Dvs 2207
Dvs 2207
Dvs 2207
2006
Letzte Änderung: 05.06.2007
File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\e2207-1\e2207-1.fm
August 2007
fittings and sheets Within the framework of the quality assurance it is recommended
4.1.1 Description of the process to produce and test samples of joints before and during welding.
4.1.2 Preparation of welding
4.1.3 Welding procedure Every welder has to be trained and has to be in possession of a
4.2 Heated tool welding of tapping tees valid qualification certificate. The intended application range may
4.2.1 Description of the process be decisive for the kind of qualification. For the heated tool butt
4.2.2 Preparation of welding welding of sheets as well as in the industrial piping system
4.2.3 Welding procedure construction, the technical code DVS 2212-1 is valid. The
5 Electro-socket welding DVGW-specification GW 330 applies analogously as qualification
5.1 Description of the process proof for heated tool butt and heated tool socket welding at the
5.2 Welding device construction of gas and water supply systems. The welding of
5.3 Preparation of welding plastics for indoor applications is described in the technical codes
5.4 Welding procedure DVS 1905-1 and -2.
6 Heated tool socket welding The equipment and devices which are used for welding must
6.1 Description of the process comply with the requirements in DVS 2208-1.
6.2 Welding devices
6.3 Preparation of welding
6.4 Welding procedure 3 Measures before welding
7 Testing of welded joints
8 Standards and directives 3.1 Requirements for welding
9 Explanations
The welding zone must be protected against bad weather
Appendix:
influences (e.g. wind, moisture). If it is ensured by suitable
Processing instructions (short versions)
measures (e.g. preheating, tent, heating) that the conditions are
Testing of welded joints
suitable for welding, work may be carried out at any outside
Welding protocols
temperature insofar as the welder is not hindered in his handling
(see explanation). If necessary, an additional proof must be
1 Scope provided by carrying out sample welds under the mentioned
conditions (section 7).
This technical code applies to the heated tool butt welding of
sheets according to DIN EN ISO 14632 and for the heated tool If the semi-finished product is heated up unevenly under
butt-, the heated tool socket- and the electro-socket welding of influence of sunshine, a temperature compensation in the area of
pipes, fittings and tapping tees made from PE-HD1) according to the welding joint can be reached by covering. A cooling down
DIN 8074 and 8075, DIN 16 963, DIN 3543-4 and DIN 3544-1, during the welding process by ventilation has to be avoided.
being used for the conduction of gas, fluids and solids. During welding the pipe ends have to be closed additionally.
With regard to the following instructions, suitability within the melt PE-HD-pipes from coils are oval and bent immediately after
flow rates MFR2) 190/5 of 0,3 up to 1,7 g/10 min or 0,2 up to 0,7 uncoiling. The pipe end must be prepared before welding, e.g. by
g/10 min respective may be assumed. For the heated tool butt careful heating up with a hot-air equipment and/or use of a
welding of tapping tees restrictions according to section 4.2 have suitable clamping res. re-rounding device.
to be attended.
The joining zones of the components to be welded must be
Deviating MFR values require an additional proof by tensile creep undamaged and have to be free of contaminations (e.g. dirt,
tests according to DVS 2203-4 or supplement 1. grease, shavings).
The material indication is the specification of thermoplastics group and includes the types PE 63, PE 80 and PE 100. The information complies to the
current standards.
old indication MFI = Melt Flow Index
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
322
Page 2 to DVS 2207-1
4.1.1 Description of the process 400 ... < 630 1,0 ≤ 1500
With the heated tool butt welding process, the joining zones of 630 ... < 800 1,3 > 1500 ≤ 2000
the components to be welded are aligned under pressure on the
heated tool (alignment), heated up to the welding temperature 800 ... ≤ 1000 1,5 > 2000 ≤ 2300
with reduced pressure (heating up) and joined under pressure
> 1000 2,0 > 2300 ≤ 3000
(joining) after removal of the heated tool (changeover). Figure 1
shows the principle of this procedure.
Both, the gap width and the misalignment have to be controlled.
The misalignment of the joining areas on the pipe outside or
sheet respectively may not exceed the permissible size of 0,1 x
wall thickness. A reduction of the quality arises in case of larger
misalignment which limits the strength of the joint. In this case,
the evaluation according to DVS 2202-1 under consideration of
requirements to the joint can be done.
The treated welding areas should be neither dirtied nor touched
by hand, as a retreatment would be necessary then. An
additional cleaning is not necessary and means no quality
improvement. Shavings fallen into the pipe have to be removed.
323
Page 3 to DVS 2207-1
Table 2. Recommended values for the heated tool butt welding of pipes, fittings and sheets made of PE-HD at an outside temperature of
approx. 20 °C and moderate air flow (interim values have to be interpolated).
1 2 3 4 5
Nominal wall Alignment Heating-up Changeover Joining
thickness s
Heated tool temperature see figure 2 Changeover time Joining pressure Cooling time
(Maximum time) build-up time under joining pressure
Bead height on Heating-up time (minimum values)
heated tool =10 x wall
p = 0,15 N/mm2 ± 0,01
on the end of the thickness
alignment time p= ≤ 0,01 N/mm2)
(alignment p =
0,15 N/mm2)
mm mm s s s min
up to 4,5 0,5 up to 45 5 5 6
4,5 ... 7 1,0 45 ... 70 5 ... 6 5 ... 6 6 ...10
7 ... 12 1,5 70 ... 120 6 ... 8 6 ... 8 10 ...16
12 ... 19 2,0 120 ... 190 8 ... 10 8 ... 11 16 ... 24
19 ... 26 2,5 190 ... 260 10 ... 12 11 ... 14 24 ... 32
26 ... 37 3,0 260 ... 370 12 ... 16 14 ... 19 32 ... 45
37 ... 50 3,5 370 ... 500 16 ... 20 19 ... 25 45 ... 60
50 ... 70 4,0 500 ... 700 20 ... 25 25 ... 35 60 ... 80
324
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After the joining, a uniform double-bead must appear. The bead heating-up is reduced to ≤ 0,01 N/mm2 during the now starting
size shows the regularity of the welds. Different beads could be heating-up time. The heating time depends on data provided by
caused by different melt flow behaviour of the joined materials. the manufacturer of the fitting. When the heating time has
Based on the experience with commercial semi-finished products elapsed the shaped heating tool is to be withdrawn without
325
Page 5 to DVS 2207-1
For axial pipe connections the pipes have to be cut rectangular welding process it runs automatically. The welding time is usually
by means of a suitable device. In case of a bevelled shrinkage of shown on the welding equipment. It has to be transferred to the
the pipe cut edge the un-treated pipe has to show the nominal welding protocol as well as other data from the welding machine,
diameter d (figure 6) at the designated insert depth minimum in if no data recording is done.
5.4 Welding procedure The heated tools are heated electrically and are coated anti-
adhesively.
The correct insert depth has to be controlled by means of the
mark. The components to be welded should be secured against 6.3 Preparation of welding
dislocation.
The fitting has to be cleaned inside and outside according to
The welding equipment is connected by a cable with the part to section 3.2.3. The treatment of the joining areas of the welding
be welded. The welding cable has to be placed without weight components should take place immediately before welding is
loaded. The contact areas must be clean. The required data of started. The pipe end has to be bevelled according to figure 8
the fitting or tapping tee for the welding process are taken and table 4. The joining area of the pipe is to be treated
automatically from the welding equipment by scanning the according to the manufacturers guidelines. Concerning manual
specific component barcode. The shown data (e.g. dimension) welds the insert depth is to be marked on the pipe with distance I
have to comply with the component data. After starting the according to table 4.
326
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25 16
2 7 Testing of welded joints
32 18
40 20 Various tests can be used to test the quality of individual welding
processes. Differentiation is made between destructive and non-
50 23 destructive tests. For details see table 6. Tests and sampling can
63 27 be carried out prior to or during welding work according to
agreement.
75 31
90 3 35
110 41
125 46
Table 5. Recommended values for the heated tool socket welding of pipes and pipeline components made of PE-HD at outside temperature of
20 °C and moderate air flow.
1 2 3 4 5
Pipe outside Heating-up Changeover Cooling
diameter d
Heated tool temperature 250 up to 270 °C
Heating up time for Heating up time for Changeover time Cooling time
SDR2) 11, SDR 7,4, SDR 6 SDR2) 17, SDR 17,6 (Maximum time)
fixed total
mm s s s s min
16
5 6
20 4 2
25 7
1)
10
32 8
40 12 6 4
20
50 18
63 24
30
75 30 18 8 6
90 40 26 40
110 50 36 50
10 8
125 60 42 60
1) Due to the low wall thickness this welding method is not recommended.
2) Standard Dimension Ratio ~ d/s (ratio outside diameter / wall thickness).
327
Page 7 to DVS 2207-1
Test method Heated tool butt welding Electro socket welding Heated tool socket welding
8 Standards and technical codes DIN EN ISO Thermoplastic piping systems for industrial
15494 applications; Polybutene (PB), Polyethylene
DIN 3543-4 Tapping tee fittings made from rigid PE for (PE), Polypropylene (PP); Requirements to
pipes made from rigid PE; dimensions pipeline components and to the piping system;
DIN 3544-1 Fittings made from rigid PE, type 1 and 2, Metric sizes
requirements and testing of tapping tee fittings DIN 16 963 Pipe joints and pipeline components for pres-
DIN 8074 Pipes made from polyethylene (PE); PE 63, sure pipelines made from polyethylene high
PE 80, PE 100, PE-HD; dimensions density (PE-HD)
DIN 8075 Pipes made from polyethylene (PE); PE 63, DIN 19537 Pipes and fittings made from polyethylene high
PE 80, PE 100, PE-HD; General quality requi- density (PE-HD) for sewage channels and
rements, testing pipelines ;
DIN EN ISO Thermoplastics; Polyethylene (PE)-moulding -1 –, dimensions
1872-1 materials; designation systems and basics for -2 –, technical delivery conditions
specifications
DVGW GW 330 Welding of pipes and pipeline components
DIN EN 12814-4 Testing of welding joints made from thermopla- made from polyethylene (PE80, PE 100 and
stics; Part 4: Peeling test PE-Xa) for gas- and water system welders;
DIN EN ISO Extruded sheets made from polyethylene (PE- Training and testing scheme
14632 HD); Requirements and test methods DVGW GW 331 Supervisor for welding of pipelines made from
PE-HD for gas and water supply; Training and
testing scheme
328
Page 8 to DVS 2207-1
DVGW VP 603 Preliminary test basis for cleaning agents and 6. Take off the planing tool at the pipe welding machine.
their tanks for the preparation of welding joints
on polyethylene pipes 7. Remove shavings from the welding area without touching
the joining zones.
Ad 4.1 Heated tool butt welding of pipes, pipeline compon- 5. Clean the joining areas even outside of the welding zone by
ents, fittings and sheets means of cleaning agents according to sections 3.2.1 and
3.2.3 with unused, absorbent, non-fuzzy and non-coloured
Processing instruction (short version) paper. Machine the pipe surface.
1. Establish acceptable working conditions, e.g. welding tent 6. Remove shavings from the welding area without touching
the joining zones.
2. Connect the welding equipment to the mains or alternating
7. Control the surface fit of the tapping tee.
current generator and control the function.
8. Fix the welding equipment onto the pipe.
3. Adjust and clamp the parts to be welded, e.g. by dollies.
9. Clamp and adjust the tapping tee.
4. Close the pipe ends against air movement.
10. Choose the correctly shaped heated tool.
5. Clean the joining areas even outside of the welding zone by
means of cleaning agents according to sections 3.2.1 and 11. Clean the connection surfaces –if contaminated – and the
3.2.3 with unused, absorbent, non-fuzzy and non-coloured heated tool according to sections 3.2.1, 3.2.2 and 3.2.3 by
paper. means of unused and absorbent, non-fuzzy and non-
Machine the joining zones, at pipes e.g. with planing tool. coloured paper and exhaust it.
329
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12. Determine forces for alignment and joining (table of Ad 6 Heated tool socket welding
manufacturer).
Processing instruction (short version)
13. Check the welding temperature (200 up to 220 °C).
17. Withdraw the connection areas to be welded from the 4. Check the welding temperature (250 up to 270 °C).
heated tool after heating-up time is finished and bring them 5. Clean all non-treated joining areas with a cleaning agent
into welding position. according to sections 3.2.1 and 3.2.3 with unused,
absorbent, non-fuzzy and non-coloured paper and exhaust
18. The joining areas should be joined together within the
it.
changeover time of maximum 10 seconds.
6. Machine the rectangular cut pipe end according to figure 8
19. Build-up joining pressure speedy and smooth within 5 and table 4 or according to the fitting manufacturer
seconds. instruction. If necessary mark the insert depth.
20. Cooling down under joining pressure, minimum 15 minutes. 7. Insert the fitting and pipe simultaneously into the heating
spigot / the heating socket till the stop / mark. The pipe end
21. Declamping of the welded parts after cooling time.
may not contact the end of the heating socket.
22. Complete the welding protocol. 8. Observe the heating-up time according to table 5, column 2.
9. Pull off the fitting and pipe and push them swiftly and axially
Ad 5.3 Electro-socket welding of fittings and tapping tees together to the stop / mark (maximum changeover time see
table 5, column 3) and fix this position (see table 5, column
4).
Processing instruction (short version)
10. Cool down the connection. Mechanical load of the
1. Establish acceptable working conditions, e.g. welding tent. connection only after finished cooling time according to table
2. Connect the welding unit to the mains or the alternating 5, column 5.
current generator and check function. 11. Complete the welding protocol.
3. Deburr the outside of the rectangular cut pipe end. Shorten
the pipe in case of too much pipe end shrinkage. See figure Ad 7 Testing of welded joints
6.
4. Ensure that pipe ends are round using re-rounding clamps, The torsion shear test and radial peeling test are applicable for a
permitted ovality up to ≤ 1,5 %, max. 3 mm. quick check of the welding quality of PE-HD pipe connections.
The wall thickness of the pipe should be ≥ 4 mm.
5. Clean the joining areas even outside of the welding zone by
means of cleaning agents according to sections 3.2.1 and
3.2.3 with unused, absorbent, non-fuzzy and non-coloured
paper. Machine the pipe surface in the welding area if
possible with a scraping tool and wall thickness removal of
approx. 0,2 mm. Remove the shavings without touching the
pipe surface.
6. Clean the treated pipe surface – if contaminated and if
necessary, according to manufacturers instructions, also the
inside of the fitting – with a cleaning agent according to
sections 3.2.1 and 3.2.3 with unused, absorbent, non-fuzzy
and non-coloured paper and exhaust it.
7. Insert the pipes into the fitting and control the insert depth by
means of the mark or suitable device. Fix the tapping tee on
the pipe. Take care for low stress installation. Secure the
pipe against dislocation.
8. Connect cable to fitting. Cable must be free of weight load.
Figure 9. Test sample from electro-socket or heated socket welding
9. Enter welding data e.g. by means of barcode scanner, joint.
check the displayed data on the equipment and start the
welding process. Four test specimen are evenly removed from the whole
circumference by longitudinal spacing. The contact sockets have
10. Control the correct welding procedure on the welding to be omitted at electro-socket welding. The dimensions are:
equipment e.g. by control of the display information and if
Test specimen length = socket length + 2 x 200 mm pipe length
available with the welding indicators. Consider error
messages. Test sample length = socket length + 2 x ≈ 10 mm pipe length
11. Disconnect cable from fitting. Test sample width b = 3 up to 6 mm at pipe wall thickness
≤ 10 mm
12. Declamping of the welded parts after cooling time. Remove b = 5 up to 6 mm at pipe wall thickness
fixing device. > 10 mm
13. Complete the welding protocol form if no automatic protocol Torsion shear test: The torsion shear test is used for the
is made. evaluation of the fracture behaviour and the fracture appearance
330
Page 10 to DVS 2207-1
of the welding joint. For this purpose the test sample (see figure Evaluation is done according to table 7.
9) is fixed completely in a bench vice with one part e.g. socket
cross section. The other part e.g. pipe cross section, is caught Radial peeling test: For this test the pipe cross section of the test
with a suitable tool and twisted for 90° in the welding section (see sample (see figure 9) which is fixed by the socket cross section in
Table 7. Evaluation criteria for torsion shear and radial peeling test.
331
332
Protocol form for the Heated tool butt welding of pipes o laid overground Material Sheet of
1 = sunny 1 = none
No. of order Name and company of the welding Machine No.: 4 = windy 4 = heating
supervisor
Year of construction: Order as above in case of multiple nominations
(e. g. 34 = rain and wind)
Weld Date pipe checked workpiece Joining Set values heating-up Joining Change- Cooling Environmental Code-No. Notes
No. dimensions heated tool movin pressure time pressure over time time under temperature
ød×s temperature pressure (data of heating up alignment build-up joining Weather Preventive
manufacturer) joining time pressure measures
mm C min/max bar bar bar bar s s s s C
R&D INTAKE MANIFOLDS
Type:
Weid Date Sheet checked Set values heating-up Joining Changeover Cooling time Environmental Notes
No. thickness heated tool time pressure time under joining temperature
temperature alignment heating up joining build-up time pressure
mm C min/max bar bar bar s s s s C
R&D INTAKE MANIFOLDS
333
334
Protocol form for the Electrofusion welding of pipes o laid overground Material Sheet of
1 = sonny 1 = none
No. of order Name and company of the welding Machine No.: 4 = windy 4 = heating
supervisor
Year of construction: Order as above in case of multiple nominations
(e. g. 34 = rain and wind)
Weld Date pipe Fitting data Unit setting Resistance Secondary Welding times Environmental Code-No. Operating mode
No. dimension of the fitting voltage temperature
ød×s A B Serial No. manual automatic joining Cooling Weather Preventive Mains Gene-
mm Ohm Volt s s C measures rator
R&D INTAKE MANIFOLDS
Enter where applicable according to system used. A = Manufacturer’s code 1 = Coupler 2 = Angle 3 = T-piece 4 = Reduction
Enter measured values. B = Fitting code 5 = Saddle 6 = Cap 7 = Connecting piece 8 = Fitting
Page 13 to DVS 2207-1
Protocol form for the Heated tool socket welding of o laid overground Material Sheet of
1 = sonny 1 = none
Page 14 to DVS 2207-1
No. of order Name and company of the welding Machine No.: 4 = windy 4 = heating
supervisor
Year of construction: Order as above in case of multiple nominations
(e. g. 34 = rain and wind)
Weld Date pipe Fitting data checked tem- heating up Change- Cooling Environmental Code-No. Notes
No. dimensions perature on time over time temperature
ød×s A B Batch-No. heated spigot Cooling time Colling Weather Preventive
and socket (pie and time measures
coupler fixed) (total)
mm C s s s min C
R&D INTAKE MANIFOLDS
These data is to be completed by agreement. A = Manufacturer’s code 1 = Coupler 2 = Angle 3 = T-piece 4 = Reduction
Enter measured values. B = Fitting code 5 = Cap 6 = Connecting piece 7 = Fitting
335
Erstellungsdatum: 20.07.2007
Letzte Änderung: 20.07.2007
File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-1-Bb1.fm
Oktober 2007
7 Other applicable standards and technical codes qualification proof for heated tool socket welding at the
8 Explanations construction of gas and water supply systems. The specification
Appendix: can in turn be used as a proof of qualification for welding plastics
Brief instructions for welding for indoor applications.
Testing of welded joints
Welding record sheets The equipment and devices which are used for welding must
correspond to the requirements in DVS 2208-1.
1 Scope
3 Measures before welding
This technical code applies for the electro socket-welding of
fittings and tapping tees made of PE-HD1) according to DIN The welding zone must be protected against bad weather
16963, DIN 3543-4 and DIN 3544-1 with pipes made of PE-Xa influences (e.g. wind, moisture). If it is ensured by suitable
(degree of cross-linking 75% to 90%) and PE-Xc (degree of measures (e.g. preheating, tent, heating) that the conditions are
cross-linking 60% to 75%) according to DIN 16892/93, that are suitable for welding, work may be carried out at any outside
being used for the conduction of gas, fluids and solids. temperature insofar as the welder is not hindered in his handling
The electro socket-welding of PE-HD fittings with pipes made of (see explanation). If necessary, an additional proof must be
PE-Xa or PE-Xc requires an additional proof by tensile creep provided by carrying out sample welds under the mentioned
tests according to DVS 2203-4 Supplement 1. conditions (section 7).
