America Inc.
2
Welding Techniques
  • Socket Fusion
  • Butt Fusion
  • IR Fusion
  • HPF (Electrofusion), BCF SIB

3
Socket Fusion
Heater
Material
  • Align/Prepare Material
  • Insert and Heat
  • Join and Cool

Inserts
Coupling
4
Socket FusionLimitations
  • Can not be Visually Inspected from Outside
  • Excessive internal Cracks and Crevices
  • Repeatability is limited
  • Limited Size Ranges

5
Butt Fusion Theory
Cool Down Time
Initial Melt Pressure
PRESSURE
Ramp Up Pressure
Change Over
Heat Soak Time Pressure
TIME
6
Butt Fusion Process
  • Plane Material
  • Align Material
  • Apply Heat
  • Join Material

7
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

8
Butt Fusion Result
9
Butt FusionLimitations
  • Material in Contact with Heating
    ElementPossible Source of Contamination
  • Smaller Crevice/Bead than Socket Fusion, but not
    small as possible

10
IR Fusion Theory
Heat Soak (Pressure of Clamps on Heater, Not
Material)
Cool Down Time
PRESSURE
Ramp Up Pressure
Change Over
TIME
11
IR Fusion Theory
  • Plane Material
  • Align Material
  • Apply Heat
  • Join Material

12
IR Fusion Result
13
Butt IR Fusion Importance of Pressure Control
No Material in Weld Zone
Failure mode COLD JOINT
14
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

15
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

16
Solef HP PVDF ResinMelt 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

17
GF PVDF ResinMelt Flow Indexes for Sygef
  • Pipes Kynar 740
  • MFI 2 - 2.5 g/10min
  • Fittings (1/2 - 9) Solef 1008/0001
  • MFI 22-27 g/10min

18
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

19
IR Weld Inspection Common Causes for Failure
  • Alignment
  • Environment
  • Incorrect Parameters
  • Improper Planing
  • Improper Joining

20
IR Weld Inspection Alignment
  • Symptom Joining Areas are offset by greater than
    10 of wall thickness.
  • Cause Misalignment, lack of alignment control or
    inspection

21
IR Weld Inspection Misalignment
  • Symptom Angular Deviation
  • Cause - Faulty Alignment- Improper Planing-
    Improper Clamping

22
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

23
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 b1 ³ 0.5 x b2

24
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

25
IR FusionPolyPure PP Inspection / Bead Size
Allowable bead size as measured on outside
bead (recommendation - only)
26
IR Fusion UF2000 Semi-Automated Welders
  • UF2000-1 1/2 - 2 UF2000-2 2 1/2 - 10

27
IR Fusion UF2000 Semi-Automated Welders
  • Programmed Parameters
  • Computer Monitored Pressure
  • Semi-Automated Process
  • Integrated Printer
  • Reliable Welds

28
IR Fusion SP Automated Welders
  • SP-110 1/2 - 4 SP-250 2 1/2
    - 10

29
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

30
IR Fusion SP Automated Welders
  • Touch Screen Control

31
IR Fusion SP Automated Welders
  • Weld Info Documentation

32
IR Fusion SP Automated Welders
  • Magnetic Clamps

33
IR Fusion SP Automated Welders
  • Quick Easy Alignment Control

34
IR Fusion SP Automated Welders
  • Quality, Uniform Welds

35
HPF Fusion Theory
36
HPF Fusion Process
  • Plane Material
  • Insert Coupling
  • Align Material
  • Insert Balloon
  • Scan Size Code
  • Complete Weld

37
HPF Fusion Result
Without Balloon
With Balloon
38
HPF Fusion Weld Time Comparison
39
HPF Fusion Labor Comparison
Total Amount of Welds 420
40
HPF Fusion Labor Comparison Cont.
41
IR Fusion Sample QA Log
42
HP SystemsThank You
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