Dvs 2207

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The document discusses various welding techniques for joining thermoplastics like PE-HD and provides guidelines and safety measures for welding.

The document covers heated tool butt welding, heated tool socket welding, electro-socket welding of pipes, fittings and tapping tees made of PE-HD. It also discusses preparation, welding procedures, testing and standards.

Heated tool butt welding, heated tool socket welding, electro-socket welding techniques are described.

Erstellungsdatum: 23.03.

2006
Letzte Änderung: 05.06.2007
File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\e2207-1\e2207-1.fm

August 2007

DVS – DEUTSCHER VERBAND Welding of thermoplastics


FÜR SCHWEISSEN UND Heated tool welding of pipes, pipeline Technical Code
VERWANDTE VERFAHREN E.V. components and sheets made of PE-HD DVS 2207-1

R&D INTAKE MANIFOLDS Translation of the German version september 2005

Content: 2 General requirements

1 Scope The quality of welded joints depends on the qualification of the


2 General requirements welder, the suitability of the utilized equipment and devices as
3 Measures before welding well as on compliance with the welding standards. The welded
3.1 Requirements for welding joint can be tested by means of non-destructive and/or
3.2 Cleaning destructive methods.
3.2.1 Cleaning agents
The welding work must be monitored. Type and range of
3.2.2 Cleaning of heated tools
supervising has to be agreed between the contract partners. It is
3.2.3 Cleaning of joining areas
recommended to record the welding data in welding protocols
4 Heated tool butt welding
(sample see appendix) or on data carriers.
4.1 Heated tool butt welding of pipes, pipeline components,
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

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.

DVS, Technical Committee, Working Group ″Joining of Plastics″

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

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Page 2 to DVS 2207-1

3.2 Cleaning 4.1.2 Preparation of welding


For the production of perfect welded joints it is very important that Prior to the start of the welding process, the welding temperature
the joining areas as well as the tools and heated tools are clean of the heated tool is to be checked. This is done e.g. by means of

R&D INTAKE MANIFOLDS


and free of grease. a fast-indicating measuring device with a contact surface of 10
mm for measuring the surface temperature. The control
3.2.1 Cleaning agents measurement must be done within the area on the heated tool
which corresponds to the semi-finished product. For adjusting a
The cleaning agents or already moistened cloths in a lock-up thermal balance, the heated tool may be inserted at the earliest
plastic box have to consist of a 100 % vaporizing solvent, e.g. 99 10 minutes after reaching the set temperature.
parts ethanol with a purity grade of 99,8 % and 1 part MEK
(methylethylketone, denaturation). Agents tested according to To ensure an optimum welding connection the heated tool has to
DVGW 603 comply with this requirement. The use of ethyl be cleaned according to section 3.2.2 before every welding
alcohol could result in a reduction of quality because of the operation. The anti-adhesive coating or covering of the heated
contained water. tool must be free of damages in the working zone.
The paper for cleaning has to be clean, unused, absorbent, non- The joining forces and joining pressures have to be specified for
fuzzy and non-coloured. Exhaust the air afterwards. the machines to be used. These can be based on e.g. manu-
facturer information, calculated or measured values. Additionally,
3.2.2 Cleaning of heated tools at the welding of pipes, the work piece moving force res. moving
The heated tools have to be cleaned with paper before every pressure is taken from the indicator of the welding machine
welding process. No residues of cleaning agents or paper may during the slow displacement of the part to be welded and have
remain on the heated tool. to be added to the prior determined joining force res. joining
pressure. Electronically controlled equipment is preferred, if pos-
sible with recording.
3.2.3 Cleaning of joining areas
Before machining the joining areas it has to be ensured that the The nominal wall thickness of the parts to be welded must match
utilized tools and components are clean and free of grease even in the joining area.
outside the welding zones, if necessary use a cleaning agent. Pipes and fittings have to be aligned in axial direction in the
The treatment of the joining areas has to be done directly before welding machine before the clamping. The easy axial movement
the welding process starts. of the part to be welded-on can be ensured e.g. by means of
dollies or swinging suspension.
Any shavings have to be removed without contacting the joining
areas. The joining areas have to be planed with a clean and grease-free
tool directly before the welding so that they are coplanar in
In case of contamination of the surface after machining, e.g. by clamped condition. Permissible gap width under alignment
contact with hands, the joining areas have to be treated with a pressure see table 1.
cleaning agent if a further machining is impossible.

Table 1. Maximum gap width between the treated welding zones.


4 Heated tool butt welding
Pipe outside diameter d Gap width Sheet width
mm mm mm
4.1 Heated tool butt welding of pipes, pipeline components,
fittings and sheets ≤ 355 0,5

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.

4.1.3 Welding procedure


With heated tool butt welding the joining areas are heated-up to
the welding temperature by means of the heated tool and joined
under pressure after removing the heated tool. The heated tool
temperature is 200 to 220 °C. In principle the upper temperature
limit is to be aspired for smaller wall thickness, the lower
temperature limit for bigger ones (see figure 2). The upper
temperature has to be chosen for PE 100 as well. The different
Figure 1. Principle of the heated tool butt welding of a pipe. steps of the welding process are illustrated in figure 3.