The maximum load of joints made with fittings of PE 80 and PE If the semi-finished product is heated up unevenly under
100 corresponds with the allowed operating pressure according influence of sunshine, a temperature compensation in the area of
to tables 8 to 13 in DIN 8074 and DIN 16893. the welding joint can be reached by covering. A cooling down
during the welding process by ventilation has to be avoided by
closing the pipe-ends during welding. During the welding the pipe
2 General requirements ends have to be closed additionally.
The quality of welding joints depends on the qualification of the PE-HD-pipes from coils are oval and bent immediately after
welder, the suitability of the utilized equipment and devices as uncoiling. The pipe end must be prepared before welding, e.g. by
well as on compliance with the welding standards. The welded careful heating up with a hot-air equipment and/or use of a
joint can be tested by means of non-destructive and/or suitable clamping or re-rounding device.
destructive methods.
The joining zones of the components to be welded must be
The welding work must be monitored. Type and range of undamaged and have to be free of contaminations (e.g. dirt,
supervising has to be agreed between the contract partners. It is grease, shavings).
The material indication is the specification of thermoplastics group and includes the types PE 63, PE 80 and PE 100. The information complies to the
current standards.
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
336
Page 2 to DVS 2207-1 Supplement 1
4 Electro-socket welding
The ovality of the pipe may exceed 1,5% of the outside diameter,
max. 3 mm. If necessary, re-rounding devices can be used.
The surface of the pipe or fitting in the welding zone has to be
completely machined. A scraping tool with a constant wall
thickness removal of approx. 0,2 mm must be used. Take care
Figure 1. Electro-socket welding of a coupler (principle). for a small annular gap!
The pipe end has to be deburred inside and outside, shavings
have to be removed without contacting the joining areas.
The fitting may only be removed from the protective package
immediately before the installation.
The treatment of the joining areas has to be done immediately
before the welding process starts.
In case of contamination of the pipe surface after machining it
must be cleaned. It has to be considered that no contamination is
rubbed to the welding zone. The cleaning agents or already
moistened cloths in a lock-up plastic box have to consist of a
100% vaporizing solvent, e.g. 99 parts ethanol with a purity grade
of 99,8% and 1 part MEK (methylethylketone, denaturation).
Agents tested according to DVGW 603 comply with this
requirement. The use of ethyl alcohol could result in a reduction
of quality because of the contained water.
The paper for cleaning has to be clean, unused, absorbent, non-
fuzzy and non-coloured. Exhaust the air afterwards.
The joining area of the fitting or tapping tee has to be cleaned
similar to the pipe.
The correct insert depth of the pipe has to be controlled by
means of a mark or suitable device. The fitting may neither be
Figure 2. Electro-socket welding of a tapping tee (principle).
tilted nor pushed onto the pipe end with force (low stress instal-
lation). The tapping fitting has to be clamped on the pipe by
4.2 Welding equipment means of a suitable device under consideration of the manu-
facturer’s instructions.
Only welding equipment adjusted to the parts to be welded may
The contact socket for the connection of the welding cable must
be used. Automatic welding equipment is preferred – possibly
be easy reachable.
with recording. The welding equipment must supply the required
welding parameters for the fitting to be welded such as welding Fitting and pipe have to show the same temperature level before
time, current and voltage. The device must switch off as soon as the welding process. Concerning welding equipment with auto-
the necessary quantity of heat has been fed to the welding zone. matic temperature compensation take care that the measured
environmental temperature corresponds to the conditions of the
4.3 Preparation of welding welding location. If necessary the welding equipment as well as
the pipe and fitting have to be protected e.g. against direct sun
Clean surfaces and a stress free installation are very important radiation.
for the fabrication of perfect welding joints. With the choice of
pipes with limited diameter tolerance according to DIN 16893 the
installation of fittings is easier.
5 Testing of welding joints
For axial pipe connections the pipes have to be cut rectangular
by means of a suitable device. In case of a bevelled shrinkage of Various tests can be used to test the quality of individual welding
the pipe cut edge the untreated pipe has to show the nominal processes. Differentiation is made between destructive and non-
diameter d (figure 3) at the designated insert depth minimum in destructive tests. For details see table 1. Tests and sampling can
the area of the heated socket. If necessary the pipe end should be carried out prior to or during welding work according to
be shortened immediately before welding. agreement.
337
Page 3 to DVS 2207-1 Supplement 1
Internal pressure creep rupture test In combination with Tensile creep test acc. to DIN 3544-1,
acc. to DIN 16963-5, section 3.2.3.1 and 4.2, sections 2.3 and 3.2
PE 80: σ=4,6 N/mm², Testing time ≥ 165 h
PE 100: σ=5,5 N/mm², Testing time ≥ 165 h
alternatively σ=5,0 N/mm², Testing time ≥ 1000 h
Testing temperature 80°C
Torsion shear test see appendix DVS 2207-1. Also applicable as site test.
Radial peeling test see appendix DVS 2207-1. Also applicable as site test.
Compression test DIN EN 12814-4, section 8.
Peeling test DIN EN 12814-4, section 7
6 standards and technical codes DVS 2207-1 Welding of thermoplastics – Heated tool
welding of pipes, pipeline components and
DIN EN 12201-3 Plastics piping systems for water supply - sheets made of PE-HD
Polyethylene (PE); Fittings
DVS 2208-1 Welding of thermoplastics; Machines and
DIN EN 12814-4 Testing of welding joints made of thermo- equipment for the heated tool welding of
plastics; Peeling test pipes, pipeline components and sheets
DIN 3543-4 Tapping tee fittings made of rigid PE for pipes DVS 2212-1 Testing of plastic welders; Test group I and II
made of rigid PE; dimensions
DVGW GW 330 Welding of pipes and pipeline components
DIN 3544-1 Fittings made of rigid PE, type 1 and 2, requi- made of polyethylene (PE80, PE 100 and PE-
rements and testing of tapping tee fittings Xa) for gas- and water system welders;
DIN 8074 Polyethylene (PE) - Pipes PE 63, PE 80, Training and testing scheme
PE 100, PE-HD – Dimensions DVGW GW 331 Supervisor for welding of pipelines made of
DIN 16892 Pipes made of cross linked polyethylene of PE-HD for gas and water supply; Training and
high density (PE-X); General quality require- testing scheme
ments, testing DVGW VP 603 Preliminary test basis for cleaning agents and
DIN 16893 Pipes made of cross linked polyethylene of their tanks for the preparation of welding joints
high density (PE-X); dimensions on polyethylene pipes
DIN 16963 Pipe joints and pipeline components for pres- Betr.Sich.V Regulation of industrial safety (Betriebssicher-
sure pipelines made of polyethylene of high heitsverordnung)
density (PE-HD)
Part 5 – General quality requirements, testing
Part 7 – Electro-socket fitting, dimensions 7 Explanation
DVS 2202-1 Failures on welded joints of thermoplastics;
features, description, evaluation Note: A Research program of the DVGW in connection with tests
by DVS showed, that fittings and tapping tees made of PE-HD
DVS 2203-1 Testing of welded joints on sheets and pipes
can be welded to pipes made of PE-Xa, using electro socket
of thermoplastics; testing methods – require-
welding. An independent test-institute analysed the same
ments
welding method with pipe made of polyethylene crosslinked by
DVS 2203-4 Testing of welded joints on sheets and pipes electron-beam (PE-Xc). The fracture pattern is similar to PE-HD/
Suppl. 1 of thermoplastics – tensile creep test; testing PE-HD and consulted as an assessment criterion.
of socket welding connections on pipes
The welding of thermoplastics at environment temperatures
below 5°C is generally problematic. This concerns less the
material specific properties of the thermoplastics but the limited
338
Page 4 to DVS 2207-1 Supplement 1
manual skill of the welder. Welding outside at any temperature 6. Clean the treated pipe surface – if contaminated and if
requires an environment which enables the welding staff to necessary, according to manufacturers instructions also the
perform the individual work steps without quality reducing inside of the fitting – with a cleaning agent according to
influences. Manufacturer’s notes and the dew point curve have to section 4.3 with unused, absorbent, non-fuzzy and non-
339
340
Protocol for electro-socket welding laid overground Material Sheet of
1 = sunny 1 = none
No. of order Name and company of welding Machine no.: 4 = wind 4 = heating
supervisor
Year of construction: in case of multiple nominations arrange numbers as above
(e.g. 34 = rain and wind)
Joint Date Pipe Fitting data Unit setting Fitting Secondary Welding times Environment Code-no. Operation mode
No. dimension resistance voltage temperature
Ød×s A B Batch no. manual automatic heating cooling Weather Preventive Mains Gene-
[mm] [Ohm] [Volt] [s] [min] [ C] measures rator
R&D INTAKE MANIFOLDS
Enter where applicable according to the used system. A = Manufacturer’s code 1 = Coupler 2 = Elbow 3 = Tee 4 = Reducer
Enter measured values. B = Fitting code 5 = Saddle 6 = Cap 7 = Transition fitting
Page 5 to DVS 2207-1 Supplement 1
Draft January 2013
This draft is being submitted to the public for examination and comments. Supplement or amendment suggestions are requested to
DVS, P.O. Box 101965, 40010 Düsseldorf.
Contents: ing) ensure the existence of conditions permissible for the weld-
ing, the work may be carried out at any outdoor temperature –
1 Scope of application provided that the dexterity of the welder is not hindered. If neces-
2 General requirements sary, additional evidence must be provided by manufacturing trial
3 Measures before the welding welds in the specified conditions.
4 Indications about the process sequence If the semi-finished product is heated non-uniformly due to solar
4.1 Temperature checking radiation, the temperatures must be equalised by covering the area
4.2 Minimise the misalignment of the joining faces of the welding point in good time. It is necessary to avoid any
4.3 Handling of the pipe trains draught-induced non-uniform cooling during the welding operation,
4.4 Removal of the welding bead
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid.
No liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
341
Page 2 to DVS 2207-1 Supplement 2
4.3 Handling of the pipe trains 4.4 Removal of the welding bead
Particular diligence is imperative when handling thick-walled com- As a rule, it is not necessary to remove the welding bead for reasons
ponents. relating to the hydraulic flow resistance or the strength. Moreover,
the removal of the welding bead makes it more difficult to evaluate
342
Erstellungsdatum: 12.06.2007
Letzte Änderung: 09.07.2007
File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-3.fm
September 2007
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
343
Page 2 to DVS 2207-3
344
Page 3 to DVS 2207-3
Table 1. Materials and seam opening angles for V and double-V welds .
Material Weld opening angle α
PE- HD(1), PP(2), PVC, PVC- C, PVDF, E/CTFE 60°-70°
MFA, FEP, PFA 0°-30° (dependent on material thickness)
(1) PE 63, PE 80, PE 100 ; (2) PP- H, PP- B, PP- R
Table 2. Examples for the weld structure dependent upon the material thickness with an opening angle of 60°.
4 per side: 1 x 4
5 per side: 3 x 3
6 per side: 3 x 3
8 per side: 1 x 3 + 2 x 4
10 per side: 6 x 3 or
per side: 1 x 3 + 3 x 4
345
Page 4 to DVS 2207-3
R&D INTAKE MANIFOLDS If the welds are produced according to this technical code, the
minimum weld quality requirements specified in DVS 2203-1
(welding factors, bending angle/distance) should be safely
achieved.
The contractor and manufacturer should agree upon and define
the specifications for the component and the welding joints in
respect of the statutory requirements for the respective
welded root finished weld application (Federal Water Management Act (WHG), European
Pressure Equipment Directive) and the required dimensioning.
Figure 5. Weld structure with a V-weld (without backing).
References and criteria for the definition of quality are included in
The layer structure is usually produced according to Table 2 and DVS 2202-1.
Fig. 5. The layer structure is to be adapted for other opening The required quality should be verified on test welds if necessary.
angles and weld geometries. If section rods or welding tapes are This particularly applies for materials for which no specifications
used, the seam geometry and welding nozzles must be adapted are stated in the aforementioned technical codes (for example
to the geometry of the welding filler. PFA, FEP, MFA, PVC-C etc.).
The weld must be filled completely and free of occlusions and
must show a weld protrusion according to DVS 2202-1. The 6.3 Requirements for welding torches and accessories
numbering of the individual rods in the table shows the Welding torches must be CE compliant, safe, functional and
recommended welding sequence. suitable for the welding task. This also applies for accessories,
such as nozzles, temperature probes etc.
6 Requirements Special requirements for the equipment are described in
Supplement 2 of this technical code.
6.1 Requirements for the materials and their weldability
6.4 Requirements for welders
Semi-finished products and welding fillers must be suitable for
hot gas welding. For welding joints to be compliant with DVS Hot gas welding is a welding technique demanding extensive
2203, a welding filler should be used which is the same as the knowledge of the materials to be welded and the operation of
base material, or at least of the same type. equipment, as well as a high level of workmanship skills.
The melt index is used as a characteristic parameter for The welder must have passed an examination corresponding to
weldability in the case of partially crystalline materials, such as DVS 2212-1 and be in possession of a valid examination
PE, PP, and PVDF. If the melt index values (MFR values) of the certificate.
welding components lie within the permissible meld index range Welding of special materials (for instance FEP, PFA, MFA, E/
of DVS 2207-1, -11, -15, weldability can generally be assumed. If CTFE...) is subject to requirements equivalent to or proof of
two semi-finished products of different MFR groups from this suitability along the technical codes of DVS 2212.
range are to be welded together, a welding filler is to be selected
whose MFR value lies between those of the semi-finished
products combination. In the case of PE-HD, PP and PVDF, the 7 Set-up of welding equipment and setting the welding
instructions from the applicable technical codes DVS 2207-1, parameters
2207-11 and 2207-15 are to be observed. If the melt index lies
outside the permissible range in the stated technical codes,
Set-up and setting takes place according to the operating in-
weldability is to be ascertained with tensile creep testing
structions of the equipment manufacturer in association with the
according to DVS 2203-4.
welding parameter recommendations specified in Supplement 1
For amorphous materials (such as PVC): Only semi-finished and possibly with the specifications from the raw material or
products of the same moulding compound are weldable. semi-finished products manufacturer. On the draw nozzles, the
nozzle shoe and the air- and material channels are to be cleaned,
The semi-finished products and welding fillers must be labelled
for example with a brass brush prior to use or when the welding
accordingly and unambiguously (on the packaging for welding
filler is changed and possibly when welding is interrupted. The
fillers).
nozzle surfaces must not be damaged.
Only semi-finished products with defined quality specifications
The temperature of the hot gas is to be checked before starting
should be welded (for example, test report in accordance with EN
welding. The measurement is made with a suitable quick display
10204).
temperature meter (with a thermo-element of 1 – 1.5 mm diame-
The welding fillers must comply with the specifications of DVS ter) approx. 5 mm inside the nozzle, in the centre for round
2211 as well as EN 12943. nozzles, at the main nozzle aperture for draw nozzles. Air flow
The base and filling materials must be in perfect condition for measurement is performed at the point of entry into the welding
processing, dry and clean. equipment using a flow meter (see Supplement 2).
If there is any doubt as to the homogeneity of the semi-finished The welding torch should be in operation at least 15 min. prior to
products and/or the welding filler, for example, the absence of commencing welding and checking the parameters.
labelling or if material changes are of a concern as a result of Repeated checks are recommended in the case of prolonged
– improper storage, welding jobs or after interruption of work.
– low joining component temperatures, The welder must establish the appropriate welding speed and
– soiling pressure with practice, and carry out regular checks. The welding
– aging, pressure required can, for example, be checked by test welding
– operational influences (media, temperatures) on a platform balance.
the welding compatibility is to be ascertained with testing on All measurements must be carried out regularly with calibrated
sample welds. and tested measuring equipment according to Supplement 2 and
346
Page 5 to DVS 2207-3
must be documented (Appendix 2). The temperature meters Especially in the case of joining parts subject to prolonged
used should have a maximum deviation in their working range of exposure to UV or media, the damaged layer can be so deep that
± 3 K. it is necessary, after mechanical processing, to check the
residual wall thickness taking into account the static
9 Welding
347
Page 6 to DVS 2207-3
To avoid stretching of the welding filler through friction in the Destructive and non-destructive tests are distinguished. They are
nozzle, it may be necessary to feed the welding filler by hand. shown in Table 3 “Possible test procedures”
The drawing motion along the welding joint takes place while Visual inspection takes place according to DVS 2202-1 and
observing the emerging bow wave, the welding seam (double particularly concerns the weld shape, score-free surfaces and
bead) and the surface of the welding filler introduced. Scoring of edges, optimal weld filling, continuous welding of the root and
the base material arising from improper handling of the draw displacement of the joining parts.
nozzle (tacking tip) should be avoided.
Defects inside the welds can be determined non-destructively
with ultrasound and x-ray testing (see DVS 2206). These
After each welding pass, the weld should be reworked without techniques alone cannot however provide an adequate indication
scoring using a suitable scraper, as with hot-gas welding with of the quality of the welded joint. The possibilities of applying
torch separate from filler rod. these test methods is also limited in regard to the weld geometry
and thickness.
9.5 Mechanical reworking of the weld The nature and scope of the tests to be undertaken in the
individual case are to be defined.
It is normally not necessary to rework the weld. If the weld is
mechanically reworked, care should be taken to avoid scoring. General material specific tests can be found in DVS 2201-1 and
Reworking may only take place once the weld has cooled DVS 2206.
sufficiently.
Non-destructive testing
Visual inspection of the intact weld Visual inspection according to DVS 2202-1 and 2206
(external findings) The evaluation group is to be defined on a case-by-case basis
Seal test with vacuum Using a vacuum bell jar and foaming liquid; the test conditions are to be defined on a
case-by-case basis. Usual testing pressure -0.4 to -0.5 bar.
Seal test with high voltage The type of test equipment (with or without counter pole) and test voltage are to be
defined on a case-by-case basis. Testing methods according to DVS 2206, para.
3.3.1.4
Radiation transmission testing Applicability: Evidence with the number, position, shape and size of pores, shrink
holes and similar defects possible. Testing method according to DVS 2206, Section
3.5
Ultrasound testing Applicable with PE-HD, restricted with PP (evidence of hollow sites, not of quality)
Testing method according to DVS 2206, Section 3.4
Pressure testing Typical application for pipelines; Testing conditions according to the German
Pressure Tank Ordinance / Pressure Equipment Directive. Test performed according
to DVS 2219-1 Supplement 2 and DIN 4279
Evidence: Sealing quality, experimental evidence for operational safety
Destructive testing
Visual inspection of the weld cross-section Form of the weld cross-section (weld geometry), inner findings according to DVS
2202-1 Tab. 4 and 5. Fracture surface of the weld destroyed by tensile testing or
technological bending trials.
Tensile testing Execution according to DVS 2203-2. Rapid tension-weld factor; DVS 2203-4 tensile
creep weld factor; Minimum requirements according to DVS 2203-1
Testing not applicable for fillet and bevel welds.
Technological bending test Minimum requirements (bending angle/distance) according to DVS 2203-1
Testing not applicable for fillet and bevel welds.
348
Page 7 to DVS 2207-3
349
Page 8 to DVS 2207-3
Appendix 1: Brief instructions for welding 4. Commissioning welding equipment and setting parameters
(Section 7)
1. Compile welding equipment (Section 8.1) – Check supply lines (electricity, air) for any possible interrup-
2. Check working conditions and plan measures – Bevel the weld end before commencing afresh
(Section 8.2) – Scrape the weld seam of each weld zone before applying
– Accessibility further weld
– Adequate illumination – Protect the welding filler from soiling
– Protective tent
8. Reworking the welds (Section 9.7)
– Heating
– Allow the welded parts to cool down sufficiently before un-
– Measurement of the semi-finished product temperature and clamping and loading
introduce measures, as required
– Mechanically process weld scoring and the welding seam
on the weld flanks
3. Check welding suitability (Section 6.1)
– Check the manufacturer’s specifications on the semi-fin- 9. Complete the welding record sheet (Section 9.6)
ished products and welding filler for compatibility
– Complete the welding record sheet (Appendix 2) and carry
– Check the identity, condition and cleanliness of the joining
out visual inspection according to DVS 2202- 1
parts and clean as required
– Check the weldability of the joining parts with contract weld-
ing according to DVS 2201- 2 or test welding
350
Appendix 2: Welding record sheet
Date Construction Weld Joining Weld Process Air flow (1) Hot-gas Ambient Semi-finished Weather Protective Visual
detail no. part shape WF, WZ l/min temperature temperature product temp. (code no.) measures assessment
thickness (symbol) °C °C °C (code no.)
mm
351
Draft May 2009
Welding of thermoplastics
DVS – DEUTSCHER VERBAND High-speed hot gas welding and hot gas welding
FÜR SCHWEISSEN UND with the torch separate from the filler rod of pipes, Technical Code
VERWANDTE VERFAHREN E.V. piping parts and panels DVS 2207- 3
Welding parameters Supplement 1
R&D INTAKE MANIFOLDS Comments until August 31, 2009
This draft is presented to the public for examination and comments. Proposals for additions or modifications should be sent to DVS
e. V., P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, before the date mentioned above.
