Title: High Purity Systems
1High Purity Systems
- Welding and Inspection
- Seminar
Presented by Roger Govaert Asahi/America Inc.
2Welding Techniques
- Socket Fusion
- Butt Fusion
- IR Fusion
- HPF (Electrofusion), BCF SIB
3Socket Fusion
Heater
Material
- Align/Prepare Material
- Insert and Heat
- Join and Cool
Inserts
Coupling
4Socket FusionLimitations
- Can not be Visually Inspected from Outside
- Excessive internal Cracks and Crevices
- Repeatability is limited
- Limited Size Ranges
5Butt Fusion Theory
Cool Down Time
Initial Melt Pressure
PRESSURE
Ramp Up Pressure
Change Over
Heat Soak Time Pressure
TIME
6Butt Fusion Process
- Plane Material
- Align Material
7Butt 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
8Butt Fusion Result
9Butt FusionLimitations
- Material in Contact with Heating
ElementPossible Source of Contamination - Smaller Crevice/Bead than Socket Fusion, but not
small as possible
10IR Fusion Theory
Heat Soak (Pressure of Clamps on Heater, Not
Material)
Cool Down Time
PRESSURE
Ramp Up Pressure
Change Over
TIME
11IR Fusion Theory
- Plane Material
- Align Material
12IR Fusion Result
13Butt IR Fusion Importance of Pressure Control
No Material in Weld Zone
Failure mode COLD JOINT
14Melt 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
15Melt 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
16Solef 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
17GF 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
18PolyPure 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
19IR Weld Inspection Common Causes for Failure
- Alignment
- Environment
- Incorrect Parameters
- Improper Planing
- Improper Joining
20IR Weld Inspection Alignment
- Symptom Joining Areas are offset by greater than
10 of wall thickness. - Cause Misalignment, lack of alignment control or
inspection
21IR Weld Inspection Misalignment
- Symptom Angular Deviation
- Cause - Faulty Alignment- Improper Planing-
Improper Clamping
22IR 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
23IR 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
24IR 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
25IR FusionPolyPure PP Inspection / Bead Size
Allowable bead size as measured on outside
bead (recommendation - only)
26IR Fusion UF2000 Semi-Automated Welders
- UF2000-1 1/2 - 2 UF2000-2 2 1/2 - 10
27IR Fusion UF2000 Semi-Automated Welders
- Programmed Parameters
- Computer Monitored Pressure
- Semi-Automated Process
- Integrated Printer
- Reliable Welds
28IR Fusion SP Automated Welders
- SP-110 1/2 - 4 SP-250 2 1/2
- 10
29IR 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
30IR Fusion SP Automated Welders
31IR Fusion SP Automated Welders
32IR Fusion SP Automated Welders
33IR Fusion SP Automated Welders
- Quick Easy Alignment Control
34IR Fusion SP Automated Welders
35HPF Fusion Theory
36HPF Fusion Process
- Plane Material
- Insert Coupling
- Align Material
- Insert Balloon
- Scan Size Code
- Complete Weld
37HPF Fusion Result
Without Balloon
With Balloon
38HPF Fusion Weld Time Comparison
39HPF Fusion Labor Comparison
Total Amount of Welds 420
40HPF Fusion Labor Comparison Cont.
41IR Fusion Sample QA Log
42HP SystemsThank You