323
Page 3 to DVS 2207-1

when the bead heights have reached the mentioned values in


table 2, column 2 on the total pipe circumference or the total
sheet surface respectively. The bead sizes are an index for a
complete contact of the joining areas on the heated tool.

R&D INTAKE MANIFOLDS Heating-up


For heating-up, the joining areas must contact the heated tool
with low pressure. The pressure is reduced to nearly zero (≤ 0,01
N/mm2). During heating-up, the heat penetrates the joining areas
and the welding temperature is reached. Heating-up times are
given in table 2, column 3.
Changeover
After heating-up, the joining areas are to be detached from the
heated tool. The heated tool should be withdrawn without
damage or contamination of the heated joining zones. The joining
areas should be joined together quickly until they almost have
Figure 2. Recommended values for the heated tool temperatures as contact. The changeover time should be as short as possible
function of the wall thickness.
(see table 2, column 4), as otherwise the plasticized areas will
cool down. The welding joint quality would be influenced
negatively.
Joining
The areas to be welded should meet with a speed of nearly zero.
The demanded joining pressure is built possibly linear. The
required times are shown in table 2, column 5. The joining
pressure is 0,15 ± 0,01 N/mm2.
Raised mechanical loads during or directly after the declamping
are allowed only after finished cooling. The joining pressure has
to be kept completely during the cooling time at ambient
temperature (see table 2, column 5).
The reduction of the cooling time up to 50 %, that means joining
pressure release and removal of the welded part from the
welding equipment, is allowed under the following requirements:
– the welding is done under workshop conditions
Figure 3. Process steps of heated tool butt welding.
– the removal from the welding equipment and the temporary
storage are causing only slight loads to the joint
Alignment
– it concerns components with a wall thickness of ≥ 15 mm.
The joining areas of the welding components are pressed to the
heated tool until all areas are coplanar on the heated tool. This A further treatment with full mechanic load of the joint is allowed
fact is visible on the formation of beads. The alignment is finished only after complete cooling down according to table 2, column 5.

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

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Page 4 to DVS 2207-1

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

R&D INTAKE MANIFOLDS


made from PE 80 and PE 100 with the mentioned MFR-range the damaging and contamination of the joining area. The changeover
weldability can be assumed, even if it results in asymmetric time should be as short as possible (maximum value see table 3,
welding beads. K has to be always > 0 (see figure 4). line 3). The joining areas should be joined together promptly
afterwards.
After complete cooling the welding device may be removed.

Table 3. Recommended values for the heated tool butt welding of


tapping tees made of PE-HD at outside temperature of
20 °C and moderate air flow.

1 Alignment under p = 0,15 N/mm2


Bead heights on heated tool
at the end of the alignment time
Min. value [mm] 1,0
2 Heating-up under p ≤ 0,01 N/mm2 acc. to
Figure 4. Bead formation at heated tool butt welding (principle) of a pipe. Heating-up time [s] manufacturer
data
Short version of processing instructions see appendix.
3 Changeover Max. time [s] 10
4.2 Heated tool butt welding of tapping tees 4 Joining pressure build-up time 5
The heated tool butt welding of tapping tees is applicable with
Joining
Cooling time under joining
PE-HD pipes according to DIN 8075 of melt-flow index values of
pressure
0,7 up to 1,3 g/10 min. For piping system components made of
PE-HD with MFI values of 0,2 up to 0,7 g/10 min the welding 5 p = 0,15 N/mm2
process is applicable only in conjunction with a reinforcement
embracing the pipe. The last-mentioned condition is also valid if, Min. value [min] 15
especially in the case of fittings attached at a subsequent stage,
an attribution within the scope of this standard is not possible. Short version of processing instructions see appendix.
Heated tool butt welds of tapping tees have to be carried out by
means of welding devices. 5 Electro-socket welding
4.2.1 Description of the process 5.1 Description of the process
The connection zones of pipe and tapping tee are aligned and The joining areas (pipe surface and inside of the fitting) are
heated up by means of a shaped heated tool under alignment overlapped and welded by resistance wires inside the fitting
pressure. After removal of the shaped heated tool the joining (heating coils) which are heated up by electrical energy (see
faces are joined under joining pressure. figure 5).
4.2.2 Preparation of welding
Prior to the start of the welding process, the welding temperature
set on the heated tool is to be checked according to section
4.1.2.
To ensure an optimum welding connection the heated tool has to
be cleaned according to section 3.2.2 before every welding
operation. The anti-adhesive coating of the heated tool must be
free of damages in the working zone.
Prior to clamping into the welding equipment the joining surface
of the pipe has to be scraped with a trimming blade or another
suitable tool. Shavings have to be removed without contacting
the joining area. The treated welding areas should be neither
dirtied nor touched by hand, otherwise cleaning of the joining Figure 5. Electro-socket welding (principle).
areas according to section 3.2.2 is necessary. The tapping tee
always has to be cleaned according to section 3.2.3. 5.2 Welding equipment
The roundness of the pipe is to be ensured by the clamps of the Only welding equipment adjusted to the parts to be welded may
welding equipment or special re-rounding devices. The fit of the be used. Automatic welding equipment is preferred – possibly
tapping tee face is to be controlled. with recording. The welding equipment must supply the required
Prior to welding the required forces for alignment and joining welding parameters for the fitting to be welded such as welding
have to be determined from the table provided with the time, current and voltage. The device must switch off as soon as
equipment. the necessary quantity of heat has been fed to the welding zone.