This supplement to the DVS 2207-3 technical code includes guide values for the parameters for high-speed hot gas welding and for hot
gas welding with the torch separate from the filler rod. They apply to manual welding with the devices described in the DVS 2207-3
technical code, Supplement 2 and with the materials listed in the table. Guide values for the parameters for thermoplastic fluoroplastics
are included in the DVS 2207-3 technical code, Supplement 3.
In addition, before the application of the parameters, attention must also be paid to the information from the manufacturers of the semi-
finished products.
By coordinating the hot air temperature, air volume and welding speed parameters, it must be guaranteed that the joining parts are
plasticised at the joint down to a depth of min. 0.3 mm.
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher
Materials Abbreviations Hot gas Hot gas volume Welding speed 3) Welding force (N)
Welding
process
High-density
torch separate from the filler rod (WF)
15 … 20
Polyvinylidene
PVDF 350 … 370 45 … 50 25 … 30
fluoride
High-density
PE- HD 300 … 340
High-speed hot gas welding
polyethylene
Polypropylene,
PP-H; PP-B; PP-R 300 … 340 250 … 350 15 … 20 25 … 35
Types 1, 2 and 3
Unplasticised
(WZ)
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49 (0) 211/1591- 0, Telefax: + 49 (0) 211/1591- 150
352
Erstellungsdatum: 15.06.2007
Letzte Änderung: 09.07.2007
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September 2007
Welding of thermoplastics
DVS – DEUTSCHER VERBAND Hot-gas string-bead welding and hot-gas welding
FÜR SCHWEISSEN UND with torch separate from filler rod of pipes, pipe Technical Code
VERWANDTE VERFAHREN E.V. components and sheets – Requirements for DVS 2207-3
Contents: – the nozzles used are also easy to remove and fit in the heated
state,
1 Applicability
– a constant welding temperature is achieved after a maximum
2 Requirements
of 15 minutes,
2.2 Safety requirements
2.3 Labeling and documentation – the operating controls are protected against inadvertent
2.4 Hot-gas supply displacement.
2.5 Nozzles
2.6 Flowmeters 2.2 Safety requirements
3 Other applicable standards and technical codes
The equipment used in a proper manner must afford the user
protection against injuries of any nature. The applicable statutory
regulations governing the use of equipment must, in particular,
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher
1 Applicability
be observed. (Also see Section 3)
This supplement to technical code DVS 2207- 3 describes, in Additionally applicable:
general terms, qualitative and safety-relevant requirements for
welding equipment and the necessary accessories for hot-gas – Parts in close proximity to hands must not exceed + 40°C
string-bead and hot-gas welding with torch separate from filler under operating condition even after prolonged usage.
rod (WZ, WF) of thermoplastics. – Equipment surfaces presenting a burn hazard are to be kept
It applies to the types of equipment described in technical code as small as possible, or isolated and labelled as required.
2207-3, with and without built-in hot-gas supply, as well as – Over-temperature protection must be fitted to avoid overheat-
controlled or regulated, and serves to ensure that the required ing or destruction of the equipment or individual elements (for
weld quality is achieved provided the equipment is operated and example due to a shortage of air).
handled correctly.
– Sharp edges on equipment and accessories are to be avoided.
Special devices for special applications are not covered within
the scope of this supplement. 2.3 Labelling and documentation
All equipment must display at all times:
2 Requirements – specifications of manufacturer and model,
2.1 General requirements – specifications on power supply, power consumption and fre-
quency,
The equipment must ensure that
– identification number,
– safe functionality is ensured within the intended temperature
application range (- 5 to + 60 °C), – CE mark and protection class.
– storage within a temperature range of - 5 to + 60°C causes no All equipment must include operating and maintenance instruc-
damage, tions, which contain at least:
– no faults or damage arise as a result of the mechanical strain – functional description and operating instructions,
arising during proper transportation and operation,
– specifications on areas of application,
– there is adequate corrosion protection against moisture
entering from the outside, – maintenance schedule specifying service intervals,
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
353
Page 2 to DVS 2207-3 Supplement 2
– the required air flow rate is adjustable for each welding tool 3 Other applicable standards and technical codes
and is displayed with an accuracy of ± 5 l/min,
EN 55014-1 EMC testing: emission
– the temperature fluctuations at the nozzle do not exceed ± 5 K
EN 55014-2 EMC testing: immission
2.6 Flowmeters
Flowmeters to measure and regulate the flow of hot gas must not
exceed a maximum deviation of 3.0% of the maximum scale
value. They should normally be designed for 100 l/min under
normal conditions at 20°C and average working pressure of the
equipment connected. Suspended body flowmeters or orifice
flowmeters calibrated with pre-pressure display in standard litres
have proven effective.
354
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Erstellt am: 18.01.2005
Zuletzt geändert am: 29.01.2008
March 2008
R&D INTAKE MANIFOLDS Translation of the German version from april 2005
es or carriers may be, for example, a light ray or inert gases. The
6.3 Requirements on the preheating material output capacity of the machines or devices determines
6.4 Requirements on the materials and their weldability the maximum weld dimensions and influences the welding
6.5 Requirements on the welders speed. The necessary joining pressure is generated by the
6.6 Requirements on the quality of the welded joints emerging material and the counterforce of the welder.
7 Start-up of the welding machines and setting of the welding
parameters A distinction is made between the following processes:
8 Welding preparation – continuous welding process
8.1 Equipment
– discontinuous welding process
8.2 Protective measures against environmental influences
9 Welding
9.1 Preparation of the joining faces 3.1 Continuous welding process
9.2 Tacking The plastified welding filler emerging from the manually or
9.3 Execution of a weld mechanically guided device or machine is continuously pressed
9.4 Finish machining of the welds into the also plastified welding groove by a welding shoe, Figs. 1,
9.5 Thermal after-treatment of the welds 3 and 4.
9.6 Welding record sheet
10 Testing of the welded joints
11 Safety instructions
12 Standards and technical codes which are also applicable
Appendix 1: Brief instructions for the welding
Appendix 2: Welding record sheet for the extrusion welding
1 Scope of application
2 Materials
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
355
Page 2 to DVS 2207-4
In the case of manual welding, the feed speed results from the This process is predominantly used where confined space-
volume of the emerging material flow and from the weld cross- related conditions or certain structural details exclude continuous
section to be filled. In the case of welding with a feed system, the welding.
welding speed must be adjusted to the material output.
Figure 3.
Diagram for continuous welding
with Machine Variant II.
356
Page 3 to DVS 2207-4
V
Double-V-seam
Double-V-seam
(X-seam)
(X-seam)
X
Double-HV-
Double-HV-seam
seam
(K-butt) (K-
butt)
K
Fillet
Fillet
Figure 4. Diagram for continuous welding with Machine Variant III.
The DVS 2205 ff. technical codes apply to the structure of the
components and the DVS 2205-3 technical code to the design of
the welds (the supplements to the respective technical codes are Figure 5. Examples of weld shapes and weld symbols.
also applicable). In particular, attention must be paid to the
following:
Depth of seams s (mm)
357
Page 4 to DVS 2207-4
must be checked regularly (e.g. by means of monitoring by the The weld overlap ∆b should be more than or equal to 0.2 times
manufacturers). the joining part thickness but it should be min. 3 mm.
The output quantity and the preheating capacity must be The weld reinforcement ∆s should be 0.1 - 0.2 times the joining
358
Page 5 to DVS 2207-4
The semi-finished products and the welding fillers must be If the material is changed, it must be ensured, by means of
marked correspondingly and unmistakably (in the case of cleaning or extruding-out, that all the material in the welding
welding fillers, on the packaging). extruder is replaced. If necessary, the nozzles must be changed.
In the case of Machine Variant II, the hose must always be
If the welds are executed properly according to this technical It must be guaranteed that the welding head of the machine or
code, those minimum requirements on the quality of the welds device has sufficient accessibility to the joining faces. Welding
which are specified in the DVS 2203-1 technical code (welding out of position should be avoided or minimised because of the
factors and bending angles) are sure to be met. With regard to required counterpressure to be applied by the welder. It must be
the application in question, to statutory stipulations if needed ensured that the welder is not hindered during the welding as a
(Water Management Act, Pressure Device Directive etc.) and to result of the necessary readjustment of the connecting cables
the necessary dimensioning, the customer and the manufacturer and hoses as well as of the welding filler.
should agree on the corresponding requirements on the
component and on the welded joints and should stipulate these. 8.1 Equipment
Instructions and criteria for stipulating the quality are described in The following equipment constitutes the minimum requirements
the DVS 2202-1 technical code. The inclusion of the weld quality for the proper execution of the welded joints:
in the component calculation is described in the DVS 2205-1 to
-5 technical codes. – hot gas extrusion welding device according to the welding job
and this technical code
If necessary, the evidence of the demanded quality may be
provided within the framework of establishing its suitability on trial – welding shoes according to the welding job
welds with reference to DVS 2212-1. This applies especially to – flow meter for welding gas
materials for which no requirements have yet been stipulated in
–- temperature gauge according to DVS 2207-4, Supplement 2
the specified technical codes (e.g. PVC-C).
– suitable measuring instruments for checking the misalignment,
the diameter and the thickness
7 Start-up of the welding machines and setting of the – suitable storage space for the devices
welding parameters
– scraper and scraper blade
The start-up is carried out according to the operating instructions – personal protective equipment
from the machine manufacturer.
– dust protection for the welding wire
Extrudate residues in the extruder, at the outlet opening as well
as, if applicable, in the transport hose must be melted completely – sufficient lighting
before the extrusion drive is switched on. – protective measures against weathering influences (see
In order to avoid the use of thermally predamaged welding filler, Section 8.2)
the reheated melt should be extruded out completely before the – special cleaning agent (not swelling, dissolving or containing
beginning of the welding. This also applies to longer interruptions greasy) and non-fraying rags
in the work. The maximum dwell times are dependent on the
– welding parameters according to DVS 2207-4, Supplement 1
material in question (in the case of PE-HD and PP, approx.
and/or instructions from the manufacturers of the semi-finished
5 min). In the case of thermally sensitive materials such as PVC
products
and PVDF, it is to be recommended to keep the extruder running
during the interruption in the welding. – welding record sheet according to Appendix 2
359
Page 6 to DVS 2207-4
8.2 Protective measures against environmental influences The welder must ensure that the molten base material at the weld
The ambient conditions may exert a fundamental influence on the sidewalls is not pushed off by the welding shoe nose.
welding operation and thus on the quality of the joint. Therefore, In the case of restarts and at the end of circumferential welds, it is
9 Welding
Figure 8. Example of a single-V butt weld with representation of the mel-
9.1 Preparation of the joining faces ting zones and the weld overlap.
The joining faces must not be damaged, oxidised or soiled. In order to avoid the excessively rapid cooling of the top layer
Therefore, they and the adjacent weld overlap areas must be and the resulting formation of shrinkage cavities, it is
subjected to chip-producing machining immediately before the recommended to cover the extrusion weld immediately after the
welding. welding.
Chip-producing tools such as scrapers, scraper blades, milling If multi-layer welds are necessary, the cooled weld sidewalls and
cutters and saws are suitable. Grinding tools are only permissible surfaces of the already welded layers must be subjected to chip-
if it is possible to exclude the soiling caused by inputting producing machining.
abrasives and the overheating of the surfaces.
Design-induced modifications to the weld geometry in the weld
Especially in the case of joining parts which have been exposed path (e.g. in the case of segment bends and branches) demand
to the influence of UV or media for a long time, the damaged particularly careful guidance of the welding shoe. If necessary,
layer may be so deep that the residual wall thickness, including the welding shoe must be changed.
the static requirements, must be checked after the machining-off.
In the case of semi-automatic and fully automatic systems and
If the joining faces must be cleaned, it is necessary to use special
facilities for extrusion welding, the welding parameters (the
cleaning agents which do not contain any grease.
material output, the preheating and the welding speed) must be
coordinated and must be set correspondingly.
9.2 Tacking
It is recommended to manufacture trial welds.
Tacking serves to fix the joining parts in their planned positions in
relation to each other in order to exclude any changes in the In the case of discontinuous welding, the welding filler is
positions of the joining parts during the welding. Tacking is extracted from the extruder with the quiver and is inserted into
usually carried out by means of the partial or continuous high- the plastified welding groove section by section. The joining
speed hot gas welding of a root layer with a welding filler wire. pressure is applied with the press-on tool across all the cross-
sectional areas of the weld (central and edge areas) in several
9.3 Execution of a weld operations and the weld surface is shaped at the same time.
Before the beginning of the welding operation, the welding shoe 9.4 Finish machining of the welds
must be heated up (e.g. using a baffle plate) since welding with a
cold welding shoe results in a rough and uneven weld surface. Subject to corresponding welding shoe formation and machine
This also applies to press-on tools in the case of discontinuous guidance during the welding, finish machining of the welds is not
welding. necessary (in this respect, see also DVS 2202-1, Table 5).
The start of the weld is preheated and completely melted with hot It is imperative to remove the lateral flow which may be pressed
air. Immediately before the welding shoe is placed on the welding through under the contact surfaces of the welding shoe.
groove, the welding filler which has already emerged is removed Reinforced weld beads and reinforced weld roots must be
from the welding shoe opening. After the filling of the groove, the machined off correspondingly without any notches.
material pressure builds up due to the counterpressure generat- The weld may only be machined off after sufficient cooling.
ed by the welder and the forward movement of the welding shoe
begins. 9.5 Thermal after-treatment of the welds
In the case of manual welding, the welding speed is determined
Residual welding stresses can be reduced by means of
by the material output of the extruder and the size of the weld
tempering. The tempering conditions depend on the material and
cross-section.
the component. Attention must be paid to the information from
The preheating of the joining parts must be adjusted to the the manufacturers of the semi-finished products.
welding speed in such a way that the base material is plastified
down to a depth of 0.5 - 1 mm. 9.6 Welding record sheet
The plastification zone must be wider than the weld width. Guide The completely filled-in welding record sheet documents the
value: weld width + 2 • (0.2 • joining part thickness s) (see Fig. welding conditions and parameters amongst other details. It is
8). the foundation for the evaluation of the weld quality by the
The melting depth is checked directly in front of the welding shoe. welding supervisor (compare DVS 2213, specimen record sheet
This may be carried out with a thin, blunt tool. in Appendix 2).
360
Page 7 to DVS 2207-4
Table 2. Usual test procedures for extrusion welds, applicability and requirements.
Non-destructive tests
Visual inspection of Visual inspection, according to DVS 2202-1 and 2206. The evaluation group must be stipulated in each
the undestroyed weld individual case.
(external findings)
Leak test with a partial Using suitable vacuum bell jars and a foaming liquid; the test conditions must be stipulated in each
vacuum individual case. Usual test pressure: -0.4 bar to -0.6 bar.
Leak test with electric The type of test device (with or without an antipole) and the test voltage must be stipulated in each
high voltage individual case. Test technique according to DVS 2206, Section 3.3.1.4.
Radiographic test Applicable; statement with the number, positions, shapes and sizes of pores, shrinkage cavities and
comparable defects possible. Test technique according to DVS 2206, Section 3.5.
Ultrasonic test Applicable to PE-HD, with restrictions to PP (statement about voids, not about quality). Test technique
according to DVS 2206, Section 3.4.
Pressure test Application usually for pipelines; test conditions according to the Pressure Device Directive. Test execution
according to DVS 2210-1, Supplement 2 and DIN 4279-7. Meaningfulness: leak tightness, experimental
evidence of the operational safety.
Destructive tests
Visual inspection of Formation of the executed weld cross-section (weld geometry), internal findings according to DVS 2202-1,
the weld cross-section Tables 4 and 5. Fracture pattern of the weld destroyed in the tensile test or in the technological bending
test.
Tensile test Execution according to DVS 2203-2: short-time tensile welding factor; DVS 2203-4: creep rupture welding
factor; minimum requirements according to DVS 2203-1. Test not applicable to fillet and single-bevel butt
welds.
Technological bending Execution according to DVS 2203-5, minimum requirements (bending angle) according to DVS 2203-1.
test Test not applicable to fillet and single-bevel butt welds.
The visual inspection concentrates, in particular, on the weld In explosion-protected areas, attention must be paid to the valid
shape, the notch-free surfaces and peripheral zones, the safety regulations with regard to the welding work and any
optimum weld filling, the full weld penetration on the root side and measures which may be necessary must be agreed on with the
the joining part misalignment. safety officer responsible; in this respect, see the Operational
Safety Ordinance (BetrSichV).
With ultrasonic and X-ray testing (see the DVS 2206 technical
code), flaws can be detected in the interior of the welds without
any destruction. However, on their own, they do not provide a
12 Standards and technical codes which are also
sufficient indication of the quality of the welded joint. Moreover,
applicable
the utilisation possibilities of these test procedures are limited
with regard to the weld geometry and the weld thickness. DIN 1910-3 Welding of plastics – Processes
For the designation and evaluation of defects, reference is made DIN V 4279-7 Internal pressure testing of pressure piping for
to the DVS 2202-1 technical code. (preliminary water – Pressure pipes made of low-density
standard) polyethylene PE-LD, pressure pipes made of
It is necessary to stipulate the type and scope of the tests to be
high-density polyethylene PE-HD (PE 80 and
performed in each individual case.
PE 100), pressure pipes made of cross-linked
Material-specific tests are indicated in DVS 2201-1 and general polyethylene PE-X and pressure pipes made of
tests such as dimensional accuracy or surface assessment in unplasticised polyvinyl chloride PVC-U
DVS 2206. DIN 16960-1 Welding of thermoplastics – Principles
DIN 32502 Defects in welded joints made of plastics –
Classification, designations and explanations
11 Safety instructions
DIN EN 12943 Welding fillers for thermoplastics – Scope of
Hazardous decomposition products and health-endangering application, marking, requirements and testing
fumes result from the overheating of some materials (such as. DIN EN ISO Plastics – Code letters and codes – Part 1: Base
PVC, PVDF and E-CTFE) or already develop during the welding 1043-1 polymers and their particular properties
of other materials (such as FEP, MFA, PFA and PTFE). On the DVS 2201-2 Testing of semi-finished products made of
basis of the DIN safety data sheets to be submitted by the thermoplastics – Weldability – Test procedures
manufacturer, the contractor must elaborate operating – Requirements
instructions which comply with Section 20 of the Hazardous
Substances Ordinance (GefStoffV) and indicate all the potential DVS 2202-1 Defects in welded joints between thermoplastics
hazards and necessary protective measures. It may be – Characteristics, description and evaluation
necessary to take further specific protective measures in each DVS 2203 Testing of welded joints between panels and
individual case. pipes made of thermoplastics
361
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362
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Appendix 1: Brief instructions for the welding 4. Prepare the welds and the joining faces (Section 9.1)
– check, stipulate and manufacture the weld geometry and the
1. Put together the welding equipment (Section 8.1)
weld shape
363
364
Extrusion welding of panels and pipes Company logo
2 = Dry 2 = Screen
Welding supervisor (3): Year of construction / last machine examination: Process variant according to DVS 2207-4:
4 = Wind 4 = Heating
Date Weld no. Joining part Weld shape Welding Air volume Material Hot gas Welding Ambient tem- Semi-finis- Weathering Protective Visual
thickness (symbol) shoe no. temperature temperature speed perature hed product (code no.) measures evaluation
temperature (code no.)
mm l/min C (1) C (2) cm/min C C
Appendix 2: Welding record sheet for the extrusion welding
(1) Measured with a pricking thermometer at the extrudate outlet of the welding machine / welding device Remarks: e.g. less favourable conditions
(2) Measured in the middle of the nozzle outlet opening, 5 mm in the nozzle
(3) E.g. specialist for plastics welding according to DVS 2213
R&D INTAKE MANIFOLDS
Welding of thermoplastics
DVS – DEUTSCHER VERBAND
Extrusion welding of pipes,
FÜR SCHWEISSEN UND Technical Code
VERWANDTE VERFAHREN E.V.
piping parts and panels DVS 2207- 4
Welding parameters Supplement 1
R&D INTAKE MANIFOLDS Comments until August 31, 2009
This draft is presented to the public for examination and comments. Proposals for additions or modifications should be sent to DVS
e. V., P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, before the date mentioned above.
This supplement to the DVS 2207-4 technical code includes guide values for the parameters for hot gas extrusion welding. They apply
to manual welding with the machines and devices specified in the DVS 2207-4 technical code, Supplement 1, and to the materials
listed in the table.
