high purity systems
DESCRIPTION
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. Material. Align/Prepare Material Insert and Heat Join and Cool. - PowerPoint PPT PresentationTRANSCRIPT
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