4.2.3 Welding procedure 5.3 Preparation of welding


The shaped heated tool, heated to the welding temperature (200 Clean surfaces and a stress free installation are very important
up to 220 °C) is introduced between the welding components. for the fabrication of perfect welded joints. With the choice of
The alignment pressure is 0,15 N/mm2. After beads have formed pipes with limited diameter tolerance according to DIN 8074 the
according to table 3, column 1, the specific set pressure for installation of fittings is easier.

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.

R&D INTAKE MANIFOLDS


the area of the heated socket. If necessary the pipe end should Consider error message! If there should be any interruption to the
be shortened immediately before welding. power supply in the early part of the welding process, the welding
may be repeated as long as no visible defects on the fitting or
error messages with the welding equipment have appeared, and
the fitting manufacturer has given his permission for re-welding to
take place.
The joining area (pipe and fitting) must be cooled down
completely before the welding process is started again.
The cables can be removed after switching off the equipment.
Check the welding indicators if available on the fitting. The
connection may be moved only after cooling down. The fitting or
mounting manufacturer supplies corresponding information. The
drilling of tapping tees may be done only after finished cooling
time.
Details from the manufacturer about additional cooling times, e.g.
till the pressure test, have to be considered.
Short version of handling instructions see appendix.

6 Heated tool socket welding


Figure 6. Bevelled shrink of the pipe end.
6.1 Description of the process
The ovality of the pipe may not exceed 1,5 % of the outside At heated tool socket welding (see figure 7), pipe and pipeline
diameter, max. 3 mm. If necessary, re-rounding devices can be components are welded in overlapped condition. Pipe end and
used. fitting are heated up to welding temperature by a socket or
The surface of the pipe or fitting in the welding zone has to be spigot-shaped heated tool and subsequently joined together.
completely machined. A scraping tool with a constant wall Heated tools and fittings are dimensionally adapted so that on
thickness removal of approx. 0,2 mm should be used. Take care joining a joining pressure will be built-up. Heated tool socket
for a small annular gap! welding can be performed manually up to 50 mm pipe diameter.
At diameters as from 63 mm, a welding device is required
The pipe end has to be deburred inside and outside, shavings
because of the higher joining force.
have to be removed without contacting the joining areas.
The fitting may only be removed from the protective package
immediately before the installation.
In case of contamination of the pipe surface after machining it
must be cleaned according to section 3.2.3. It has to be
considered that no contamination is rubbed into to the welding
zone. The joining area of the fitting or tapping tee respectively
has to be cleaned according to section 3.2.3.
The insert depth of the pipe has to be controllable by an added
mark or suitable device. The fitting may neither be tilted nor
pushed onto the pipe end with force (low stress installation). The
tapping fitting has to be clamped on the pipe by means of a
suitable device under consideration of the manufacturer’s
instructions.
The contact socket for the connection of the welding cable must
be easy reachable.
Fitting and pipe have to show the same temperature level before
the welding process. Concerning welding equipment with
automatic temperature compensation, take care that the
measured environmental temperature corresponds to the
conditions of the welding location. If necessary the welding Figure 7. Heated tool socket welding (principle).
equipment as well as the pipe and fitting have to be protected
e.g. against direct sun radiation. 6.2 Welding device

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
Page 6 to DVS 2207-1

Before welding starts the welding temperature (250 to 270 °C)


set on the heated tool has to be controlled according to section
4.1.2.

R&D INTAKE MANIFOLDS


Heating socket and heating spigot must be free of
contaminations and should be cleaned before welding according
to section 3.2.2. The anti-adhesive coating of the heating spigot
and heating socket must be free of damages in the welding area.

6.4 Welding procedure


For the purpose of heating, fitting and pipe are pushed swiftly and
axially onto the devices fitted on the heated tool and held until the
stop at machine welding or until the mark at manual welding. It
has to be absolutely avoided that the pipe is pushed onto
the end of the heating socket. Afterwards the heating-up time
starts according to the time values in table 5, column 2.
Figure 8. Bevelling of the pipe end. After the heating time has elapsed, the fitting and pipe should be
withdrawn sharply from the heated tool and pushed together
immediately without any twisting until the stop or mark (maximum
Table 4. Values for pipe chamfer and insert depth. adjusting time see table 5, column 3).
At manual welding the joined components have to be kept fixed
Pipe outside diameter Pipe chamfer Insert depth according to the time mentioned in table 5, column 4. The
d [mm] b [mm] l [mm] connection may be loaded by further installation works only after
16 13 cooling time is over (table 5, column 5).

20 14 Short version of handling instructions see appendix.

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).

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Table 6. Test methods for weld joints.