If necessary, other parameters may also be used for the welding with automatic welding machines (see Section 9.3).
By coordinating the hot air temperature, air volume and welding speed parameters, it must be guaranteed that the joining parts are
plasticised at the joint and down to a depth of 0.5 - 1 mm beyond the weld width (see Section 9.3).
Materials Abbreviations Material temperature 1) Hot gas temperature 2) Hot gas quantity 3)
°C °C l/min
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher
1) Measured with an insert thermometer at the extrudate outlet of the welding machine.
2) Measured 5 mm in the nozzle, in the centre of the nozzle opening.
3) Drawn-in cold air volume at the ambient pressure.
4) PE 63, PE 80 and PE 100.
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
365
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-4\englisch\Jan_08\e2207-4bb2.fm
Erstellt am: 17.01.2008
Zuletzt geändert am: 29.01.2008
March 2008
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
366
Page 2 to DVS 2207-4 Supplement 2
If the material temperature and, wherever integrated by means of Table 1. Examples of the welding nozzle geometry and the air outlet
appliance engineering, the hot gas temperature move above or cross-sections for weld widths up to 40 mm.
below the stipulated tolerance limits, an automatic drive cut-off
Shape of nozzle Seam Dimensions
and overtemperature protection must take effect.
width x1)
367
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4 Literature
368
Erstellungsdatum: 04.11.1999
Letzte Änderung: 13.02.2002
File-Name: C:\DVS Merkblätter\2207\2207-05\englisch\e2207t5.fm
Directive D
DVS – DEUTSCHER VERBAND Welding of Thermoplastics –
DVS 2207-5
FÜR SCHWEISSEN UND Welding of PE Casing Pipes, V
VERWANDTE VERFAHREN E.V. Tubes and Tubular Components (Februar 1993) S
R&D INTAKE MANIFOLDS
Contents: – Permanent mechanical joint under thermal load resulting from
the temperature of the medium under simultaneous external
1 Scope and internal mechanical load.
2 General requirements imposed on welded joints
– Permanent watertight joint of the PE-HD casing in all operating
3 Material
conditions and load cases.
4 Types of execution of welded joints on PE-HD casing pipes
4.1 Casing pipe/Sleeve joints – Transition of the forces acting on the sleeve into the casing
4.2 Welds on fittings pipe, caused for example by the increased resistance of the
5 Carrying out the welding process soil pressure in the sliding region. The increased soil
5.1 Heated plate welding (HS) resistance results from the thermal expansion of the moving
5.2 Hot gas extrusion welding (WE) long distance heating piping, when the largest sleeve diameter
5.3 Electrofusion (HM) exceeds the diameter of the casing pipe.
5.4 Indirect heated tool sleeve welding (-)
5.5 Hot gas welding (W)
6 Testing the welded joints 3 Material
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher
1) Melt index group 005 = MFI 190/5 = above 0.4 to 0.7 g/10 min. Melt index group 010 = MFI 190/5 = above 0.7 to 1.3 g/10 min.
2) Formerly called "Spiegelschweißen" ("mirror welding")
This publication was prepared by a group of experienced specialists working together in an honorary capacity, and it is recommended that it should be respected as
an important source of knowledge. The user must at all times check the extent to which the contents apply to his or her special case and whether the version available
to him or her is still current. Any liability on the part of the German Welding Society and of those participating in the preparation of this document is excluded.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
369
Page 2 to DVS 2207-5
Detail “X” accordance with the seam shape is to be used (see Fig. 5b).
V-weld, extrusion
welding with filler 4.1.3 Electrofusion
Spacer/pressure support
Heating conductor
Casing pipe
“X”
Figure 3. Basic design of a welding sleeve with a longitudinally slit sleeve tube or a sleeve plate.
370
Page 3 to DVS 2207-5
4.1.3.3 Slip-on sleeve with built-in heating grids – The manufacturer's documentation must include detailed
For this variant, basically the same welding principle is used as working instructions for the welding method used and in
for the variants with heating conductors built into the sleeve tube particular indicate the welding parameters (guide value tables).
parts in the works, as described above. The essential difference – The welding area must be protected against environmental
371
Page 4 to DVS 2207-5
For welding sleeve circumferential welds as per Variant II circumferential welds in the region at the beginning of the weld)
partially mechanized equipment is used. To reduce the and after welding over with the welding unit tilted forwards the
necessary working space the welding machine is arranged in a material being welded must be held with a hand plunger.
narrow angular position with respect to the tube axis and
372
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*) DIN 1910 Part 3: “Sleeve welding with incorporated electric heating element”
373
Page 6 to DVS 2207-5
same basic stipulations and operational steps as described for short term strength the specimens are pulled at constant test
the process in Section 5.3. speed. For PE-HD the test speed is 50 mm/min.
The tensile test is carried out in accordance with DIN 53 455 or Specimen Supporting Bending beam
DVS 2203 Parts and 1 and 2. The welded joints are tested in Thickness Width Length width thickness
accordance with the actual execution, i.e. with or without bead. h LS d
The joint lies in the middle of the specimen. At least 6 welded and
6 unwelded specimens (reference specimens) are tested. 3<h≤5 20 150 80 4
5 < h ≤ 10 20 200 90 8
If the strip specimens of Shape 1 to Fig.6 tear in the clamping 10 < h ≤ 15 30 200 100 12,5
region, specimens of Shape 2 must be used. The dimensions of 15 < h ≤ 20 40 250 120 16
the particular specimen shape should be taken from Table 1. 20 < h ≤ 30 50 300 160 25
Table 1. Dimensions of the specimens for the tensile test. On smaller tubes if necessary a smaller specimen diameter
In the case of lap welded joints the dimensions L and Lf must be should be chosen. However, 15 mm should be the minimum.
increased by the welded overlap length.
6.2.1 Execution
Thickness Specimen Shape 1 Specimen Shape 2
h Unless agreed otherwise, this test is carried out at room
b Lf L b Lf L be
temperature (+ 23 °C ± 2 °C). The specimens of PE-HD are bent
< 10 15 120 ≥ 170 10 115 ≥ 170 20 in the test rig at a test speed of 50m m/min until fracture/incipient
> 10 30 120 ≥ 300 30 115 ≥ 300 40 tearing. The arrangement of the bending beam should be taken
> 20 1,5 h 200 ≥ 400 1,5 h 200 ≥ 400 80 from Fig. 7 for the various design versions of the joints.
The bending angle reached on incipient tearing or fracture is
6.1.1 Execution
measured. Complete bending of the specimen, without tearing or
Unless agreed otherwise, the test is carried out to DVS 2203 Part fracture, corresponds to a bending angle of 160° and is to be
2 at room temperature (+ 23 °C ± 2 °C). For determining the evaluated as > 160°.
374
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Fig. 8 until fracture or until the free ends of the specimen come
into contact with the bar.
b)
6.3.1 Execution
The execution can only take place after adequate cooling of the
joint to room temperature (approx. + 23 °C). 5 strip specimens of
15 to 20 mm width – taken at intervals over the weld length – are
d) tested.
Here the end of the sleeve is clamped in the vice and the non-
welded end of the plastic casing pipe projecting into the sleeve is
Detail “X” bent away from the sleeve until it can be gripped by a pair of
pliers. Then an attempt is made to peel off the joint, see Fig.9.
Groove 1 mm deep, The free leg is bent until it kinks.
4 mm wide
Sleeve
The technological bending test does not supply mathematical The joining surfaces should not separate.
values for the design calculations. On the basis of the deformati-
on behaviour determined and the fracture photomicrograph the 6.4 Tensile creep test
results however allow a general qualitative assessment of the The long-term behaviour under the required forms of stress is the
joint to be made. most important proof of quality in relation to the suitability for use
For a general good/bad assessment the minimum requirements of load carrying components made of thermoplastic polymers. In
indicated in Fig. 14, Section 7, of Directive DVS 2203 Part 1 can the case of pressure loaded structures, such as pipes and
be taken as the basis. fittings, carrying out the long-term internal pressure test has been
the proven state of the art for a long time. For pipes of larger
For max. 2 specimens, which do not fulfill the requirements, 2 dimensions, however, these tests are increasingly expensive in
replacement specimens each from the same part can be tested. cost terms, so that this test is only seldom used in testing
No value should lie below the required minimum value. practice.
6.2.3 Manual test To assess the execution of the weld the long-term tensile test in
combination with other tests has proved itself. The tests are
This version of the technological bending test is a simple
carried out at + 80 °C. The applied stresses are 4 and 3 N/mm2.
indicative workshop test. Because of the force required this
If no brittle fracture should occur during the execution of the test,
method is limited to small thickness specimens.
lower stresses must be chosen. In order to shorten the time-to-
The specimen is bent with the machined side of the weld over a failure (acceleration effect), a 2% aqueous wetting solution (for
rounded, 6 mm thick bar with powerful application of force as per example Arkopal N 100 3) ) should be used as the test medium.
3) (R) Messrs Hoechst AG. Extensive testing experience is available for this test medium, which facilitates comparison of the results and the determination
of requirements. If other products on the same basis are used, compare the number of ethylene oxide molecules in the polyglycol ether chain.
375
Page 8 to DVS 2207-5
The required joining factors (fs) in the tensile creep test (Table 4, 6.4.2 Evaluation
Section 7) and the fracture photomicrograph give an indication of For determining the long-term joining factor4) (fs) the creep curve
the quality of the weld execution. of the welded and unwelded specimens must be determined, the
gradient of the straight lines being particularly important. The
4) On the basis of the shape and nature of the lap welded joints involved here with superimposed types of stress in the joints in the tensile test, the long-
term joining factor is defined here, as a departure from DVS 2203 Part 4.
376
Page 9 to DVS 2207-5
– a process-specific, correct weld/weld edge formation (root and – homogeneity of the material being welded; weld surface
edge welding) – weld flash, weld shoe guidance (WE)
– presence of notches, cavities, lack of fusion, etc – bulge/double bulge formation (HS, WZ)
– the effect of heat, fusion zones, overheating, etc
S = weld specimen
B = reference specimen
Time-to-failure (h)
Figure 11. Diagramatic representation for defining the joining factor in the tensile creep test.
Stress (N/mm2)
Time-to-failure (h)
Figure 12. Diagram for defining the joining factor in the tensile creep test in the case of only one test stress on the refrence specimen.
7.2 Mechanical-technological tests in the short-term test proposed as an alternative for these joint shapes the surfaces to
be joined must not separate.
In principle, in the short-term tests described (tensile and
technological bending tests) the requirements of DVS 2203 Part With this form of joint the technological bending test cannot be
1 must be satisfied; see Table 3 and Fig.14. carried out easily. Likewise, essentially only the weld edge
regions are covered by the test.
In the case of lap welded joints with flat welding in the joint the
result of the tensile stress is primarily determined by the weld The results of these tests have less informative value for lap
edge execution; the welding itself is covered to a lesser extent in welded joints, in particular for flat welds in the lap joint, than for
this tensile/shear test. During the manual peel test to Section 6.3 plane butt joints.
377
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Stress (N/mm2)
R&D INTAKE MANIFOLDS
S = weld specimen
B = reference specimen
Time-to-failure (h)
Figure 13. Simplified method for minimum proof of a required long-term joining factor.
Table 4. Requirements for the joining factor in the tensile creep test
for the reference stress σ = 4 N/mm2 (on the basis of DVS
2203 Part 1).
Figure 14. Requirements for the technological bending test (from DVS In accordance with the current quality standard, here the inclined
2203 Part 1). load range of the curves is shifted in such a way along the time
axis that the test point (4.0 N/mm2 /+ 80 °C) lies at 1000 hours.
Table 3. Joining factor requirements in the shoert-term tensile test In comparative tests it has been shown that in the case of the lap
(on the basis of DVS 2203 Part 1).
welded joints the deformations in the test specimens (strips or
Welding method Short-term tensile shoulder specimens) have no influence on the test result (pairs of
joining factor fz forces).
Heated plate welding 0.9
V-weld extrusion welding 0.8
7.4 Imperviousness test
Extrusion welding on the lap joint with fillet
weld 0.8 During the imperviousness test (as per 6.5) no leaks, atypical
Electrofusion in the lap joint 0.8 deformations or other impermissible changes may occur.
378
Page 11 to DVS 2207-5
8 Quality Assurance The welders used must demonstrate adequate training5) in the
material science of PE- HD, having passed the welder
Because the quality of plastic welded joints for specific examination6). These must be carried out and certified as per
applications can in the last analysis only be demonstrated by Directive DVS 2212 or in rational application for the particular
379
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DIN 16 776 Polyethylene (PE) moulding compounds DVS 2205 Design of containers ans appaartus made from
Part 1 – Classification and description thermoplastics
Part 2 – Manufacturing the test specimens and Part 1 Characteristic values
determining the properties Part 3 Welded joints
DIN 16 963
Part 5 R&D INTAKE MANIFOLDS
Pipe connections and piping components for high
pressure pipelines of high density polyethylene
(PE-HD); general quality requirements, testing
DVS 2206 Testing of components and constructions made of
thermoplastic materials
DVS 2207 Welding of thermoplastics, PE-HD (high density
DIN 18 200 Supervision (quality monitoring) of building Part 1 polyethylene) Pipes and pipeline components for
materials, components and structures, general gas and water mains
principles Part 2 Heated plate welding – pipes and pipelines for
DIN 32 502 Effects on welded joints in plastics, classification, sewerage pipes and lines
designation, explanations Part 3 with Annex Hot gas welding of thermoplastics –
DIN 50 049 Certificates for material tests sheets and pipes, welding parameters)
DIN 53 444 Testing of plastics, tensile creep test Part 4 Welding of thermoplastic polymers, panels and
DIN 53 455 Testing of plastics, tensile test pipes – extrusion welding
DIN 53 479 Testing of plastics and elastomers; determining the DVS 2208 Machines and equipment for welding of
density thermoplastics
DIN 53 735 Testing of plastics; determining the melt flow index Part 1 – heated tool welding
of thermal plastics Part 2 – hot-gas welding (not extrusion welding)
ISO Plastics; determination of the melt flow index (MFR) DVS 2209 Welding of thermoplastics – extrusion welding,
1133:1991 and the volume flow index (MVR) of thermal Part 1 methods – features
plastics DVS 2211 Filler materials of thermoplatics, scope,
ISO Plastic pipes for conveying liquids; determination of designation, requirements, tests
1167:1973 the resistance to internal pressure DVS 2212 Testing of welders for welding plastics,
ISO Plastics; methods for determining the density and Part 1 Test group I (hot gas string bead welding and
1183:1987 relative density of non-expanded plastics heated plate welding)
ISO/DIS Tubes of polyethylene (PE); Part 1: Determination Part 2 Test group II; Hot gas extrusion welding (WE)
6259-1:1985 of the properties in the tensile test
GKR- Casing pipes for the manufacture of sleeves and
ISO/TR Determination of the thermal stability of Guideline fittings of PE-HD (high density polyethylene) for
10 837:1991 polyethylene (PE) for gas piping and fittings R 9.3.17 preinsulated bonded pipe systems for underground
hot water networks with the quality symbol of the
9.2 Directives Plastic Pipes Quality Association e.V., Bonn
DVS 2201 Testing of semifinished products of thermoplastics "Building of district heating networks" – Technical Guidelines of
Part 1 – fundamentals, references the AGFW
DVS 2202 Imperfections in thermoplastic welded joints – AGFW membbers information "Plastic jacket pipes for district
Part 1 features, description, evaluation heating lines".
DVS 2203 Testing of welded joints og thermoplastics
Part 1 Test methods – requirements
Part 2 Tensile test
Part 4 Tensile creep test
Part 5 Technological bending test
380
Assembly Report
Sleeve No. Type Section Date Ambient Weather Weather Displays Sleeve Remarks
temperature protection
(°C)
A B C
Tent
Sunny
Wind
Time
Temperature
Snow
Open
Rewelds
Screen
Replacement welds
Watertight
Programme
Cloudy
Non-watertight
Rain
Annex 1: Report form (proposal) for the electrofusion method
This Annex is only for information and is not a binding part of this Directive.
381
382
Report form for heated plate welding of tubular Laid above ground Material
Laid underground Sheet of
components
Employer Contracting company Welding machine Weather conditions Protective measures
2 = dry 2 = screen
Order title Name of the welder Identy No. Type: 3 = rain or snowfall 3 = tent
4 = wind 4 = hetating
Maschine No.:
Order No. Name and company of the welding Year of manufacture: In the case of multiple designations follow the sequence of the figures as above
inspector (e. g. 34 = rain and wind)
Weld Date Input data Adjustment/measurement values1): theoretical/acutal information Ambient conditions Remarks
No.
Pipe size Movement Heating Equalizing Heating up Joining Heating Adaption Time to Cooling Ambient Weathe- Code No.
Ø dA × t pressure, element temperature up time2) time2) complete time under temperature ring of the
measured, temperature’ joining joining code No. protective
P pressure pressure2) measures
bar oC bar bar bar s s s s oC
Annex 2: Report form (proposal) for heated plate welding
This Annex is only for information and is not a binding part of this Directive.
1 )The settings are the sum of the movement pressure and the indications of the manufacturer of the welding machine concerning equalization and joining pressure.
2) The measured values must be entered.
Page 15 to DVS 2207-5
This Annex is only for information and is not a binding part of this Directive.
Welding Report
R&D INTAKE MANIFOLDS
for the extrusion welding of panels and tubes
General Information
Contracting Company:
Process/Equipment
Material
Material to be welded:
Welding filler:
Welding Conditions
Remarks:
Date/signature Date/signature
Welder Welding supervisor
383
Page 16 to DVS 2207-5
This Annex is only for information and is not a binding part of this Directive.
Project:
Remarks:
384
Page 17 to DVS 2207-5
385
386
Table A5-1. Monitoring tests on semi-finished products (casing pipes and tubular sleeves and sleeve plates); FM = moulding compound, HZ = semi-finished product.
1 – Technological tests
1.1 5.2.1 – Density of the tube material × DIN 53 479 DIN EN 253, Section 4.2.1.1
E.g. Method A GKR Guideline R 9.3.17
ISO 1183:1987 "A" or "D" > 0.944 g/cm3
1.2 5.2.1 – Melt index, × × DIN 653 735 DVS 2207-5, Section 3
"MFI 190/5" (g/10 minutes) ISO 1133:1981 DIN EN 253, Section 4.2.1.2
GKR Guideline R 9.3.17
Execution of the
For moulding compounds: Execution of the In general twice
tests described
tests described per year1)
a) 0.4. ... 1.3 on each delivery
a) (classes 005 and 010
a) DIN 16 776 T1)
For welded joints:
a) ∆MFI ≤ 0.5
b) MFI(HZ) ≤ MFI (FM) + 0.22)
1.3 4.2.1.3 – Oxidation stability (OIT) × (×) ISO/TR 10 837 DIN EN 253, Section 4.2.1.3 Manufacturer's
GKR Guideline R 9.3.17 certificate per
200°C/> 20 minutes batch
1.4 – if necessary dry loss × GKR Guideline R 9.3.17 GKR Guideline R 9.3.17
> 0.1 % Execution of the
Execution of the In general twice
tests described
1.5 – if necessary homogeneity × × GKR Guideline R 9.3.17 GKR Guideline R 9.3.17 tests described per year1)
on each delivery
Non-homogeneities < 0.02 mm2
R&D INTAKE MANIFOLDS
Table A5-1. Continuation.
Explanations:
1) Inspection of the execution and the indications of the internal supervision; if necessary taking of samples for laboratory tests
2)
R&D INTAKE MANIFOLDS
387
388
Table A5-2. Monitoring tests on welded joints (works and site welds)
Explanations:
1) Inspection of the execution and the indications of the internal supervision; if necessary taking of samples for laboratory tests
a) At least for each compound type, machine and diameter group once per year
b) Per method, type of material and welding machine
Welder examinations based on DVS 2212
Project-related work tests at the beginning of work; at least half yearly
R&D INTAKE MANIFOLDS
Page 21 to DVS 2207-5
Annex 6: Determination of the time factor and a fictitious joining factor for a welded joint
This Annex is only for information and is not a binding part of this Directive.
Applied stress
in the tests R
ef
As
e
su
re
nc
m
pt
e
io
sp
n:
ec
w
i m
el
en
di
ng
Z-
S-
sp
Z-
ec
V
im
(8
en
0o
cu
)
rv
e
Time-to-failure in years
Time-to-failure in hours
Figure A6-1. Formation of a fictitious joining factor f′s(σ ) from test results of the tensile creep test (Z-S-Z-V) for only one test stress; for example
σ = 4.0 N/mm2.
