High Purity Systems

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High Purity Systems

• Welding and Inspection
• Seminar

Presented by Roger Govaert Asahi/America Inc.
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Welding Techniques

• Socket Fusion
• Butt Fusion
• IR Fusion
• HPF (Electrofusion), BCF SIB

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Socket Fusion
Heater
Material

• Align/Prepare Material
• Insert and Heat
• Join and Cool

Inserts
Coupling
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Socket FusionLimitations

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

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Butt Fusion Theory
Cool Down Time
Initial Melt Pressure
PRESSURE
Ramp Up Pressure
Change Over
Heat Soak Time Pressure
TIME
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Butt Fusion Process

• Plane Material
• Align Material

• Apply Heat
• Join Material

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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

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Butt Fusion Result
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Butt FusionLimitations

• Material in Contact with Heating
  ElementPossible Source of Contamination
• Smaller Crevice/Bead than Socket Fusion, but not
  small as possible

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IR Fusion Theory
Heat Soak (Pressure of Clamps on Heater, Not
Material)
Cool Down Time
PRESSURE
Ramp Up Pressure
Change Over
TIME
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IR Fusion Theory

• Plane Material
• Align Material

• Apply Heat
• Join Material

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IR Fusion Result
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Butt IR Fusion Importance of Pressure Control
No Material in Weld Zone
Failure mode COLD JOINT
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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

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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

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Solef HP PVDF ResinMelt 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

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GF PVDF ResinMelt 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

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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

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IR Weld Inspection Common Causes for Failure

• Alignment
• Environment
• Incorrect Parameters
• Improper Planing
• Improper Joining

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IR Weld Inspection Alignment

• Symptom Joining Areas are offset by greater than
  10 of wall thickness.
• Cause Misalignment, lack of alignment control or
  inspection

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IR Weld Inspection Misalignment

• Symptom Angular Deviation
• Cause - Faulty Alignment- Improper Planing-
  Improper Clamping

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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

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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 ³ 0.5 x b2

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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

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IR FusionPolyPure PP Inspection / Bead Size
Allowable bead size as measured on outside
bead (recommendation - only)
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IR Fusion UF2000 Semi-Automated Welders

• UF2000-1 1/2 - 2 UF2000-2 2 1/2 - 10

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IR Fusion UF2000 Semi-Automated Welders

• Programmed Parameters
• Computer Monitored Pressure
• Semi-Automated Process
• Integrated Printer
• Reliable Welds

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IR Fusion SP Automated Welders

• SP-110 1/2 - 4 SP-250 2 1/2
  - 10

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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

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IR Fusion SP Automated Welders

• Touch Screen Control

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IR Fusion SP Automated Welders

• Weld Info Documentation

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IR Fusion SP Automated Welders

• Magnetic Clamps

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IR Fusion SP Automated Welders

• Quick Easy Alignment Control

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IR Fusion SP Automated Welders

• Quality, Uniform Welds

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HPF Fusion Theory
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HPF Fusion Process

• Plane Material
• Insert Coupling
• Align Material

• Insert Balloon
• Scan Size Code
• Complete Weld

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HPF Fusion Result
Without Balloon
With Balloon
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HPF Fusion Weld Time Comparison
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HPF Fusion Labor Comparison
Total Amount of Welds 420
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HPF Fusion Labor Comparison Cont.
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IR Fusion Sample QA Log
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HP SystemsThank You