Test method Heated tool butt welding Electro socket welding Heated tool socket welding

R&D INTAKE MANIFOLDS


Sheets, pipes, fittings Tapping tees Fittings Tapping tees Pipes, fittings
DVS 2202-1 Smooth welding joint on DVS 2202-1 DVS 2202-1 DVS 2202-1
Table 1 the complete Table 3 Table 3 Table 2
Visual test circumference
Mechanical treatment of pipe surface has to be visible also
outside of the welding area.
Radiographic
applicable. Statement about e.g. voids is possible, but not about the quality.
and X-ray test
DVS 2203-2;
Short-term welding
Tensile test non applicable
factor
DVS 2203-1, Suppl. 1
DVS 2203-4;
Tensile creep tensile creep welding
DVS 2203-4, Suppl. 1
test factor
DVS 2203-1, Suppl. 2
DVS 2203-5.
Minimum bending
angle acc. to
DVS 2203-1, Suppl. 3,
Technological
Figures 1 and 2 non applicable
bending test
Minimum bending
distance acc. to
DVS 2203-1, Suppl. 3,
Figures 7 and 8
DIN 16963-5, section
5.4.3.1,
Internal Length of each pipe DIN 3544-1,
DIN 16963-5,
pressure piece DIN 3544-1, sections 2.3 sections 2.3 DIN 16963-5,
section
creep rupture acc. to table 6. and 3.2 at 80 °C and 3.2 section 5.4.3.1
5.4.3.1
test Non meaningful for at 80 °C
long-term welding
factor > 0,5
Torsion shear
non applicable see appendix. Also applicable as site test for pipe wall thickness ≥ 4 mm.
test
Radial
non applicable see appendix. Also applicable as site test for pipe wall thickness ≥ 4 mm.
peeling test
Compression
non applicable DIN EN 12814-4, section 8. Also applicable as site test.
test
Peeling test non applicable DIN EN 12814-4, section 7 non applicable

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
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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.

R&D INTAKE MANIFOLDS


DVS 2202-1 Failures on welded joints of thermoplastics;
features, description, evaluation 8. Check the coplanarity by moving the joining areas together
(maximum gap width according table 1).
DVS 2203-1 Testing of welded joints on sheets and pipes of
thermoplastics; testing methods – requirements 9. Check the misalignment (maximum 0,1 x wall thickness).
Suppl. 1 Requirements for tensile test 10. Check the heated tool temperature subject to the wall
Suppl. 2 Requirements for tensile creep test thickness (see figure 2).
Suppl. 3 Requirements for technological bending test, 11. Clean the heated tool with a cleaning agent according
bending angle/bending distance sections 3.2.1 and 3.2.2 with unused, absorbent, non-fuzzy
and non-coloured paper and exhaust it.
-2 –, tensile test
-4 –, tensile creep test 12. Determine the moving pressure res. moving force before
each welding and record it in the welding protocol.
-4 Suppl. 1 –, tensile creep test; testing of socket welding
connections on pipes 13. Determine the values for aligning, heating-up and joining
pressure.
-5 Technological bending test
DVS 2208-1 Welding of thermoplastics; Machines and 14. Set the reference values according to table 2.
equipment for the heated tool welding of pipes, 15. Bring the heated tool to the welding position.
pipeline components and sheets
16. Align the welding areas to the heated tool until a bead is
DVS 2212-1 Testing of plastic welders; Test group I and II formed (according to table 2, column 2).
Betr.Sich.V Regulation of industrial safety
17. Heating-up with reduced pressure ≤ 0,01 N/mm2, heating-
up time according to table 2, column 3.
9 Explanation 18. After heating-up is finished, withdraw the joining areas from
the heated tool and remove it from the welding position.
This technical code has been adjusted according to the state-of-
the-art with regard to improved cleaning agents and the 19. The joining areas should be joined together quickly within
development of larger pipeline components. The non-contact the changeover time (table 2, column 4) until they almost
heated tool welding is explained in DVS 2207-6. touch. At contacting, they have to meet with a speed of
nearly zero. Build up a linear joining pressure (table 2,
The welding of thermoplastics at environmental temperatures column 5) immediately afterwards.
below 5 °C is generally problematic. This concerns less the
20. After joining with a pressure of 0,15 N/mm2 a bead must
material specific properties of the thermoplastics but the limited
exist. According figure 5, K has to be > 0 on every section.
manual skill of the welder. Welding outside at any temperature
requires an environment which enables the welding staff to 21. Cooling down under joining pressure according to table 2,
perform the individual work steps without quality reducing column 5.
influences. The parts to be welded must have the same
temperature level. Test welds have to be performed and tested. 22. Declamping of the welded parts after cooling time. For shop
works see joining in section 4.1.3.
Regarding the pipe end condition it has to be considered that the
welding preparations include also the remove of frost, ice and 23. Complete the welding protocol.
moisture from the joining area (≥ 0,5 x fitting length) by means of
heat (e.g. hot gas device). Fittings and tapping tees must be
stored in closed, frost-free rooms and provided / used for welding Ad 4.2 Heated tool butt welding of tapping tees
only in the required quantity.
Processing instruction (short version)
The quality evaluation of socket welding joints by the internal
pressure creep test is only insufficiently possible. In combination 1. Establish acceptable working conditions, e.g. welding tent
with the tensile creep test a first sign is contained in DVS 2207-1, 2. Control the function of the welding equipment.
suppl. 1 (draft), table 1.
3. Ensure the roundness of the pipe by the clamps of the
welding equipment or corresponding re-rounding devices.
Appendix: Processing instructions (short versions)
4. Adjust and clamp the parts to be welded, e.g. by dollies.