389
Page 22 to DVS 2207-5
σR σST σT σres
[N/mm2] [N/mm2] [N/mm2] [N/mm2]
Case 1 µ = 0.25 0.3 0 approx 1 1.3
σ = 1 N/mm2
T = + 25 oC
E = 120 N/mm2
Case 2 µ = 0.5 0.6 0.2 approx 0.8 1.6
σ = 0.75 N/mm2
T = + 30 oC
E = 180 N/mm2
Case 3 µ = 0.5 2.7 0.7 approx 0.8 4.2
σ = 0.75 N/mm2
T = + 30 oC
E = 180 N/mm2
390
Erstellungsdatum: 12.02.2002
Letzte Änderung: 18.02.2002
File-Name: C:\DVS Merkblätter\2207\2207-05\BEIBL1\e2207-5b1.fm
This publication was prepared by a group of experienced specialists working together in an honorary capacity, and it is recommended that it should be respected as
an important source of knowledge. The user must at all times check the extent to which the contents apply to his or her special case and whether the version available
to him or her is still current. Any liability on the part of the German Welding Society and of those participating in the preparation of this document is excluded.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
391
Page 2 to DVS 2207-5 Supplement 1
3.1 Preparation and requirements for carrying out the process – A user-friendly adjustment facility for aligning the work at the
Equipment operation tests and parameter checks must be welding point (to minimise face offset).
carried out before work commences, and the following conditions
guaranteed. Table 1. Permissible gap widths and deviations from plane-paralle-
– Heat regulation, temperature maintenance, maintenance of Permissible gap width Nominal external casing pipe diameter
settings;
[mm] [mm]
– Water- and oil-free air supply for extrusion and hot gas
processes; maintenance units for stationary compressed air ≤ 0.5 ≤ 355
supply;
≤ 1.0 400 ≤ 560
– Correct allocation and dimensions of hot gas jets (WZ and WE)
and welding tools (welding shoes for WE) for the types of weld ≤ 1.3 630 ≤ 800
to be completed. ≤ 1.5 > 800
3.1.2 Operating test of the equipment and machines used
– Sufficient heated plate output and an even heat flux – also in
The operational safety of the machines and equipment used the case of split heated plates – into the welding zones; no
must be tested: residual parting marks in the weld and bead;
– Target/actual comparison of the parameters set for sufficient – Permissible overall temperature deviation of both the opposing
working time/preheating time with suitable measuring points of the heated plate and across the entire area of the
equipment and probes. The steady state condition must be working surfaces (including standard machine deviation);
achieved.
∆TTotal ≤ 10 (≤ ∅ 355 mm) up to ≤ 20 °C (≥ ∅ 800 mm)2) (dia-
– A test weld and at least one test idle cycle specimen for larger meter-dependent)
components.
– Plane-parallelism of the heated plate – split heated plates
3.1.3 Work and workplace correspondingly dimensionally stable and firmly mounted; per-
missible deviation from plane-parallelism within the effective
The working sequence and execution must ensure: surface area in accordance with table 2.
– A self-contained, clean working area with no interference from – Reliably-operating control/regulatory facilities for the appli-
other working areas, draughts or invasion by dust, dirt, cation of reproducible welding parameters within the limits of
moisture or the like; permissible application.
– The provision of clean, undeformed workpieces. If prefabri-
– A data recording facility displaying the pressure-(path)-time
cation takes place outside the welding area, internal and exter-
graph is advantageous
nal temperature differences must not differ by more than
approximately ∆T ≤ 5 °C from each other and the workplace;
Table 2. Permissible deviations from plane parallelism of the heated
– Cleaning processes only with grease-free cleaners and plates, including split elements, within the effective surface
sufficient ventilation time. The cleaning processes or surface area.
machining of the joint faces must be repeated at the welding
site, if necessary, in the case of prefabricated segments and Permissible deviation from Nominal external casing pipe
joint faces. plane parallelism diameter
The requirements of DVS 2207-5, paragraph 5, must be fulfilled. [mm] [mm]
The machines and equipment used must guarantee a safe, ≤ 0.8 630 ≤ 800
reproducible process with sufficiently constant welding
≤ 1.2 > 800
parameters, c.f. DVS 2208-1. This requires:
– Secure clamping (fixing and aligning) and control of the work 3.2.2 Preparation of the welded material/joint sub-faces
with even transmission of compressive forces over the entire
welding surface/circumference of the pipe (a); diameter- The following points must be checked for workpieces clamped
dependent admissible gap widths by bending up and into the machine before the welding process commences:
machining deviations from plane-parallelism in accordance – Alignment of the joint sub-faces with minimal offset, so that the
with table 1; see also DVS 2208-1, paragraph 4.1.2; requirements for the finished weld can be guaranteed;
– Adapted jigs enveloping the pipe, which do not cause any
– Sufficient contact of the welding surfaces around the entire
inadmissible embossing/notching of its surface;
circumference of the pipe must be ensured. If necessary, the
– Chucking/clamping of the work close to the welding plane, with prefabricated workpieces must be machined while clamped
appropriately-shaped jigs in the case of segmental mitred into the machine (by a plane integral to the machine). The
welds; permissible gap width/deviation from plane parallelism must
1) Clamped pipe ends, carefully machined flat, are used for measurement. Two reference specimens (spacers) are placed on the axis of the pipe parallel
to the plane of the guide/power spar and the pipe ends brought into contact with each other at the joint pressure applicable to the pipe. The difference
in gap widths measured, unpressurised and under joint pressure, must not exceed a tolerance range of 0.25 mm.
2) Measured in the working position in a draught-free environment with the heated plate temperature set at 210°C
392
Page 3 to DVS 2207-5 Supplement 1
satisfy the requirements of table 1, point (b) of this Supple- “Intermittent” variant I is used for T-pieces with mounted
ment. discharge pipes and for special forms of weld when producing
fittings from PE casing pipes. In particular, it is used if the face
– The cleanliness of the welding (workpiece) faces must be
geometry charges in the course of the weld, which cannot be
verified (see also paragraph 3.1.3).
accomplished reliably using the invariable welding shoe shapes
3.2.3 Welding process
R&D INTAKE MANIFOLDS
The heated plate welding process and guide settings for the
of “continuous” process variant II.
process parameters are described in DVS 2207-1. The Alignment pressure Joint pressure
parameters specified for execution of the process (heated plate
temperature, pressure and time increments) must be observed.
Pressure
The heating plate temperature range is between 200 and 220 °C.
Notes on the process stages shown in diagrammatic form in
Fig. 1: Heating-up pressure
Alignment Joining
– Alignment: time Heating-up time time Cooling time Time
Change-over time
Initial fusion of the welding surfaces until the parts to be
welded are in full contact with the heated plate (small molten Figure 1. Diagrammatic representation of stages in the process of
bead) around the entire circumference (inside and out). heated plate welding (based on DVS 2207-1).
The alignment time (tAG) emerges from the necessary depth of
3.3.1 Equipment requirements
burn-off.
The equipment used must guarantee even preheating (initial
Alignment pressure = joining pressure: pAG ≈ 0.15 N/mm2
fusion) of the joint faces and continuous feed of the
homogenously plasticised welding filler into the welding groove
– Heating-up/melting process: (V- or fillet weld) with the exercise of sufficient welding pressure
The depth of fusion of the joints required for welding is created through the welding shoe/the workpiece to be welded on to the
at reduced pressure (fixing pressure only). welding deposit. This principally requires the following:
Guideline for tAS – dependent on wall thickness – in accor- – Adjustment/alignment of the hot gas jet to the shape and path
dance with working instruction or DVS 2207-1. of the weld;
Heating-up pressure pAW ≈ 0.01 N/mm2 – A simple welding unit readjustment facility for the enclose
support of the welding shoe (tool) on the circumference of the
– Change-over time (tU): pipe and centred longitudinal guidance across the path of the
weld;
The time between lifting off the heated plate and the welding
faces encountering each other for joining/welding must be kept – Appropriate shaping and a welding shoe adapted to the
as short as possible. dimensions of the weld (width of joint coverage, weld camber,
contact length, the front “shoe tip” closing the joint, edge
Guide settings under working instruction or DVS 2207-1. rounding and recessing), in accordance with the process
(The change-over time should be ≥ tU 5 ≤ 8 seconds, directive and working instructions;
depending upon the thickness of the wall, where pipe wall – PTFE or equivalent plunger for suitable shaping (weld shape
thicknesses are 3 – 15 mm. and width) for manual pressure on the weld deposit at the
– Jointing ends, etc. and for intermittent execution of the process.
The joining pressure (pF) is established quickly with bead 3.3.2 Preparation of the parts to be welded/joint sub-faces
formation during the joining period (tF).
– The specific welding parameters of PE moulding material must
tF approximately 5 to 15 seconds – depending upon the wall match. The melt flow rate (MFR 190/5) of the workpieces and
thickness. the fillers must not deviate from each other by more than
The cooling time (tK) for the joint/cross-section of the weld 0.5g/10 minutes under DIN EN 253. Control measurements
follows, maintaining the joining pressure (pF) up to approxi- must be taken if necessary.
mately ≤ 70 °C. – The surfaces to be welded (joint faces and surface areas in the
Guide settings for tK and pF in accordance with working vicinity of the edges of the joint) must be machined; see also
instruction or DVS 2207-1. DVS 2207-5, paragraph 5.
Mechanical stresses on the welded joint must be precluded – Secure anchorage of the workpiece and maintenance of the
until it has cooled close to the temperature of the pipe. joint shape and root gap specific to the process in accordance
with working instructions and process directive DVS 2207-4
3.3 Hot gas extrusion welding must be guaranteed. If necessary, tack welds or a WZ root
pass in the intermittent process must be provided.
Hot gas extrusion welding is described in Directives DVS 2207-4
and its Supplement (parameters) and DVS 2207-5. The major – The cleanliness of the welding surfaces and the welding filler
requirements and specifications are set out below, in conjunction material must be verified, see also section 3.1.3.
with DVS 2207-5, paragraph 5.2.
3.3.3 Welding process
As well as process variant II (in accordance with DVS 2209),
applied predominantly to longitudinal and circumferential welds Continuous observance of the parameters of face/welding
on PE casing pipes, variant I, the intermittent process, is used. deposit temperature, welding pressure on the welding deposit
Experience has shown that the greater demands of long-term and an appropriate welding speed must be ensured. This
strength (welding factor “fs”) are not achieved by process variant I requires:
due to manual execution with separate functions and the
– Controlled, safe tool guidance;
observance of parameters which can be influenced to a high
degree by the welder, unlike the mechanised and partially – Penetration tests on the joint faces in the entire weld face im-
mechanised process variants in accordance with DVS 2207-5, mediately in front of the welding tool. Necessary depth of
table 4; see DVS 2207-4, paragraph 17. fusion ≥ 0.5 mm.
393
Page 4 to DVS 2207-5 Supplement 1
– Continuous observation of the weld site and any necessary 4.2 Destructive test methods
readjustment of the welding unit (centring and bearing on the
pipe) and adjustment of the advance control system. 4.2.1 Tensile test
– Subsequent manual pressing of the welding deposit into the The tensile test is carried out in accordance with paragraph 6.1 of
L fKurz
V Kurz = V Normal × ----------------------
L fNormal
394
Page 5 to DVS 2207-5 Supplement 1
closed so that the resultant longitudinal and lateral forces are 5.1.2 Indications of good WE welded joints
completely removed from the fitting itself. A good WE welded joint displays the following crucial formation
characteristics (Fig. 5):
4.3 Imperviousness test
5 Requirements imposed on welded joints – Even weld camber running centrally to the joint, joint edge cov-
erage by V-weld ≥ 2 mm (3 ± 1 mm)
The requirements imposed on welded pipe joints in paragraph 7
– Smooth weld form, reflecting the shape of the welding shoe,
of Directive DVS 2207-5 apply to fittings.
with the weld surface not showing any signs of disintegration,
The requirements for welded joints to be inspected in accordance overheating, rising bubbles, inhomogeneity, inclusions, etc.
with paragraph 4 of this Supplement are set out below.
– Minimal face offset.
5.1 Visual inspection – Notch-free, penetrative weld root with slight root sag; root con-
cavity and lack of fusion at the edges of the weld (notches with
The subjects of visual inspection are:
sharp edges) are serious faults in production.
– Maintenance of the process-specific weld formation, particu-
– Weld edge machining depth ≤ 10% of the pipe wall thickness
larly in respect of the weld shape, dimensions, geometry and
and ≤ 1 mm
symmetry;
– Inspection of the surface characteristics for any damage to the 5.1.3 Indications of good WZ welded joints
surface of the pipe in the vicinity of the weld as a consequence A good WZ welded joint has the following particular features
of the handling of the fittings, clamping, the effects of tempe- (Fig 6):
rature etc. during implementation of the process.
Welds (face shape, bead/weld formation, presence of blowholes,
large pores, accumulations of pores, root and edge notches, root
suck-backs and lack of side wall fusion in weld cross-sections)
are assessed in accordance with evaluation group 2 in DVS
2202-1. Should deviations from the requirements occur in
individual cases, they must be specified in advance.
Increased face offset limits of ∆s ≤ 0.2 s (s = thickness of the
thinner wall) are accepted for PE casing pipe fittings at the
relatively low wall thickness usual within the scope compared to
the pipe diameters on one hand and the difficult production
conditions of some structural forms with internal medium pipes
on the other, such as outward necked T-pieces in heated plate
welding. Under particularly difficult conditions for fittings – e.g.
the outward-necked T-piece – up to ∆s ≤ 0.3 s is admissible, if
the associated greater weakness is observed in static testing.
395
Page 6 to DVS 2207-5 Supplement 1
5.3 Requirements for the technological bend test 7 Standards and directives
The requirements of Directive DVS 2207-5, paragraph 7.2 and
Fig. 14, apply. DIN EN 253 Preinsulated bonded pipe systems for directly
burried hot water networks – Pipe assembly for
steel service pipe, polyurethane thermal insulation
396
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-6\e2297-6\e2207-6.fm
Erstellt am: 16.11.2003
Zuletzt geändert am: 02.12.2003
September 2003
Welding of thermoplastics
DVS – DEUTSCHER VERBAND
Non-contact heated tool butt welding of
FÜR SCHWEISSEN UND
pipes, pipeline components and sheets Technical Code
VERWANDTE VERFAHREN E.V.
DVS 2207-6
5.4.1 Start-up control and adjusted to the joining force control by a thermal
5.4.2. Heating up reduction after falling below a certain joining force.
5.4.3 Changeover
5.4.4 Joining
5.4.5 Cooling 3 Requirements on welding equipment
5.5 Safety indications
6 Testing of welded joints 3.1 General
7 Standards and Technical Codes
7.1 Standards The requirements on welding machines for the non-contact
7.2 Technical Codes heated tool butt welding method are mentioned in the Technical
8 Explanations Code DVS 2208-1. Further detailed requirements are listed in
Appendix: Indications and protocol for testing of equipment section 3.2.
Welding protocols
3.2 Special requirements for distance control
1 Scope Welding machines with an automatic joining process demand the
adjustment for an exact distance control. With manual controlled
In this Technical Code the non-contact heated tool butt welding machines the position of the guiding devices must be exactly
and the requirements for devices and machines are described. adjustable by distance bolts.
With the mentioned features the processor can check which With the application of mechanic distance limits (distance bolts)
devices or machines are most suitable for the safety realizable these have to be suitably protected so that dirt or falling in of
performance of his welding works appropriate to the materials shavings is absolutely avoided. The reproducible position
involved. exactness must be ± 0,05 mm.
This Technical Code relates to methods and the different types of
processes of heated tool butt welding where the heating up of the
joining areas is done without any contact. Machines, devices and 4 Radiant heated tools
their parameters for the welding of pipeline components, sheets
and other components out of PP (PP-H/PP-B/PP-R) and PVDF Heated tool and machine are a unit. Therefore the machine has
are described. Occasionally the system dependency according to to be re-calibrated after exchange of the heated tool.
the manufacturer’s instructions with material combinations of PP
and PVDF have to be considered. Concerning the welding The construction of the heated tool must guarantee a perfect
suitability of materials PP and PVDF see the topic “scope” in DVS heating up of the joining areas to the welding temperature under
2207-11 and DVS 2207-15. working conditions. The handling of the heated tool must enable
keeping the adjustment time according to table 2.
With the welding of other plastics e. g. PFA, E-CTFE the
parameters have to be checked and possibly adjusted. The The voltage supply in the heated tool area has to be protected
welding joint quality must be proved depending on the system against thermal damages, just as the active surface of the heated
(machine, parameters, component). tool against mechanical damages.
The mounting and guidance of the heated tool must enable a
plane parallel position of heated tool to the joining areas.
2 General description of methods
The used heated tool must be plane parallel within its active
With the non-contact heated tool butt welding the joining areas of surface and the maximum deviation must be lower than 0,2 mm.
the parts to be welded have to be shaved in order to reach a plan The measurement is done at 23 ± 2 °C.
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
397
Page 2 to DVS 2207-6
4.1 Radiators The welding works must be supervised. The type and scope of
supervision has to be agreed. It is recommended to record the
The heated tools for non-contact welding are radiant heated tools procedure data in welding protocols (example see appendix) or
which are classified depending on wave ranges. data carriers.
398
Page 3 to DVS 2207-6
the welding machine in a horizontal and vertical direction. The Table 2. Start-up and changeover time.
slight longitudinal mobility of the part to be welded on has to be
fixed e. g. by adjustable roller blocks or oscillating suspension. Wall thickness Start-up time Changeover time
[mm] (maximum) [s] (maximum) [s]
5.4.1 Start-up Bild 1. Bead design at heated tool butt welding (principle on example
pipe).
The start-up of the heated tool between the joining areas must be
done quickly (start-up time) as otherwise the additional heating
would be uneven and unregulated, see table 2. 5.4.4.1 Pressure controlled joining
399
Page 4 to DVS 2207-6
Table 3. Possible test methods for welding connections. 7.2 Technical Codes
Test method Heated tool butt welding DVS 2202-1 Failures on welding connections out of
sheets, pipes, fittings thermoplastics; Features, description,
400
Page 5 to DVS 2207-6
Appendix
Test protocol for heated tool butt welding machines (pipeline components)
Evaluation of total condition (for comments about total condition please use supplementary sheet)
Evaluation key for tests and condition Evaluation key for measurements
1 = without claim 1 = within allowed tolerances
2 = minor claim 2 = deviation with minor influence
3 = claim which reduces the use 3 = deviation which reduces the use
4 = further use is not allowed 4 = unacceptable deviation
Auditor:
401
Page 6 to DVS 2207-6
Product/Manufacture Type
Machine/Serial number
Heated tool serial number R&D INTAKE MANIFOLDS Dimension range*
* also valid for required heated tools
Elevating spar
Plan parallelism
Straightness and alignment
Elevation adjustment
Evaluation of total condition (for comments about total condition please use supplementary sheet)
Evaluation key for tests and condition Evaluation key for measurements
1 = without claim 1 = within allowed tolerances
2 = minor claim 2 = deviation with minor influence
3 = claim which reduces the use 3 = deviation which reduces the use
4 = further use is not allowed 4 = unacceptable deviation
Auditor:
402
Material
Protocol form for non-contact heated tool butt welding of sheets Sheet of
Customer Executive company Welding equipment:
403
404
Protocol form for non-contact heated tool butt welding of pipes and pipeline aboveground Material Sheet of
components buried
December 2008
R&D INTAKE MANIFOLDS Translation of the German edition from August 2008
1 Scope of application The quality of the welded joints is dependent on the qualification
2 General requirements of the welders, on the suitability of the utilised machines and jigs
3 Measures before the welding as well as on the compliance with the technical codes for
welding. The weld can be tested using non-destructive and/or
3.1 Prerequisites for the welding
destructive procedures.
3.2 Cleaning
3.2.1 Cleaning agents The welding work must be monitored. The contracting parties
3.2.2 Cleaning of the heated tools must reach agreement on the type and scope of the monitoring. It
is recommended to document the process data on welding
3.2.3 Cleaning of the joining faces
record sheets (for a specimen, see the appendix) or on data
4 Heated tool butt welding carriers.
4.1 Heated tool butt welding of pipes, piping parts, fittings and
panels Within the framework of the quality assurance, it is recommended
to manufacture and test trial welds in the given working
4.1.1 Process description
conditions before commencing and during the welding work.
