FUSION WELDING MATT W. BAKER STEPHEN G. HLOPICK SCOTT J. MORAVEK ELECTROFUSION SIDEWINDER BUTT FUSION

PURPOSE Also known as “hot plate welding” Fusion welding is intended to mechanically bond plastic Uses thermoplastic properties Ability to be re-melted and re-solidified

OUTLINE Introduction Definition Basic Operation Types & Equipment Materials Areas of Use Advantages/Disadvantages Conclusion

INTRODUCTION Wide variety of applications Creates a very strong bond Plumbing Piping Plastic Repair Creates a very strong bond

DEFINITION Fusion – the act or process of liquefying or rendering plastic by heat. Welding – to unite two parts by heating and allowing to flow together.

BASIC OPERATION Prepare/clean surfaces to be joined Heat surfaces Apply pressure to interface to ensure bonding

TYPES Butt Fusion Socket Fusion Infrared Fusion Bead & Crevice-Free Joining Electrofusion Joining

BUTT FUSION Hot plate used to heat surfaces Plate is typically aluminum Large OD possible Up to 120 in. Weld is stronger than part Animation http://www.mcelroymfg.com/fusion/flash/fusion101.html

EQUIPMENT

SOCKET FUSION A metal fitting is used as a heating source Heats the inside and outside of connection Similar to butt welding Limited to small OD pipe Up to 4 in. Used on the job site Small equipment is easy to use Popular method of welding

EQUIPMENT

INFRARED FUSION Uses IR radiant heat to fuse the pipe and fitting together The pipe never touches the heating surface Purer, non-contaminated end-product Smaller uniform weld bead Highly computerized, eliminating error

EQUIPMENT

BEAD & CREVICE-FREE JOINING Used with: Semiconductors Biotechnical Food and beverage industries Creates a beadless, crevice-free joint Aesthetic reasons Electrical uniformity

EQUIPMENT

ELECTROFUSION JOINING Easy to operate Can be taken to the job site Fail-safe operation Senses resistance and continuity Temperature sensor Supplies necessary energy Multiple fusion capability Up to 8 joints

EQUIPMENT

TYPES OF MATERIAL Polypropylene (PP) Polyethylene (PE) Polyvinyl Chloride (PVC) Chlorinated Polyvinyl Chloride (CPVC) Polyvinylidene Fluoride (PVDF) NOTE: Mating materials must have Basic compatibility Similar melt temperatures Similar flow characteristics

AREAS OF USE Waste Water Potable Water Hazardous/Corrosive Fluid Oil Thermoplastic Repair Piping Waste Water Potable Water Hazardous/Corrosive Fluid Oil Natural Gas Thermoplastic Repair

ADVANTAGES Water and air tight seal Permanent and strong seal Stronger than main part Elimination of extraneous parts/adhesives Final product can be easily recycled Convenient use Consistent final product Easy to operate

DISADVANTAGES Limited material selection Cost of equipment Equipment availability Time to weld i.e. 1 ½ to 2 minutes per inch of diameter for a butt weld

CONCLUSION Fusion welding produces a high quality joint with exceptional strength Available for a broad range of applications. Feel free to ask questions now!