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
Page 9 to DVS 2207-1

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).

R&D INTAKE MANIFOLDS


1. Establish acceptable working conditions, e.g. welding tent.
14. Set the heated tool to the welding position.
2. Connect the welding equipment to the mains or alternating
15. Align the welding areas to the heated tool until a bead of 1 current generator and control the function.
mm arises.
3. Clean the heating tools by means of a cleaning agent
16. Heating-up with reduced pressure ≤ 0,01 N/mm2, heating-up according to sections 3.2.1 and 3.2.2 with unused,
time according to manufacturers data. absorbent, non-fuzzy and non-coloured paper.

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

R&D INTAKE MANIFOLDS


figure 10). The pitch rate is very low in order to widely exclude the the winch vice by means of a suitable pliers or another clamping
fracture behaviour of the test sample. The clamping areas should device is radially peeled at possibly low speed (see figure 11).
be slightly undercut in order to insert the twisting moment Evaluation is done according to table 7.
directed to the welding joint section.

Figure 10. Application of force during torsion shear test.

Figure 11. Application of force during radial peeling test.

Table 7. Evaluation criteria for torsion shear and radial peeling test.

Fracture behaviour Type, characteristic Evaluation


High release forces, ductile fracture, > 80 % Very structured fracture appearance with plastic and No resp. minor faults
of the welding zone ductile yield
Welding zone is partly or completely melt, but Isolated delaminations, contaminations, insufficient sur- Unacceptable faults
only spot-welded face peeling
Brittle fracture Release zone is large-pored, fine structured, intersper-
sed with a lot of voids, partly burnt, overheated welding
joint
Pipe surface is not melt, welding joint too cold, too large
welding gap

331
332
Protocol form for the Heated tool butt welding of pipes o laid overground Material Sheet of

and pipelines components o laid underground

Customer Executive company Welding equipment: Weather Preventive measures

1 = sunny 1 = none

Name of order Name of welder Identifi- Label: 2 = dry 2 = umbrella


cation No.
Type: 3 = rain or snow 3 = tent

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

Welder signature: Date and signature of welding supervisor:

From periodic interval, frequency according to 4.1.2.


According to data of equipment manufacturer resp. welding equipment test plus workpiece moving pressure.
Enter measured values.
Page 11 to DVS 2207-1
Protocol form for the Heated tool butt welding of sheets Material Sheet of

Customer Executive company Welding equipment:

Name of order Name of welder Identification Label:


No.
Page 12 to DVS 2207-1

Type:

No. of order Name and company of the welding Machine No.


supervisor
Year of construction

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

Welder signature: Date and signature of welding supervisor:

From periodic interval, frequency according to 4.1.2.


According to data of equipment manufacturer resp. welding equipment test plus workpiece moving pressure.
Enter measured values.

333
334
Protocol form for the Electrofusion welding of pipes o laid overground Material Sheet of

and pipeline components o laid underground

Customer Executive company Welding equipment: Weather Preventive measures

1 = sonny 1 = none

Name of order Name of welder Identifi- Label: 2 = dry 2 = umbrella


cation No.
Type: 3 = rain or snow 3 = tent

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

Welding signature: Date and signature of welding supervisor:

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

pipes and pipeline components o laid underground

Customer Executive company Welding equipment: Weather Preventive measures

1 = sonny 1 = none
Page 14 to DVS 2207-1

Name of order Name of welder Identification Label: 2 = dry 2 = umbrella


No.
Type: 3 = rain or snow 3 = tent

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

Welder signature: Date and signature of welding supervisor:

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

DVS – DEUTSCHER VERBAND Welding of thermoplastics


FÜR SCHWEISSEN UND Heated tool welding of pipes made of PE-Xa Technical Code
VERWANDTE VERFAHREN E.V. with pipeline components made of PE-HD DVS 2207-1

R&D INTAKE MANIFOLDS


Supplement 1

Translation of the German version from December 2005

Contents: recommended to record the welding data in welding protocols


(sample see appendix) or on data carriers.
1 Scope
2 General requirements Within the framework of the quality assurance it is recommended
3 Measures before welding to produce and test samples of joints before and during the
4 Electro-socket welding welding works.
4.1 Description of method Every welder has to be trained and has to be in possession of a
4.2 Welding device valid qualification certificate. The intended application range may
4.3 Preparation of welding be decisive for the kind of qualification.
4.4 Welding procedure
5 Testing of welded joints The DVGW-specification GW 330 applies analogously as
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

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.

DVS, Technical Committee, Working Group ″Joining of Plastics″

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

4.1 Description of method

R&D INTAKE MANIFOLDS


The joining areas (pipe surface and inside of the fitting) are
overlapped and welded by resistance wires inside the fitting
(heating coils) which are heated up by electric energy (see figure
1and 2).