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
405
Page 2 to DVS 2207-11
406
Page 3 to DVS 2207-11
pressure possible, with a linear rise. The times necessary for this purpose
are shown in Table 2, Column 5. The joining pressure is
joining pressure 0.10 ± 0.01 N/mm².
alignment pressure
changeover time
heating-up the cooling time by as much as 50%, i. e. joining pressure relief
time cooling time and removal of the welded part from the welding machine:
alignment joining pressure build-up time – the joint is manufactured in workshop conditions,
time
total joining time
– the removal from the welding machine and the temporary
total welding time storage cause only a slight load on the joint and
– the joining parts have wall thicknesses ≥ 15 mm.
Figure 2. Process steps in heated tool butt welding. Further processing with a full mechanical load on the joint may
only take place after complete cooling according to Table 2,
Alignment Column 5.
In this respect, the joining faces to be welded are pressed on to
A uniform double bead must exist after the joining. The bead
the heated tool until the entire faces are in contact with the
formation provides orientation with regard to the uniformity of the
heated tool with parallel faces. This can be recognised by the
welds with each other. Different bead formations may be caused
formation of the beads. The alignment is finished when the bead
by the various types of flow behaviour of the joined materials.
heights around the entire pipe circumference or on the entire top
The weldability may be assumed from the experience with the
side of the plate have reached the values specified in Table 2,
commercially available semi-finished PP products in the specified
Column 2. The bead heights are regarded as an indicator that the
MFR range, even if this may lead to asymmetric welding beads.
whole area of the joining faces is in contact with the heated tool.
K must always be > 0 (see Figure 3).
The alignment pressure of 0.10 N/mm² is effective throughout the
alignment operation.
Heating-up
For the heating-up, the faces must be in contact with the heated
tool at a low pressure. To this end, the pressure is reduced to
nearly zero (≤ 0.01 N/mm²). During the heating-up, the heat
penetrates into the faces to be welded and heats these up to the
welding temperature. The heating-up times are shown in Table 2,
Column 3.
Changeover
After the heating-up, the joining faces must be detached from the
heated tool which must be taken out without damaging or soiling
the heated joining faces. The joining faces must then be moved
together quickly until they almost touch. The changeover time
should be kept as short as possible (see Table 2, Column 4)
since the plastified faces would otherwise cool down. This would
exert a detrimental influence on the weld quality. Figure 3. Bead formation in the case of heated tool butt welding
(principle using the example of a pipe).
Joining
The faces to be welded should come into contact at a speed of For a short version of the processing instructions, see the
nearly zero. The required joining pressure is applied, if at all appendix.
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PP at an outdoor temperature of approx. 20°C with
moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
Alignment Heating-up Changeover Joining
Heated tool temperature 210 ± 10°C
Nominal wall Changeover Joining Cooling time under
Bead height at the heated tool time pressure joining pressure
thickness s
at the end of the alignment time (Heating-up (maximum build-up (minimum values)
(minimum values) p = ≤ 0.01 N/mm2) time) time p = 0.10 ± 0.01 N/mm²
(alignment p = 0.10 N/mm2)
mm mm s s s min
Up to 4.5 0.5 up to 135 5 6 6
4.5 ... 7 0.5 135 ... 175 5 ... 6 6 .. 7 6 ...12
7 ... 12 1.0 175 ... 245 6 ... 7 7 .. 11 12 ... 20
12 ... 19 1.0 245 ... 330 7 ... 9 11 ... 17 20 ... 30
19 ... 26 1.5 330 ... 400 9 ... 11 17 ... 22 30 ... 40
26 ... 37 2.0 400 ... 485 11 ... 14 22 ... 32 40 ... 55
37 ... 50 2.5 485 ... 560 14 ... 17 32 ... 43 55 ... 70
407
Page 4 to DVS 2207-11
5 Sleeve welding with an incorporated electric heating The out-of-roundness of the pipe must not exceed 1.5% of the
element outside diameter, max. 3 mm, in the welding area.
Corresponding round pressing clamps must be used if
5.1 Process description necessary.
The cables can be removed when the device has been switched
off. If there are any welding indicators on the fitting, these must
be checked. The joint may only be moved after the cooling.
Information about this is provided by the fitting manufacturer.
heater heater If the manufacturer provides any information about additional
spiral spiral cooling times (e. g. until the pressure test), attention must be paid
zone zone to this.
408
Page 5 to DVS 2207-11
409
Page 6 to DVS 2207-11
Table 4. Guide values for the heated tool sleeve welding of pipes and fittings made of PP at an outdoor temperature of 20°C with moderate air
movement.
1 2 3 4 5
DVS 2203-4
Tensile creep test Tensile creep welding factor DVS 2203-4, Supplement 1
DVS 2203-1, Supplement 2
DVS 2203-5
Minimum bending angle according to
Technological DVS 2203-1, Supplement 3, Figs. 2 and 3 Not applicable
bending test
Minimum bending path according to
DVS 2203-1, Supplement 3, Figs. 8 and 9
DIN 16962-5, Section 5.4.3.1
Length of each pipe piece according to
Internal pressure Table 5 DIN 16962-5, Sections 3.2.3.1 and 4.2 at 95°C
creep test
Not meaningful for long-time welding
factor > 0.5.
410
Page 7 to DVS 2207-11
411
Page 8 to DVS 2207-11
Re. 4.1 Heated tool butt welding of pipes, piping parts, 4. Guarantee the roundness of the pipes using round pressing
412
Welding record sheet for the heated tool welding above ground Material Page of
of pipes underground
1 = sun 1 = none
No. of Order Name and company of welding supervisor Machine-No.: 4 = wind 4 = heating
Seam Date Pipe Measured heating- Moving Joining Parameters Heating-up Changeover Joining Cooling time Ambient Key-number
No. dimension element temperature pressure pressure time time pressure under joining temperature
ød×s (Machine table) Alignment Heating up Joining built-up time pressure weather protection
min max
[mm] [ C] [ C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [ C]
R&D INTAKE MANIFOLDS
413
Page 9 to DVS 2207-11
414
Welding record sheet for heated tool butt welding of panels Material Sheet of
Type:
Year of building:
Seam Date Thickness Measured Reference values Heating-up Changeover Joining Cooling time Temperature Comments
number of sheet heated tool time time pressure under joining of environment
temperature Alignment Heating-up Joining build-up time pressure
[mm] [ C] min/max [bar] [bar] [bar] [s] [s] [s] [s] [ C]
1 = sun 1 = none
Number of order Name and company of supervisor Number of machine: 4 = wind 4 = heating
Year built: If more than one condition applies order of numbers as above
(e. g. 34 = rain and wind)
Seam Date Pipe Fitting data Adjustment of device Resistance Induced Welding time Temperature Key-number Operating conditions
number demension of fitting voltage of
ød×s A B Serial manual automatic Joining Cooling environment Weather Protection Line- Gene-
[mm] number [Ohm] [Volt] [s] [s] [ C] powered rator
R&D INTAKE MANIFOLDS
415
Page 11 to DVS 2207-11
416
Welding record sheet for heated tool socket welding o above ground Material Page of
1 = sun 1 = none
Page 12 to DVS 2207-11
Number of order Name and company of supervisor Number of machine: 4 = wind 4 = heating
Year built: If more than one condition applies order of number as above
(e. g. 34 = rain and wind)
Seam Date Pipe Fitting data Measured Heating Changeover Cooling time Temperature Key-number Comments
number dimension heated tool time time of
ød×s A B Serial temperature fixed total environment Weather Protection
number (spigot/socket)
[mm] [ C] [s] [s] [s] [min] [ C]
R&D INTAKE MANIFOLDS
January 2009
R&D INTAKE MANIFOLDS Translation of the German edition from December 2006
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
417
Page 2 to DVS 2207-12
The joining faces must be machined immediately before the given to electronically controlled machines – if at all possible,
beginning of the welding. with recording.
Any chips must be removed without touching the joining faces. The nominal wall thicknesses of the parts to be welded must
pipe heated tool pipe The misalignment must be checked at the same time as the gap
width. The misalignment of the joining faces in relation to each
heating-up other must not exceed the permissible dimension of 0.1 x wall
thickness on the outside of the pipe or on the panel. The
objective must be a minimum misalignment. A larger
misalignment results in a reduction in quality which restricts the
load-bearing capacity of the joint. In this case, an evaluation may
be carried out according to the DVS 2202-1 technical code taking
account of the requirements on the joint.
welding joint The machined welding faces must not be either soiled or touched
by the welder's hands since another chip-producing machining
operation would otherwise be necessary. An additional cleaning
operation is not required and does not give rise to any
improvement in quality. Any chips which have fallen into the pipe
must be removed.
418
Page 3 to DVS 2207-12
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PVC-U at an outdoor temperature of approx. 20°C
with moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
Nominal wall Alignment Heating-up Changeover Joining
thickness
s Heated tool temperature 230 ± 8°C
Bead height at the Heating-up time Changeover time Joining Cooling time
heated tool at the = 15 x wall thickness (maximum time) pressure = 2 x wall thickness
end of the alignment (heating-up build-up time under joining pressure
time p ≤ 0.01 N/mm2) = 1+0.5 x wall p = 0.60 N/mm2 ± 0.01
(minimum values) thickness (minimum values)
(alignment
p = 0.60 N/mm2)
mm mm s s s min
1.9 28.5 2 4
3 0.5 45 6
3
4 60 8
6 90 4 12
8 1.0 120 5 16
≤2
10 150 6 20
12 180 7 24
15 225 9 30
1.5
20 300 11 40
25 375 14 50
419
Page 4 to DVS 2207-12
Table 3. Test procedures for welded joints. DIN 16963-5 Pipe joints and fittings for pressure piping made
of PE – General quality requirements and
Test Heated tool butt welding testing
procedure Panels, pipes and fittings
420
Page 5 to DVS 2207-12
Appendix: Processing instructions (short versions) 14. Determine the setting values for the alignment, heating-up
and joining pressures.
Re. 4.1 Heated tool butt welding of pipes, piping parts,
fittings and panels 15. Stipulate the guide values according to Table 2.
2. Connect the welding device to the mains or to the alternating 17. Align the faces to the heated tool until a bead arises
current generator and check its function. (according to Table 2, Column 2).
3. Align and clamp the parts to be welded, e. g. with dollies. 18. Heating-up at a reduced pressure ≤ 0.01 N/mm², heating-up
4. Close the pipe ends against draughts. time according to Table 2, Column 3.
5. Clean the joining faces beyond the welding area with a
19. At the end of the heating-up, detach the joining faces to be
cleaning agent according to Section 3.2.1 with unused,
welded from the heated tool and move this out of the welding
absorbent, non-fraying and non-dyed paper.
position.
6. Machine the joining faces, in the case of pipes using a plane
(for example). 20. Within the changeover time (Table 2, Column 4), quickly
7. Take out the plane in the case of a pipe welding machine. move together the faces to be welded until they almost
touch. The faces must come into contact at a speed of nearly
8. Remove the chips from the welding area without touching zero. Immediately afterwards, build up the joining pressure
the joining faces. with a linear rise in the joining pressure build-up time (Table
9. Check the plane parallelism by moving the joining faces 2, Column 5).
together (max. gap width according to Table 1).
21. A bead must exist after the joining at a pressure of 0.60 N/
10. Check the misalignment (max. 0.1 x wall thickness). mm². According to Figure 3, K must be > 0 at every point.
11. Check the heated tool temperature (230 ± 8°C).
22. Cooling under the joining pressure according to Table 2,
12. Clean the heated tool with a cleaning agent according to Column 5.
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-
fraying and non-dyed paper and ensure extraction. 23. Unclamping of the welded parts when the cooling time has
13. Determine the movement pressure or the movement force elapsed.
before every welding operation and make a note of it on the
welding record sheet. 24. Complete the welding record sheet.
421
422
Welding record sheet for the heated tool welding of Material Page of
panels
Constructor Executing company
Welding device:
Page 6 to DVS 2207-12
Manufacturer:
Job description Name of welder ID-No.
Type:
Machine-No.:
No. of job Name and company of welding supervisor
Year built:
Seam Date Panel thickness Measured heating- Parameters Heating-up Changeover Joining pressure Cooling time Ambient- Remarks
No. element temperature time time built-up time under joining temperature
Alignment Heating-up Joining pressure
min max
[mm] [ C] [ C] [bar] [bar] [bar] [s] [s] [s] [min] [ C]
R&D INTAKE MANIFOLDS
of pipes underground
1 = sun 1 = none
No. of Order Name and company of welding supervisor Machine-No.: 4 = wind 4 = heating
Seam Date Pipe Measured heating- Moving Joining Parameters Heating-up Changeover Joining Cooling time Ambient Key-number
No. dimension element temperature pressure pressure time time pressure under joining temperature
ød×s (Machine table) Alignment Heating up Joining built-up time pressure weather protection
min max
[mm] [ C] [ C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [ C]
R&D INTAKE MANIFOLDS
423
Page 7 to DVS 2207-12
November 2012
4.3.2 Alignment
4.3.3 Heating-up 3 Measures before the welding
4.3.4 Changeover
4.3.5 Joining pressure build-up time 3.1 Prerequisites for the welding
4.3.6 Joining The welding area must be protected from unfavourable weather-
5 Testing of the welded joints ing influences (e.g. the action of moisture, great air currents and
6 Literature temperatures below + 5°C). If suitable measures (e.g. preheating
7 Explanation or heated assembly tents) ensure that a semi-finished product
Appendix: Processing instructions (short version) temperature sufficient for the welding can be complied with, the
Welding record sheets work may be carried out at any outdoor temperature – provided
that the handling of the welder is not hindered. In any case, it is
recommendable to provide additional evidence by manufacturing
1 Scope of application trial welds in the conditions of the construction measure (see
Section 5).
This technical code applies to the heated tool butt welding of
panels, pipes and piping parts made of PVC-C. If the semi-finished product is heated non-uniformly due to solar
radiation, the temperatures must be equalised by covering the
The PVC-C panels are used for the fabrication of storage and area of the welding point in good time. It is necessary to avoid
process tanks and miscellaneous construction elements by means any draught-induced cooling or non-uniform heat distribution during
of heated tool butt welding. These components are predominantly the welding operation. When pipes are welded, it is recommended
utilised in the field of the storage of liquids and solids as well as in to close the pipe ends in addition.
the field of process chemistry.
The joining faces of the parts to be welded must not be damaged
The PVC-C panels and piping parts must comply with the DVS
and must be free from contaminations (e.g. dirt, grease, deposits,
2205-1 technical code, Supplement 9 and Supplement 11, as well
chips etc.).
as with the properties specified for compounds in ASTM D 1784-03,
Cell 23448. The Vicat softening temperature must exceed 105°C.
3.2 Cleaning
The fittings made of PVC-C must exhibit the same properties as
For the manufacture of flawless welded joints, it is decisively im-
the piping. If these are not available, it is recommended to fabricate
portant that not only the joining faces but also the tools and the
these from pipes. Piping and fittings predominantly serve to trans-
heated tools are clean and free from grease.
port liquids, gases and solids.
3.2.1 Cleaning agents
2 General requirements The cleaning fluid or the cloths which have been moistened with
cleaning fluid in the factory and are kept in a lockable plastic box
The quality of the welded joints is dependent on the qualification must consist of a solvent with 100 % or complete vaporisation.
of the welders, on the suitability of the utilised machines and jigs For example, the cleaning fluid consists of 99 parts ethanol with a
as well as on the compliance with the technical codes for welding. degree of purity of 99.8 % and one part MEK (methyl ethyl ketone
The weld can be tested using non-destructive and/or destructive for denaturation). Agents tested according to DVGW VP 603
procedures. comply with this stipulation. If commercially available spirit which
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid.
No liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
424
Page 2 to DVS 2207-13
has a lower purity and may contain other additives is used, this 4.2 Preparation for the welding
may lead to a quality reduction due to the water contained in it
and to other contaminations. The heated tool temperature necessary for the welding must be
checked before the beginning of the welding work. This is carried
The paper for the cleaning must be clean, unused, absorbent, out, for example, with a quick-display temperature gauge for sur-
non-fraying and undyed.
Welding bead In the case of heated tool butt welding, the faces to be joined are
heated up to the welding temperature using the heated tool and,
Figure 1. Principle of heated tool butt welding using the example of a pipe when the heated tool has been removed, are joined together un-
weld. der pressure (Fig. 2).
425
Page 3 to DVS 2207-13
.
Alignment Joining
.
R&D INTAKE MANIFOLDS
Heating-up
Pressure in N/mm²
4.3.1 Heated tool temperature The alignment pressure of 0.50 ± 0.01 N/mm² is effective through-
out the alignment operation.
For wall thicknesses up to 5 mm, the heated tool temperature is
230°C. Wall thicknesses > 5 mm are welded at a reduced heated
4.3.3 Heating-up
tool temperature according to Fig. 3.
For the heating-up, the faces must be in contact with the heated
The permissible temperature tolerance of the heated tool is ± 4 K.
tool at a low pressure. To this end, the pressure is reduced to
The step-by-step sequence of the welding operation is illustrated
nearly zero (0.01 N/mm²). Here, it is recommended to enter a
on Fig. 3.
maximum value, e.g. 0.05 N/mm². During the heating-up, the heat
240 penetrates into the faces to be welded and heats these up to the
welding temperature. The heating-up times are shown in Table 2,
Heated tool temperature [°C]
235 Column 3.
Upper limit
230 4.3.4 Changeover
225 After the heating-up, the joining faces must be detached from the
Lower limit heated tool. The heated tool must be taken out without damaging
220 or soiling the heated joining faces. The joining faces must then be
215 moved together quickly until they almost touch. The changeover
time must be kept under two seconds (see Table 2, Column 4)
210 since the plastified areas would otherwise cool down. This would
0 5 10 15 20 25 30 exert a negative influence on the welding quality.
Wall thickness [mm] 4.3.5 Joining pressure build-up time
Figure 3. Heated tool temperatures as a function of the wall thickness. The joining pressure build-up time is four seconds, irrespective of
the wall thickness of the parts to be welded. In this case, the
4.3.2 Alignment pressure should have a linear rise.
During the alignment, the joining faces to be welded are pressed
on to the heated tool until the entire faces are in contact with the 4.3.6 Joining
heated tool with parallel faces. This can be recognised by the for- The faces to be welded should come into contact at a speed
mation of the alignment beads. The alignment is finished when of nearly zero. The required joining pressure is applied without
the bead heights around the entire pipe circumference or on the delay with a rise as linear as possible. The joining pressure is
entire top side of the plate have reached the values specified in 0.50 ± 0.01 N/mm².
Table 2, Column 2. The bead development on the heated tool is
regarded as an indicator that the whole area of the joining faces
is in contact with the heated tooI.
426
Page 4 to DVS 2207-13
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PVC-C at an outdoor temperature of 20°C with
moderate air movement (no draughts) – intermediate values must be interpolated.
1 2 3 4 5
The joining pressure must be maintained during the cooling time Table 3. Possible test procedures for welded joints.
(see Table 2, Column 5). Increased mechanical stresses during
or immediately after the unclamping are only permissible after Test procedure Heated tool butt welding
prolonged cooling. Panels, pipes and fittings
The assembly or the further processing may only take place after Visual inspection DVS 2202-1 technical code, Table 1
the complete cooling of the weld. DVS 2206-1 technical code
After the joining, a double bead as uniform as possible must exist Tensile test DVS 2203-2 technical code
around the entire circumference. Different bead formations may Short-time tensile welding factor
be caused by the different types of flow behaviour of the joined DVS 2203-1 technical code, Supplement 1
materials. On the basis of the experience with the commercially Tensile creep test DVS 2203-4 technical code
available PVC-C parts until now, the following is applicable: If Tensile creep welding factor
PVC-C pipes and fittings comply with the DIN 8079/80, DIN EN DVS 2203-1 technical code, Supplement 2
ISO 15493 or DIN EN ISO 15877 standard and semi-finished
Technological DVS 2203-5 technical code
PVC-C products correspond to the properties with reference to
bending test Minimum bending angle not yet stipulated
DIN EN ISO 11833, it may be assumed that these are weldable
(the entered testing speed is for PVC-U and
even if this may lead to asymmetric welding beads. K must always
it is missing for PVC-C)
be greater than 0 (see Fig. 4).
Internal pressure DIN 8080, according to Table 1
creep test 95°C, = 5.7 N/mm², service life: > 165 h
6 Literature
427
Page 5 to DVS 2207-13
DIN 8080 Pipes made of chlorinated polyvinyl chloride Appendix: Processing instructions (short version)
(PVC-C) – General quality requirements and
testing 1. Create permissible working conditions, e.g. housing or tent.
