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 Align/Prepare Material Insert and Heat Join and Cool Heater Inserts Coupling Material

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

Butt Fusion Theory TIME PRESSURE 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 Fusion Limitations 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 PRESSURE 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 in Weld Zone Failure mode: COLD JOINT No Material in Weld Zone

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

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

Solef ® HP PVDF Resin Melt Flow Indexes for Purad by Asahi/America Pipes 1010/0001 MFI = g/10min Fittings (2-1/2” - 12”) 1008/0001 MFI = g/10min Fittings (1/2” - 2”) 1009/0001 MFI = g/10min

GF PVDF Resin Melt Flow Indexes for Sygef ® Pipes Kynar 740 ® MFI = g/10min Fittings (1/2” - 9”) Solef ® 1008/0001 MFI = 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 Alignment Environment Incorrect Parameters Improper Planing Improper 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

b1b1 b2b2 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 = b 1  0.5 x b 2

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 Fusion PolyPure & PP Inspection / Bead Size Allowable bead size as measured on outside bead (recommendation - only)

IR Fusion UF2000 Semi-Automated Welders UF /2” - 2” UF /2” - 10”

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

IR Fusion SP Automated Welders SP-110 1/2” - 4” SP /2” - 10”

IR Fusion SP Automated Welders F Automated Fusion Process F Touch Screen Operation F Controls and Monitors: F Welding Parameters F Heating F Joining Force and Time F Computer Memory F Engineered 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

HPF Fusion Labor Comparison Total Amount of Welds = 420

HPF Fusion Labor Comparison Cont.

IR Fusion Sample QA Log

HP Systems Thank You