Figure 3. Bevelled shrink of the pipe end.

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

Table 1. Test method for welding joints.

Test method Electro socket welding

R&D INTAKE MANIFOLDS


Fittings Tapping tees
Visual test DVS 2202-1, Table 3 DVS 2202-1, Table 3
Mechanical treatment of pipe surface has to be visible even outside of the welding area.
Tensile creep test DVS 2203-4, Suppl. 1
Fitting material stress rupture life part of fracture in the
[h] 1) heating wire plane 2)
PE 80 40 min. 75%
PE 80 400 evaluation omitted
PE 100 120 min. 75% non applicable
PE 100 1200 evaluation omitted
Testing temperature ϑ=80°C
Testing load σ=3 N/mm²
1) average of 6 circumferential specimens
2) average of all 6 specimens

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-

R&D INTAKE MANIFOLDS


be taken in account. coloured paper and exhaust it.
The parts to be welded must have the same temperature level. 7. Insert the pipes into the fitting and control the insert depth by
Test welds have to be produced and tested. 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.
Appendix:Processing instructions (short versions) 8. Connect cable to fitting. Cable must be free of weight load.
Ad 4 Electro-socket welding of fittings and tapping tees 9. Enter welding data e.g. by means of barcode scanner, check
the displayed data on the equipment and start the welding
Processing instruction (short version) process.
1. Establish acceptable working conditions, e.g. welding tent. 10. Control the correct welding procedure on the welding equip-
2. Connect the welding unit to the mains or the alternating ment e.g. by control of the display information and if available
current generator and check function. with the welding indicators. Consider error messages.
11. Disconnect cable from fitting.
3. Deburr the outside of the the rectangular cut pipe end.
Shorten the pipe in case of too much pipe end shrinkage. 12. Declamping of the welded parts after cooling time. Remove
fixing device.
4. Ensure that pipe ends are round using re-rounding clamps,
permitted ovality up to ≤1,5%, max. 3 mm. 13. Complete the welding protocol form as far as no automatic
protocol is made.
5. Clean the joining areas even outside of the welding zone by
means of cleaning agents according to section 4.3 with
unused, absorbent, non-fuzzy and non-coloured paper.
Machine the pipe surface in the welding area with a scrap-
ping tool and wall thickness removal of approx. 0,2 mm.
Remove the shavings without contacting the pipe surface.

339
340
Protocol for electro-socket welding  laid overground Material Sheet of

of pipeline components  laid underground


Customer Executive company Welding equipment: Weather Preventive measures

1 = sunny 1 = none

Name of order Name of welder Identifica- Product: 2 = dry 2 = umbrella


tion
Type: 3 = rain or snow 3 = tent

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

Signature of the welder: Date and signature of the welding supervisor:

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

DVS – DEUTSCHER VERBAND


FÜR SCHWEISSEN UND
Heated tool butt welding of Technical Code
VERWANDTE VERFAHREN E.V.
large-diameter pipes made of PE 100 DVS 2207-1
Supplement 2

R&D INTAKE MANIFOLDS Objections by April 30, 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

e.g. by closing the pipe ends.

1 Scope of application 4 Indications about the process sequence


This technical code applies to the heated tool butt welding of large-
When thick-walled pipes are welded, it is necessary to pay explicit
diameter pipes made of PE 100 according to DIN 8074 / DIN 8075
attention to the points described below:
with wall thicknesses > 30 mm.
The process sequences basically correspond to the procedure de- 4.1 Temperature checking
scribed in the DVS 2207-1 technical code. The recommendations
In order to be certain to achieve a suitable welding temperature,
described below constitute additional indications.
a heated tool temperature of 220°C (± 10°C) is stipulated for
thick-walled piping. The uniform temperature of the heated tool
must be checked in the welding area at a minimum of eight meas-
2 General requirements
uring points evenly distributed around the circumference. Calibrated
thermal-contact measuring devices must be used for the measure-
The quality of the welded joints is dependent on the qualification
ment (according to the DVS 2208-1 technical code).
of the welders, on the suitability of the utilised machines and jigs as
well as on the compliance with the technical codes for welding.
4.2 Minimise the misalignment of the joining faces
The welding work must be monitored by a welding supervisor
According to the DVS 2207-1 and DVS 2202 technical codes, the
qualified according to the DVS 2213 or DVGW GW 331 guideline.
maximum permissible misalignment is 10 % of the wall thickness
The contracting parties must reach agreement on the type and
(max. 5 mm).
scope of the monitoring. The process data must be documented
on welding record sheets or on data carriers. In this respect, pref- – The misalignment must be minimised in order to avoid any
erence should be given to electronic data acquisition. notch effect or stress concentrations.
Within the framework of the quality assurance, it is recommended – As compensation for any fabrication-induced tolerances in the
to manufacture and test trial welds in the given working conditions wall thickness or in the ovality, orientation to the marking is
before commencing and during the welding work. recommended during the alignment of the pipes in order to
minimise the misalignment. For this purpose, it is recommended
Every welder must be trained and must possess a valid qualification
to join the pipes according to the production sequence (metering).
test certificate according to the DVS 2212-1 or GW 330 guideline.
The planned area of application determines the type of the quali- – Since different pipe end sagging may be a cause of impermis-
fication. sible misalignment, the pipe end sagging must be checked
according to the DVS 2206-5 technical code. In order to mini-
The machines and jigs used for the welding must satisfy the re-
mise the misalignment, it is recommended to carry out planing
quirements according to the DVS 2208-1 technical code.
(if necessary, also on one side only) or to shorten the pipe end.
– Welds between pipes and fittings require particular attention
3 Measures before the welding because the fitting was manufactured from a different pipe batch,
was injection-moulded or was subjected to chip-producing
The immediate welding area must be protected from unfavoura- machining. If the ovality of a pipe end leads to a non-tolerable
ble weathering influences (e.g. wind or the action of moisture). If misalignment, this must be compensated for with suitable aids
suitable measures (e.g. preheating, enclosing with tents or heat- (e.g. hydraulic tool).

