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

2. 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

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

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

5. 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.

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

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

8. 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

9. EQUIPMENT

10. 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

11. EQUIPMENT

12. 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

13. EQUIPMENT

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

15. EQUIPMENT

16. 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

17. EQUIPMENT

18. 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

19. 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

20. 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

21. 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

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