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High Purity Systems

Welding Techniques. Socket Fusion Butt Fusion IR Fusion HPF (Electrofusion), BCF

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High Purity Systems

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Presentation Transcript

    1. High Purity Systems Welding and Inspection Seminar

    2. Welding Techniques Socket Fusion Butt Fusion IR Fusion HPF (Electrofusion), BCF & SIB

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

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

    5. Butt Fusion Theory

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

    10. IR Fusion Theory

    11. IR Fusion Theory Plane Material Align Material Apply Heat Join Material

    12. IR Fusion Result

    13. Butt & IR Fusion Importance of Pressure Control

    14. 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

    15. 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

    16. 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

    17. GF PVDF Resin Melt 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 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

    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

    38. HPF Fusion Weld Time Comparison

    39. HPF Fusion Labor Comparison

    40. HPF Fusion Labor Comparison Cont.

    41. IR Fusion Sample QA Log

    42. HP Systems Thank You

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