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.

DVS, Technical Committee, Working Group "Joining of Plastics"

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

R&D INTAKE MANIFOLDS


– The outer fibre strains must be minimised in order to avoid any
the weld and does not improve the quality of the weld.
stress peaks on the welds. Therefore, it is recommended to
carefully observe the following bending radii in relation to the Special applications (e.g. relining processes) demand the removal
outside diameter (OD) in question: of the external and/or internal welding bead on butt-welded piping.
With regard to the tools used for this purpose (bead removers), it
20°C 30 x OD must be ensured that, during the removal of the bead, the pipe is
10°C 52.5 x OD not damaged (notches) and the wall thickness of the pipe in the
area of the weld is not lower than the nominal wall thickness of
0°C 75 x OD the pipe. This can only be guaranteed with suitable devices specially
Applies to pipe series SDR 26 and smaller developed for this purpose. The indications from the device manu-
facturer must be observed.
– In order to avoid having to unnecessarily apply any force for
the movement of the pipes, the friction of the pipe train to be
moved must be reduced by taking suitable measures (e.g. dollies).
It is preferable to move the shorter pipe train.
– Since the pipe trains consisting of thick-walled pipes naturally ex-
hibit a higher weight, it must be ensured that the utilised welding
machines can produce enough force reserves for the application
of the tractive force necessary in order to achieve the stipulated
changeover time. (Remark: The tractive force required during
the quick changeover is higher than the movement force to be
established for the joining process.)
– Any bending in the welding machine must be avoided during
the alignment of the pipe trains.

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

DVS – DEUTSCHER VERBAND Welding of thermoplastics


FÜR SCHWEISSEN UND
Hot-gas string-bead welding and hot-gas welding
with torch separate from filler rod of pipes, pipe Technical Code
VERWANDTE VERFAHREN E.V. components and sheets – Methods, requirements
DVS 2207-3

R&D INTAKE MANIFOLDS


Translation of the German version from April 2005

Contents: welding of semi-finished thermoplastic products in tank, process


equipment and pipeline manufacture. It describes the various
1 Applicability methods, shows the method limitations and defines the quality
2 Materials assurance requirements.
3 General description of the method
3.1 Hot-gas welding with torch separate from filler rod (WF) Hot gas welding is mainly used for welding material thicknesses
3.2 Hot-gas string-bead welding (WZ) between 2 and 10 mm. Larger thicknesses are generally hot-gas
4 Device types extrusion welded according to DVS 2207-4. Special applications,
5 Constructional design, weld shapes and weld structure such as welding of waterproof sheeting, are described in
6 Requirements DVS 2225-1 and 2225-4; welding of PE pipe jackets is described
6.1 Requirements for the materials and their weldability in DVS 2207-5.
6.2 Quality requirements for welding joints
6.3 Requirements for welding tools and accessories
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

6.4 Requirements for welders 2 Materials


7 Commissioning welding equipment and setting the welding
parameters
8 Preparation for welding This technical code applies for the materials stated in DVS 2207-3
8.1 Equipment Supplement 1. The technical code can be applied in principle to
8.2 Protection against environmental influences other materials and material modifications (e.g. electrically
9 Welding conducting). Supplementary notes from the semi-finished
9.1 Preparing the joining surfaces and the welding filler products manufacturer are to be observed.
9.2 Tacking
9.3 Hot-gas welding with torch separate from filler rod (WF)
9.4 Hot-gas string-bead welding (WZ) 3 General description of the method
9.5 Mechanical reworking of the weld
9.6 Thermal reworking A welding filler (for example round or section rod) is used in hot-
9.7 Welding record sheet gas string-bead welding and hot-gas welding with torch separate
10 Testing the welded joints from filler rod. The joining surfaces of the base material and the
11 Safety instructions welding filler are plasticized with hot gas, usually air (require-
12 Other applicable standards and technical codes ments – see DVS 2207-3 Supplement 2), and joined under
Appendix 1: Brief instructions for welding pressure.
Appendix 2: Welding record sheet
3.1 Hot-gas welding with torch separate from filler rod (WF)
1 Applicability
The base material and the welding filler are heated with a stream
This technical code applies for hot-gas welding with torch of hot gas directed to the joining surfaces by means of the round
separate from filler rod (WF) and hot-gas string-bead (WZ) nozzle fitted on the welding tool, Figure 1.