ASTM D 1784-03 Standard specification for rigid poly(vinyl 2. Connect the welding device to the mains or to the alternating
The technical code was elaborated according to the state of the art. 19. Within the changeover time (Table 2, Column 4), quickly
move together the faces to be welded until they almost
The welding of thermoplastics at ambient temperatures below touch. They must come into contact at a speed of nearly
5°C is generally considered to be problematical. This relates not zero. Immediately afterwards, build up the joining pressure
so much to the material-specific properties of the plastic but, to a with a linear rise in max. 4 s.
greater extent, to the restricted dexterity of the welder. Therefore,
the prerequisite for open-air welding at any outdoor temperatures is 20. A bead must exist after the joining at a pressure of 0.50 N/mm².
an environment which enables the welding personnel to perform According to Fig. 4, K must be > 0 at every point.
the individual work steps without any quality-reducing influences. 21. Cooling under the joining pressure of 0.50 N/mm².
In this respect, it is necessary to pay attention to the information
22. Unclamping of the welded parts when the cooling time has
from the manufacturers and to the dew point curve. The parts to
elapsed.
be joined must exhibit an identical temperature level. Trial welds
must be produced and tested. 23. Complete the welding record sheet.
With regard to the condition of the pipe ends, it must be ensured
that, within the framework of the welding preparations, any white
frost, ice or moisture is removed from the area of the joining
zones (> 0.5 x fitting length) by supplying heat (e.g. hot gas de-
vice). Fittings must be stored in closed, frost-free rooms and may
only be supplied to the welding point in the number required in
each case.
428
Record sheet for the heated tool butt welding Material Sheet of
of panels
Building owner Executing company Welding machine:
Page 6 to DVS 2207-13
Type:
No. of the order Name and company of the welding supervisor Machine no.:
Year of construction:
Weld Date Panel Measured heated tool Setting values2) Heating-up Changeover Joining pressure Cooling time Ambient Remarks
no. thickness temperature1) time3) time3) build-up time3) under joining temperature
pressure
min. max. Alignment Heating-up Joining
[mm] [°C] [°C] [bar] [bar] [bar] [s] [s] [s] [min] [°C]
429
430
Record sheet for the heated tool butt welding Overground Material Sheet of
1 = sunny 1 = none
Title of the order Name of the welder Code no. Make: 2 = dry 2 = screen
No. of the order Name and company of the welding Machine no.: 4 = wind 4 = heating
supervisor
Year of construction: In the case of multiple designations, sequence of the numbers as above
(e.g. 34 = rain and wind)
Weld Date Pipe data Measured heated Movement Joining pressure Setting values2) Heating-up Changeover Joining Cooling time3) Ambient Code no.
no. d×s tool temperature1) pressure (machine table) time3) time3) pressure under joining temperature3)
build-up time3) pressure
min. max. Alignment Heating-up Joining Weather Protection
[mm] [°C] [°C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [°C]
R&D INTAKE MANIFOLDS
side (principle).
6 Testing of the welded joints
6.1 Specimen preparation
In the case of panels with s > 6 mm, a flat heated tool which
6.2 Execution of the testing heats up the rear side of the panel is arranged on the underside
6.3 Evaluation of the machine (see Fig. 2). This serves to prevent any non-
7 Literature uniform stretching (tapering) in the folding zone and to achieve a
8 Explanations reduction in the stresses.
Appendix: Welding record sheet
Upper
heated tool
1 Scope of application
2 Process description The wedge faces of the upper heated tool have a bevel angle
adapted to the folding [α]. The heated tool is pressed in by
Welding by bending using a heated tool, also called folding weld- approx. 75 % of the panel thickness under the effect of heat and
ing, is a mixed form of forming and heated tool butt welding and is subsequently withdrawn. Thereafter, the panel is folded ac-
is carried out on stationary machines, predominantly in the work- cording to the bevel angle. In this respect, the plastified joining
shop area. In the case of panel thicknesses of s ≤ 6 mm, the faces are joined with each other under joining pressure. In order
1)
The material designation should be understood as a generic term for the group of thermoplastics and includes the PE 63, PE 80 and PE 100 types. The
information corresponds to the current status of the standardisation.
2) MFR = melt flow rate (old designation: MFI = melt flow index)
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
431
Page 2 to DVS 2207-14
to shorten the heating-up time, panels with s ≥ 15 mm can be (methyl ethyl ketone, denaturation). Cleaning agents tested
provided with a groove milled in a wedge shape (depth: approx. according to DVGW 603 comply with this stipulation.
0.5 x wall thickness) on the top side of the panel into which the
The cleaning fluid may be used in the form of cloths which have
heated tool is pressed.
been moistened in the factory and must be kept in a lockable
432
Page 3 to DVS 2207-14
5.4 Cooling
The bent panel remains clamped during the cooling phase. The
cooling time is included in DVS 2207-1, Table 2, Column 5 for PE
Steel plate
and in DVS 2207-11, Table 2, Column 5 for PP. No mechanical
with polished
loads on the joint are permissible before the end of the cooling
surface
time.
After the folding and the joining, the weld executed by bending
using a heated tool must exhibit a uniform double bead. K must
always be > 0 (see Fig. 3). Non-uniform bead formations are an
indication that the execution of the welding was not optimum. Edges broken
with a scraper
6.3 Evaluation
The fracture pattern, the position of the fracture plane, the degree
of deformation as well as the type and scope of inhomogeneities
serve as the evaluation criteria. Fractures in the joining plane (in
so far as these are not of a ductile kind) or fracture faces with
pronounced shrinkage cavity points (air inclusions or voids) pro-
Figure 3. Bead formation in the case of welding by bending using a vide initial indications of mistakes during the execution of the
heated tool (representation of the principle). welding.
433
Page 4 to DVS 2207-14
434
Material Sheet of
Record sheet for welding by bending using a heated tool for panels
Building owner Executing company Welding machine
Type
No. of the order Name and company of the welding supervisor Machine no.
Year of construction
Weld no. Date Panel Measured heated tool temperature 1) Angle Melt Heating-up Cooling Ambient Angle Remarks
thickness Upper heated tool Lower heated tool of the upper penetration time 3) time 3) temperature 3) after
min. max. min. max. heated tool 2) depth 3) 4) folding 3)
[mm] [oC] o
[oC] [oC] [oC] [o] [mm] [s] [min] [oC]
435
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-15\englisch\Jan_08\e2207-15.fm
Erstellt am: 14.01.2008
Zuletzt geändert am: 29.01.2008
March 2008
R&D INTAKE MANIFOLDS Translation of the German version from december 2005
The machines and jigs used for the welding must comply with the
4.3 Execution of the welding requirements in DVS 2208-1.
5 Heated tool sleeve welding
5.1 Process description
5.2 Welding jigs 3 Measures before the welding
5.3 Preparation for the welding
5.4 Execution of the welding 3.1 Prerequisites for the welding
6 Testing of the welded joints
7 Standards and technical codes which are also applicable The immediate welding area must be protected from unfavour-
8 Explanations able weathering influences (e. g. wind or the action of moisture).
Appendix: If suitable measures (e. g. preheating, tenting or heating) ensure
Processing instructions (short versions) conditions permissible for the welding, the work may be carried
Testing of the welded joints out at any outdoor temperature – provided that the dexterity of
Welding record sheets the welder is not hindered (see explanations). If necessary, addi-
tional evidence must be provided by manufacturing trial welds in
the specified conditions (see Section 6).
1 Scope of application If the semi-finished product is heated non-uniformly due to solar
radiation, the temperatures must be equalised by covering the
This technical code applies to the heated tool butt welding of area of the welding point in good time. It is necessary to avoid
panels and to the heated tool butt and sleeve welding of pipes any draught-induced cooling during the welding operation. When
and fittings which are made of PVDF and serve to transport pipes are welded, the pipe ends must be closed in addition.
gases, liquids and solids.
The joining faces of the parts to be welded must not be damaged
Paying attention to the following instructions and on the basis of and must be free from soiling (e. g. dirt, grease and chips).
the practical experience, it may be assumed that melt flow rates
MFR1) 230/5 of 1.0 - 25 g/10 min are suitable for densities of 3.2 Cleaning
1.70 - 1.80 g/cm³. For this purpose, reference must be made to
the data sheets from the suppliers of the semi-finished products – For the manufacture of flawless welded joints, it is decisively
in cases of doubt, Works Certificate 2.1 according to DIN EN important that not only the joining faces but also the tools and the
10204. heated tools are clean and free from grease.
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
436
Page 2 to DVS 2207-15
3.2.2 Cleaning of the heated tools The nominal wall thicknesses of the parts to be welded must
The heated tools must be cleaned with paper before every match in the joining region.
welding operation. No residues of cleaning agents or paper may Pipes and fittings must be aligned axially before they are
If the surface is soiled after the chip-producing machining (e. g. Pipe outside diameter d Gap width Panel width
because of contact with the welder's hands), the welding faces [mm] [mm] [mm]
must be treated with a cleaning agent if an additional chip-
producing machining operation is not possible for process-related ≤ 355 0.5 -
reasons. 400 ... < 630 1.0 ≤ 1500
- 1.3 > 1500 ≤ 2000
4 Heated tool butt welding of pipes, piping parts, fittings
and panels - 1.5 > 2000 ≤ 2300
4.1 Process description - 2.0 > 2300 ≤ 3000
During heated tool butt welding, the faces of the parts to be
welded are aligned to the heated tool under pressure (alignment),
are subsequently heated up to the welding temperature at a The misalignment must be checked at the same time as the gap
reduced pressure (heating-up) and, when the heated tool has width. The misalignment of the joining faces in relation to each
been removed (changeover), are joined together under pressure other must not exceed the permissible dimension of 0.1 x wall
(joining). Fig. 1 shows the principle of the process. thickness on the outside of the pipe or on the panel. The objec-
tive must be a minimum misalignment. A larger misalignment
results in a reduction in quality which restricts the load-bearing
capacity of the joint. In this case, an evaluation may be carried
out according to the DVS 2202-1 technical code taking account
of the requirements on the joint.
The machined welding faces must not be either soiled or touched
by the welder's hands since another chip-producing machining
operation would otherwise be necessary. An additional
cleaning operation is not required and does not give rise to
any improvement in quality. Any chips which have fallen into
the pipe must be removed.
437
Page 3 to DVS 2207-15
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PVDF at an outdoor temperature of approx. 20°C
with moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
Nominal wall Alignment Heating-up Changeover Joining
thickness s
Heated tool temperature 240 ± 8°C Changeover time Joining pressure Cooling time under
(maximum time) build-up time joining pressure
Bead height at the Heating-up time p = 0.10 ± 0.01 N/mm²
heated tool at the end ≈ 10 x wall thickness t ≈ 1.2 x wall thickness
of the alignment time + 40 s (heating-up + 2 min
(minimum values) p ≤ 0.01 N/mm²) (minimum values)
(alignment
p = 0.10 N/mm²)
[mm] [mm] [s] [s] [s] [min]
1.9 … 3.5 0.5 59 … 75 3 3…4 5…6
5.5 ... 10.0 0.5 … 1.0 95 ... 140 4 5 ... 7 8.5 ... 14
10.0 ... 15.0 1.0 … 1.3 140 ... 190 4 7 ... 9 14 ... 19
15.0 ... 20.0 1.3 … 1.7 190 ... 240 5 9 ... 11 19 ... 25
20.0 ... 25.0 1.7 … 2.0 240 ... 290 5 11 ... 13 25 ... 32
438
Page 4 to DVS 2207-15
The heated tools and the fittings are dimensionally coordinated in 5.4 Execution of the welding
such a way that a joining pressure builds up during the joining.
For the heating-up, the fitting and the pipe are quickly and axially
Heated-tool-sleeve-welded joints with a pipe diameter up to
pushed on to the tools attached to the heated tool as far as the
40 mm can be executed manually. In the case of diameters as
439
Page 5 to DVS 2207-15
Table 4. Guide values for the heated tool sleeve welding of pipes and piping parts made of PVDF at an outdoor temperature of 20°C with
moderate air movement.
1 2 3 4 5 6
Test procedure Heated tool butt welding Heated tool sleeve welding
Panels, pipes and fittings Pipes and fittings
Radiographic Applicable
and ultrasonic tests Statement possible, for example, about voids, not about quality
Internal pressure ISO 10931-3. Test temperature 95°C, test pressure 11.5 N/mm²,
creep test creep rupture time ≥ 200 hours
Not meaningful for long-time welding factor > 0.5
The technical code was revised editorially and was adjusted to With regard to the condition of the pipe end, it must be ensured
the state of the art with regard to improved cleaning agents. that, within the framework of the welding preparations, any white
Possibilities for the testing of sleeve-welded joints were frost, ice and moisture are removed from the area of the joining
incorporated. Non-contact heated tool welding is dealt with in zone (≥ 0.5 x fitting length) by supplying heat (e. g. hot gas
DVS 2207-6. device). In principle, this must be carried out before the
machining of the pipe surface. Fittings must be stored in closed,
The welding of thermoplastics at ambient temperatures below frost-free rooms and may only be transported to the welding
5°C is generally considered to be problematical. This relates not location in the number required in each case.
so much to the material-specific properties of the plastic but, to a
greater extent, to the restricted dexterity of the welder. Therefore,
the prerequisite for open-air welding at any outdoor temperatures Appendix: Processing instructions (short versions)
is an environment which enables the welding personnel to
perform the individual work steps without any quality-reducing
Re. 4.1 Heated tool butt welding of pipes, piping parts,
influences. In this respect, it is necessary to pay attention to the
fittings and panels
information from the manufacturers and to the dew point curve.
The parts to be joined must exhibit an identical temperature level. Processing instructions (short version)
440
Page 6 to DVS 2207-15
1. Create permissible working conditions, e. g. welding tent. 7. Simultaneously push the fitting and the pipe on to the heated
2. Connect the welding device to the mains or to the alternating spigot or into the heated bush as far as the stop or the mark.
current generator and check its function. Do not bump the pipe end into the end of the heated bush.
5. Clean the joining faces beyond the welding area with a 9. Pull the fitting and the pipe off the heated tools with a jolt, im-
cleaning agent according to Sections 3.2.1 and 3.2.3 with mediately push them together as far as the mark or the stop
unused, absorbent, non-fraying and non-dyed paper. (for max. changeover time: see Table 4, Column 4) and fix
them in this position (see Table 4, Column 5).
6. Machine the joining faces, in the case of pipes using a plane
(for example). 10. Let the joint cool down. Only subject the welded joint to me-
7. Take out the plane in the case of a pipe welding machine. chanical loads when the cooling time according to Table 4,
Column 6 has elapsed.
8. Remove the chips from the welding area without touching
the joining faces. 11. Complete the welding record sheet.
9. Check the plane parallelism by moving the joining faces to-
gether (max. gap width according to Table 1). Re. 6 Testing of the welded joints
10. Check the misalignment (max. 0.1 x wall thickness). The torsion shear test and the radial peeling test are suitable for
11. Check the heated tool temperature (240 8°C). quick checking of the welding quality of PVDF pipe joints.
12. Clean the heated tool with a cleaning agent according to The wall thickness of the pipe should be ≥ 3 mm.
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fray-
ing and non-dyed paper and ensure extraction.
13. Determine the movement pressure or the movement force
before every welding operation and make a note of it on the
welding record sheet.
14. Determine the setting values for the alignment, heating-up
and joining pressures.
15. Stipulate the guide values according to Table 2.
16. Move the heated tool into the welding position.
17. Align the faces to the heated tool until a bead arises accord-
ing to Table 2, Column 2.
18. Heating-up at a reduced pressure ≤ 0.01 N/mm², heating-up
time according to Table 2, Column 3.
19. At the end of the heating-up, detach the joining faces to be
welded from the heated tool and move this out of the weld-
ing position.
Figure 6. Preparation of a test specimen from a heated-tool-butt-welded
20. Within the changeover time (Table 2, Column 4), quickly joint.
move together the faces to be welded until they almost
touch. The faces must come into contact at a speed of Four test pieces are removed by means of slitting, uniformly
nearly zero. Immediately afterwards, build up the joining distributed around the circumference. The dimensions are:
pressure with a linear rise in the build-up time (Table 2, Col-
umn 5). Test piece length
21. A bead must exist after the joining at a pressure of 0.10 N/ = sleeve length + 2 x 200 mm pipe length
mm². According to Fig. 3, K must be > 0 at every point. Test specimen length
22. Cooling under the joining pressure according to Table 2, = sleeve length + 2 x approx. 10 mm pipe length
Column 5.
Test specimen width
23. Unclamping of the welded parts when the cooling time has b = 3 - 6 mm with a pipe wall thickness ≤ 10 mm
elapsed. b = 5 - 6 mm with a pipe wall thickness > 10 mm
24. Complete the welding record sheet.
Torsion shear test: The torsion shear test serves to evaluate the
Re. 5 Heated tool sleeve welding fracture behaviour and the fracture pattern of the weld. For this
purpose, one part (e. g. the sleeve cross-section) of the test
Processing instructions (short version) specimen (see Fig. 6) is completely clamped in a vice. The other
1. Create permissible working conditions, e. g. welding tent. part (e. g. the pipe cross-section) is gripped with a suitable tool
2. Connect the welding device to the mains or to the alternating and is then twisted by 90° in the welding plane (see Fig. 7). The
current generator and check its function. rotating speed is very low in order to largely exclude its influence
on the fracture behaviour of the test specimen. The clamping
3. Clean the heated tools with a cleaning agent according to faces should have a slight undercut in order to be able to input
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fray- the torsional moment into the weld plane in a targeted way.
ing and non-dyed paper.
4. Check the welding temperature (250 - 270°C).
5. Clean all the non-machined joining faces with a cleaning
agent according to Sections 3.2.1 and 3.2.3 with unused,
absorbent, non-fraying and non-dyed paper and ensure ex-
traction. Figure 7.
Force introduction during the
6. Bevel the pipe end cut off as a rectangle according to Fig. 5 torsion shear test.
and Table 3 or machine it according to the information from
the fitting manufacturer. If necessary, mark the insert depth. The evaluation is made according to Table 6.
441
Page 7 to DVS 2207-15
Table 6. Evaluation criteria for the torsion shear and radial peeling tests.
High separating forces, tough fracture, over 80 % Extremely structured fracture pattern with plastic deformation and stretching No or slight defects
Welding face melted partially or totally but welded Isolated detachments, soiling and insufficient surface removal Impermissible defects
together at certain points only
Separating point with coarse pores, finely structured, interspersed with a lot of
Brittle fracture small shrinkage cavities, partially burnt and overheating of the weld
Pipe surface not melted, weld too cold and welding gap too wide
Radial peeling test: In the case of this test, the pipe cross-section
of the test specimen (see Fig. 6) which is clamped in a vice with
the sleeve cross-section is peeled radially at the lowest possible
speed with the aid of suitable pliers or another clamping jig (see
Fig. 8).
The evaluation is made according to Table 6.
442
Record sheet for the heated tool butt welding Material Sheet Of
of panels
Building owner Executing company Welding machine:
Page 8 to DVS 2207-15
Type:
No. of the order Name and company of the welding supervisor Machine no.:
Year of construction:
Weld no. Date Panel Measured heated tool Setting values Heating-up Change- Joining Cooling time Ambient Remarks
thickness temperature time over time pressure under joining temperature
build-up time pressure
min. max. Alignment Heating-up Joining
443
444
Record sheet for the heated tool butt welding Overground Material Sheet Of
1 = Sunny 1 = None
Title of the order Name of the welder Code no. Make:
2 = Dry 2 = Screen
Type:
3 = Rain or snowfall 3 = Tent
No. of the order Name and company of the welding super- Machine no.:
visor 4 = Wind 4 = Heating
Year of construction:
In the case of multiple designations, sequence of the numbers as above
Weld no. Date Pipe data Measured heated Movement Joining pressure Setting values Heating-up Change- Joining Cooling Ambient Code-no.
∅dxs tool temperature pressure (machine table) time over time pressure time under temperature
build-up time joining
min. max. Alignment Heating-up Joining pressure Weathering Protection
[mm] [ C] [ C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [ C]
R&D INTAKE MANIFOLDS
1 = Sunny 1 = None
Page 10 to DVS 2207-15
Weld no. Date Pipe data Fitting data Measured temperature Heated-up Change- Cooling time Ambient Code no. Remarks
∅dxs time over time temperature
A B Serial no. Heated spigot Heated bush Fixed Total Weathering Protection
If necessary, entries according to the utilised system A = Manufacturer’s code 1 = Sleeve 2 = Angle 3 = T-piece 4 = Reducer
The measured values must be entered B = Fitting code no. 5 = Saddle 6 = Cap 7 = Transition piece
445
July 2010
PA 12 pipes from the ring coil are oval and curved immediately
This technical code applies to the heated tool butt welding and after the unrolling. The pipe end to be welded must be straight-
sleeve welding with an incorporated heating element of pipes and ened before the welding, e. g. by means of careful heating-up
fittings which are made of Polyamide 12 (PA 12) according to ISO and/or using a suitable clamping or round pressing jig.
22621-5 (under preparation) with a density of 1,000 -1,040 kg/m3
and serve to transport gases, liquids and solids. The joining faces of the parts to be welded must not be damaged
In normal storage conditions, the semi-finished product absorbs and must be free from contaminations (e. g. dirt, grease and
up to max. 0.8% moisture. The weldability up to this moisture chips).
content has been proven on the basis of tests.
3.2 Cleaning
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
446
Page 2 to DVS 2207-16
3.2.2 Cleaning of the heated tools read the movement force or movement pressure arising during
slow movement of the workpiece off the display instrument of the
The heated tools must be cleaned with paper before every weld-
welding machine and to add this to the previously determined
ing operation. No residues of plastic, cleaning agent or paper
joining force or to the joining pressure. Preference should be
Heating-up pressure
Finished joint
Time
Changeover time
Figure 1. Principle of heated tool butt welding using the example of pipes. Alignment Joining pressure build-up
time Total joining time time
4.1.2 Preparation for the welding
The heated tool temperature necessary for the welding must be Total welding time
checked before the beginning of the welding work. This is carried
out, for example, with a quick-display temperature gauge for sur- Figure 2. Process steps in the case of heated tool butt welding.
face measurements with a contact area covering a diameter of
approx. 10 mm. The control measurement must be taken within Alignment
the heated tool area corresponding to the semi-finished product. In this respect, the joining faces to be welded are pressed on to
So that a thermal equilibrium can occur, the heated tool may be the heated tool until the entire joining faces are in contact with the
used, at the earliest, ten minutes after the nominal temperature heated tool with parallel faces. This can be recognised by the
has been reached. formation of the beads. The alignment is finished when the bead
For optimum welds, it is necessary to clean the heated tool heights around the entire pipe circumference have reached the
according to Section 3.2.2 before every welding operation. The values specified in Table 1, Column 2. The bead heights are
anti-adhesive coating of the heated tool must be undamaged in regarded as an indicator that the whole area of the joining faces
the working area. is in contact with the heated tool. The alignment pressure of
0.25 N/mm2 is effective throughout the alignment operation.
The respective joining forces or joining pressures must be stipu-
lated for the machines to be used. These may refer, for example, Heating-up
to information from the manufacturer or to calculated or mea- For the heating-up, the faces must be in contact with the heated
sured values. In the case of pipe welding, it is also necessary to tool at a low pressure. To this end, the pressure is reduced to
447
Page 3 to DVS 2207-16
nearly zero (≤ 0.01 N/mm2). During the heating-up, the heat 5 Sleeve welding with an incorporated heating element
penetrates into the faces to be welded and heats these up to the
welding temperature. The heating-up times are shown in Table 1, 5.1 Process description
Column 3.
Table 1. Guide values for the heated tool butt welding of pipes and fittings made of PA 12 at an outdoor temperature of approx. 20°C with
moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
Nominal wall Alignment Heating-up Changeover Joining
thickness
s Joining Cooling time under
Heated tool temperature 230 ± 10°C Changeover time
pressure joining pressure
build-up time
Bead height at (Heating-up time (maximum time) (minimum values)
the heated tool at the end p ≤ 0.01 N/mm2) p = 0.25 N/mm2 ± 0.05
of the alignment time 12 x wall thick-
(minimum values) ness s
(alignment
p = 0.25 N/mm2)
[mm] [mm] [s] [s] [s] [min]
up to 4.5 0.5 up to 54 5 5 6
4.5 ... 7 1.0 54 ... 84 5 ... 6 5 ... 6 6 ...10
7 ... 12 1.5 84 ... 144 6 ... 8 6 ... 8 10 ...16
12 ... 19 2.0 144 ... 228 8 ... 10 8 ... 11 16 ... 24
448
Page 4 to DVS 2207-16
The fitting and the pipe must be at the same temperature level
before the welding. In the case of welding devices with automatic
temperature compensation, it must be ensured that the recorded
ambient temperature corresponds to the conditions at the loca-
Cold zone
Cold zone
Cold zone
Heater Heater welded. The welding cables must be attached in a weight-
spiral spiral relieved form. The contact faces must be clean. As a rule, the
zone zone welding device acquires the fitting data required for the welding
by reading in a component-specific bar code. The displayed data
(e. g. dimensions) must coincide with the component data. After
Figure 5. Conical collapsing of the pipe end or insufficient pipe insertion
before the welding (principle).
the welding operation has started, this proceeds automatically.
The welding duration is usually displayed by the welding device.
The out-of-roundness of the pipe must not exceed 1.5% of the Just like the other data displayed by the device, it must also be
outside diameter, max. 3 mm, in the welding zone. Correspond- indicated on the welding record sheet unless the data is stored.
ing round pressing clamps must be used if necessary. Pay attention to error messages! For example if the power supply
Beyond the area of the insert depth or the length of the saddle is interrupted, a prematurely terminated welding operation can be
fitting, the complete surface of the pipe or of the pipe spigot on repeated on one occasion in so far as there are no defects on the
the fitting must be subjected to chip-producing machining. A fitting or on the welding device (error message) and the fitting
rotating peeling device with constant wall thickness removal of manufacturer permits this. It is necessary to wait for the entire
approx. 0.2 mm must be used. Attention must be paid to the cooling time before carrying out the welding once again (fire
formation of a small annular gap! hazard).
The pipe end must be deburred on the inside and outside. Chips The cables can be removed when the device has been switched
must be removed without touching the joining face. off. If there are any welding indicators on the fitting, these must
be checked. The joint may only be moved after the cooling. Infor-
The fitting may only be removed from the protective packaging mation about this is provided by the fitting manufacturer.
immediately before the assembly.
If the manufacturer provides any information about additional
If the machined pipe surface is contaminated after the chip-pro- cooling times (e. g. until the pressure test), attention must be paid
ducing machining, it must be cleaned according to Section 3.2.3. to this.
In this respect, it must be ensured that no contamination is intro-
duced into the welding zone. The joining face of the fitting must For a short version of the processing instructions, see the appen-
be cleaned according to Section 3.2.3. dix.
It must be possible to check the insert depth of the pipe either on
the basis of a mark to be applied or using a suitable jig. The fitting 6 Testing of the welded joints
must not be tilted or pushed on to the pipe end with force (low-
stress assembly). The saddle piece must be tightly clamped on
Various test procedures are applied for the individual welding
the pipe with the aid of a suitable jig according to the information
processes. A distinction is made between non-destructive and
from the manufacturer.
destructive test procedures. They are listed in Table 2. Depend-
The contact bushes for the connection of the welding cable must ing on the agreement, checking and sampling operations should
be easily accessible. be carried out on a random basis during the welding work.
Test procedure Heated tool butt welding Sleeve welding with an incorporated heating element
Pipes and fittings Fittings and saddle fittings
Visual inspection DVS 2202-1, Table 1 DVS 2202-1, Table 3
The machining of the pipe surface must be visible beyond
the welding area; check the insert depth on the basis of
the mark.
Radiographic and DVS 2206 applicable to a limited extent
ultrasonic tests
Statements possible, for example, about voids and the position of the heater spiral, not about the quality.
Tensile test DVS 2203-2; Not applicable
Short-time tensile welding factor ≥ 0.9
DVS 2203-1, Supplement 1
Tensile creep test DVS 2203-4; With reference to DVS 2203-4, Supplement 1
Tensile creep welding factor ≥ 0.8 The test parameters must be determined in preliminary
DVS 2203-1, Supplement 2 tests.
449
Page 5 to DVS 2207-16
Table 2. Continuation.
Test procedure Heated tool butt welding Sleeve welding with an incorporated heating element
Pipes and fittings Fittings and saddle fittings
Technological bending
test R&D INTAKE MANIFOLDS
DVS 2203-5;
Minimum bending angle according to
DVS 2203-1, Supplement 3, Figs. 2 and 3
Not applicable
7 Standards, technical codes and guidelines which are DVS 2208-1 Welding of thermoplastics; machines and
also applicable devices for the heated tool welding of pipes,
piping parts and panels
ISO 22621-5 Plastic piping systems for gas supply for a Supplement 1 –, requirements on tools and devices (under
(under maximum permissible operating pressure of preparation)
preparation) 2 MPa (20 bar) – Polyamide (PA)
DVS 2212-1 Qualification testing of plastics welders; Quali-
DIN EN ISO Plastics; determination of the water content,
fication Test Groups I and II
15512 Method B
Betr.Sich.V Operational Safety Ordinance
DIN EN 12814-4 Testing of welded joints between thermoplastics;
Part 4: Peeling test
DVGW VP 603 Test basis for cleaning agents and their recep-
8 Explanations
tacles for the preparation of welded joints
between polyethylene pipes
The welding of thermoplastics at ambient temperatures < 5°C is
DVS 2202-1 Defects in welded joints between thermoplastics; generally considered to be problematical. This relates not so
characteristics, description and evaluation much to the material-specific properties of the plastic but, to a
DVS 2203-1 Testing of welded joints between thermoplastics; greater extent, to the restricted dexterity of the welder. Therefore,
test procedures – requirements the prerequisite for open-air welding at any outdoor temperatures
is an environment which enables the welding personnel to
Supplement 1 Requirements in the tensile test
perform the individual work steps without any quality-reducing
Supplement 2 Requirements in the tensile creep test influences. In this respect, it is necessary to pay attention to the
Supplement 3 Requirements in the technological bending information from the manufacturers and to the dew point curve
test, bending angle / bending path (formation of moisture on the workpiece). The parts to be joined
must exhibit an identical temperature level. Trial welds must be
Supplement 4 Requirements on shear and peeling tests for produced and tested.
sleeve welding with an incorporated heating
element (HM) and heated tool sleeve welding It must be ensured that, within the framework of the welding
(HD) on pipes and fittings preparations, any white frost, ice and moisture are removed from
the welding area by supplying heat (e. g. a hot gas device but not
DVS 2203-2 Testing of welded joints between thermoplastics;
test procedures – tensile test a naked flame). Any damage must be avoided.
DVS 2203-4 Testing of welded joints between thermoplastics; Fittings must be stored in closed, frost-free and dry rooms and
test procedures – tensile creep test may only be transported to the welding location in the number
required in each case.
Supplement 1 Testing of sleeve-welded joints between pipes
In the event of water storage over a lengthy period, the semi-
Supplement 3 Testing of the resistance to slow crack growth finished product may absorb up to max. 1.5% moisture (measured
in the full-notch creep test (FNCT)
according to DIN EN ISO 15512, Method B).
DVS 2203-5 Testing of welded joints between thermoplastics;
Attention must be paid to this, for example, in the case of repairs
test procedures – technological bending test
to piping which has been used for a lengthy period. If necessary,
DVS 2203-6 Testing of welded joints between thermoplastics; trial welds must be produced in order to ensure the weldability.
test procedures – testing of joints between
polymeric materials
Supplement 1 Torsion shear and radial peeling tests for
joints manufactured by means of sleeve weld-
ing with an incorporated heating element and
heated tool sleeve welding
450
Page 6 to DVS 2207-16
15. Move the heated tool into the welding position. 10. Check the correct welding sequence on the welding device
(e. g. by checking the display and, if present, the welding
16. Align the faces to the heated tool until a bead arises (accord- indicators). Pay attention to error messages!
ing to Table 1, Column 2).
11. Detach the cables from the fitting.
17. Heating-up at a reduced pressure ≤ 0.01 N/mm2, heating-up
12. Unclamping of the welded parts when the cooling time
time according to Table 1, Column 3.
according to the information from the manufacturer has
18. At the end of the heating-up, detach the joining faces to be elapsed. Remove the utilised holding jigs.
welded from the heated tool and move this out of the welding 13. Complete the welding record sheet unless there was any
position. automatic recording.
19. Within the changeover time (Table 1, Column 4), quickly
move together the faces to be welded until they almost touch.
The faces must come into contact at a speed of nearly zero.
Immediately afterwards, build up the joining pressure with a
linear rise in the build-up time (Table 1, Column 5).
20. A bead must exist after the joining at a pressure of
0.25 ± 0.05 N/mm2. According to Fig. 4, K must be > 0 at
every point.
21. Cooling under the joining pressure according to Table 1,
Column 5.
22. Unclamping of the welded parts when the cooling time has
elapsed.
23. Complete the welding record sheet.
451
452
Record sheet for the heated tool butt welding Overground Material Sheet of
Title of the order Name of the welder Code no. Make: 1 = sunny 1 = none
No. of the order Name and company of welding supervisor Machine no.: 3 = rain or snowfall 3 = tent
2)
Weld Date Pipe data Measured heated tool Movement Joining Setting values Heating-up Changeover Joining pres- Cooling time Ambient Code no.
1) 3)
no. dxs temperature pressure pressure (ma- Alignment Heating-up Joining time3) time sure build- under joining temperature3 Weather Protec-
3) 3)
min. max. chine table) up time pressure tion
[mm] [°C] [°C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [°C]
R&D INTAKE MANIFOLDS
1)
From the control interval, frequency according to Section 4.1.2.
2)
According to information from the manufacturer of the welding machine or from the machine test plus the movement pressure or force.
3)
The measured values must be entered.
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Record sheet for the sleeve welding of piping parts Overground Material Sheet of
Title of the order Name of the welder Code no. Make: 1 = sunny 1 = none
No. of the order Name and company of welding supervisor Machine no.: 3 = rain or snowfall 3 = tent
Weld Date Pipe data Fitting data Device setting Fitting Secondary Welding times 2) Ambient Code no. Operating mode
1)
no. dxs A B Serial no. Manual Automatic resistance voltage1) Heating Cooling temperature2 Weather Protective Mains Gener-
[mm] [ohm] [volt] [s] [min] [°C] measures ator
1)
If necessary, entries according to the system used. A = manufacturer's code 1 = sleeve 2 = angle 3 = T-piece 4 = reducer
2)
The measured values must be entered. B = fitting code no. 5 = saddle 6 = cap 7 = adapter
453
Erstellungsdatum: 17.07.2000
Letzte Änderung: 05.02.2002
File-Name: C:\DVS Merkblätter\2207\2207-25\e2207-25.fm
4 Welding processes
2 Terminology
The welded joints made from extruded PVC-U sections covered
Matching Section 4 and Fig. 1 by these directives, are produced by means of heated tool butt
Matching time Fig. 1 welding. Welding machines, as per Section 5 of these directives,
Heating cycle Fig. 1 are to be used for this. The connecting surfaces of the sections to
Heating time Fig. 1 be welded are matched on the heated tool under pressure
Heating pressure Fig. 1 and Section 5.5.1 (matching) until their entire surfaces are in contact. This has
Working pressure Section 5.2. been achieved if a clearly visible bead has formed over the entire
Adjustment plates Section 5.2. periphery of the section.
Jointing Section 4 and Fig 1
Components to be jointed Section 7 Matching is completed by a stop or by control of the working table
Jointing path Section 4 and Fig 1 movement, and passes directly into the heating process. Here
Jointing time Section 4 and Fig 1 the connecting surfaces are heated to the welding temperature
Jointing pressure Section 4 and Fig 1 and a sufficiently deep molten layer is formed. The heating
Heated tool butt welding (HS) Sections 4 and 8 process is controlled on a time basis, and the pressure in the joint
Bead limitation Section 5.3. surface corresponding to Fig, 1 must be reduced to the heating
pressure, PAW. When the warning-up time is over, the sections
Burn-off Section 7
are released by the heated tool and the heated tool is removed
Gap width Section 5.3.
from the welding plane (repositioning).
Clamping pressure Section 5.2.
Repositioning Section 4 and Fig 1 Directly after this, the two welding surfaces of the section are
Repositioning time Section 4, Fig. 1 and joined under the jointing pressure (jointing). The jointing path is
Section 5.5.2. limited by a stop or by control of the working table movement.
1) The internationally used term PVC-U, standing for 'unplasticised polyvinyl chloride' corresponds to the term 'rigid PVC' formerly in use.
2) Training courses on machining plastic casement sections are provided by the Plastics Processing Institute at the Aachen University of Technology (tel.:
+49 241/80 38 12), and in the associated course workshops, and by the South German Plastics Centre in Würzburg (tel.: +94 931/4104-0).
This publication was prepared by a group of experienced specialists working together in an honorary capacity, and it is recommended that it should be respected as
an important source of knowledge. The user must at all times check the extent to which the contents apply to his or her special case and whether the version available
to him or her is still current. Any liability on the part of the German Welding Society and of those participating in the preparation of this document is excluded.
DVS, Technical Committee, Working Group W 4 "Plastics, Welding and Adhesive Bonding"
and Plastic Casement Section Quality Group of Plastics Products Quality Association
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
454
Page 2 to DVS 2207-25
The jointing time should be selected in such a way that the joint b) It must. be possible to set. the clamping pressure, matching
weld is sufficiently cooled. The jointing pressure should be pressure and jointing pressure separately and externally, and
selected in such a way that the stop is not reached until the the settings must be repeatable and easily read off
second half of the jointing time (0.3 to 0.7 N/mm²) and the fusion
c) The control and display elements must be clearly indicated3)
455
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maintained, the strength and viscosity of the welds meet the Table 2. Permissible angular deflection on V-form heated tools.
requirements, and the pre-set dimensions of the window are
maintained. Fig. 1 gives schematic diagrams for the pressure- Length of a side mm permissible deflection mm
time progression and the path-time progression. It must be l a
possible to calibrate the control and adjustment equipment, and it ≤ 100 0.3
Heated tools must be suitable for the jointing surfaces in terms of 5.6.3 Useful area of heated tool
form and dimensions. If laminar heated tools are used on both
sides, they must be plane parallel within their useful areas. The external dimensions of a heated tool should exceed the
Permissible deviations from plane parallelism are given in Table length of the sides of the useful area by at least 5% all the way
1 and are based on room temperature. round. The useful area AN is then obtained from the external
dimensions of the heated tool, aH and bH, for example as in Fig.
3:
Table 1. Plane parallelism of laminar heated tools.
AN = aN x bN in cm², where aN = 0. 9 aH, bN = 0.9 bH
Useful area cm² Permissible deviation mm
Plane paralellism Heated tool thickness
≤ 250 ≤ 0.2 ± 0.1
> 250 ... 400 ≤ 0.4 ± 0.15
> 400 ≤ 0.5 ± 0.2
The entire welding surface must lie within the useful area.
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Page 4 to DVS 2207-25
5.6.5 Minimum temperature range are to be set or checked. The heated tool temperature in the
The heated tool must be continuously adjustable over the useful area should be measured using a suitable gauge (see
required temperature range within the useful area, at least Section 5.6.7). The average standard interval should not deviate
between 200 °C and 300 °C. from the nominal value by more than the amounts listed in Table
4) .
Information can be obtained from the Casement Sections Quality Group, 2, Dyroffstraße, 5300 Bonn 1, W.Germany (tel 02 28/22 35 7M.).
457
Page 5 to DVS 2207-25
– Do not release the welded jointing components from the The maximum force values for corner welds depend on the
clamping devices and remove them from the machine until the profile geometry and the test rig. The maximum corner weld
welded joints have cooled down sufficiently. values measured, F, must not be less than the calculated limiting
values for the breaking force, Fsoll. Fsoll is calculated as follows,
– Since the weld has not yet cooled completely, as little stress as
with a failure stress of σ = 35 N/mm²:
The welded joints are tested using corner samples of (90 ± 1)° or Figure 5. Representation of parameters for calculation of Fsoll.
T-connections from which one side of the continuous section is
out off. The welding bead should not be removed. In this context is:
The sides of the corner under test are cut to length, at an angle of F Maximum force
(45 ± 1)°, in such a way that the neutral fibres (approximately at Fsoll Breaking force limiting value
the centre of the main chamber of the section) lie above the axis I Axial angular impulse
of rotation of the test chassis. W Section modulus in direction of stress (inside corner)
The side lengths on the internal sides (Li) can be derived from the σ Failure stress (see DIN 16 830, Part 2 (at present draft)
lengths of the neutral fibres (Ln = 283 mm), minus twice the a Distance between axes of rotation; a = (400 ± 2) mm
distance of the section's internal sides from the neutral fibre (e): e Distance between critical fibre and neutral fibre
Li therefore equals 283 mm – 2e. Ln Length of neutral fibre; Ln = 283 mm.
Li Side length on internal side; Li = 283 mm – 2 ∙ e
For corners from sections with articulated asymmetrical external
h Lever arm
sides, the pressure stamp is to be adjusted to impose a uniform
stress on the profile section of the form of the external section
flank at the point of the corner (using adjustment plates as well,
for example).
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