Figure 1. Hot-gas welding with torch separate from filler rod.

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.

DVS, Technical Committee, Working Group ″Joining of Plastics″

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

R&D INTAKE MANIFOLDS

Figure 2. Hot-gas string-bead (rod) welding.

The welding tool is passed along the welding joint in continuous


motion. The plasticized welding rod, positioned by hand is placed
in the welding joint with the application of joining pressure. The
main areas of application are hard to access places, as well as
the weld root, especially in the case of PVC.
a)
3.2 Hot-gas string-bead welding (WZ)
In this method, the welding filler is fed through a channel located
in the nozzle into the joining zone. The nozzle channel must
match the shape of the welding filler.
The welding filler and the base material are evenly pre-heated
and plasticized by directing the stream of hot gas and as a result b)
of the shape of the draw nozzle. The required joining pressure is
applied via a beak shaped tip on the end of the nozzle (nozzle Figure 3. Hot gas welding torch;
shoe). When handled correctly, welding is more continuous, even a) Torch with external gas supply,
and faster than with hot-gas welding with torch separate from b) Torch with internal blower.
filler rod.
Hot-gas string-bead welding is therefore preferable to hot-gas 5 Constructional design, weld shapes and weld structure
welding with torch separate from filler rod. However, it is not
always practicable in inaccessible places. DVS 2205 applies to the construction of the components.
The constructional design and dimensioning of the welds is
subject to DVS 2205-3. The terminology, drawing and symbolic
4 Device types representation of the welds is subject to DIN EN 22553.
Welding tools (torches) consist of an electrical lead, welding gas Special attention should be paid that:
supply, handle, heating element including regulator or controller, – Crossing welds must be avoided.
as well as replaceable nozzle. The welding gas is usually heated
with an electrical resistance heater. Torches are distinguished – The separation of welds must be approx. 3x the width of the
between those with an external welding gas supply and those covering layer, however at least 30 mm.
with an integrated blower, as well as between electronically – The different thicknesses of the connection ends for butt joints
regulated and electronically controlled torches. must be matched with the thickness of the workpiece (DVS
2205).
– Torches with an external welding gas supply require an additio-
nal blower, compressed gas bottles or a compressed air con- – In the case of accessibility from only one side only, a weld
nection for their gas supply. This also enables the use of gases shape should be chosen which ensures that the cross-section
other than air (for example nitrogen in the case of oxidation- of the respective thinner joining part can be completely con-
sensitive materials). They are better suited for prolonged use nected (for example for a T-butt with single-bevel weld).
on account of their lightweight construction, Fig. 3 a. – It must be ensured that the joining surfaces allow for proper
– As a result of their high weight, torches with integrated blowers handling of the welding torch.
are mostly used for brief welding jobs, for example on-site wel- The most important seam geometries are V butt, double-V butt,
ding, Fig. 3 b. single-bevel, double-bevel weld.
– Regulated torches include incorporated welding gas tempera- Welding fillers can be round or profile rods according to DVS
ture measurement with regulating electronics integrated into 2211. Round rods are usually multi-layer welded depending on
the tool. The tools allow a highly consistent welding gas tem- the weld cross-section. Profile rods are usually processed in a
perature irrespective of environmental influences, fluctuation in single layer. This requires adaptation of the seam geometry to
air flow rates and changes in voltage. This is normally indica- the section in accordance with the welding filler manufacturer’s
ted on a display with target and actual values. specifications.
– Controlled torches do not include internal temperature com- Table 1 shows the common materials and seam opening angles
pensation. The actual temperature is subject to fluctuations of for V and double-V welds. The angles 45° and 90° are common
the air flow applied and of the supply voltage. for fillet welds, Fig. 4.

344
Page 3 to DVS 2207-3

R&D INTAKE MANIFOLDS


0 – 2 mm
0 – 2 mm

a) V-weld on butt joint – b) V-weld on butt joint – c) Double V-weld


without backing with backing at a butt joint
0 – 2 mm

d) Single-bevel weld with e) Double-bevel weld at T-joint f) Double fillet weld


fillet weld at T-Joint
Figure 4. Common welding geometries.

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°.

Base material thickness Welding rod (round)


in mm Number x diameter [mm]
V-weld 2 1x4
3 3x3
4 1x3+2x4
5 6x3
if possible, additionally with
backing (7) in each case

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

The nature and scope of testing are to be agreed upon. Relevant


references are given in technical codes DVS 2203-1 and 2201-2.

6.2 Quality requirements for welding joints

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

R&D INTAKE MANIFOLDS


requirements.
8 Preparation for welding
For the materials PVC, PP, PE and PVDF, the welding filler must
be mechanically treated (scraped) with suitable tools prior to
The weld edges of the joining surfaces are prepared according to welding.
Section 5. It must be ensured that adequate accessibility to the
welding equipment to the joining surfaces is achieved. Problems Should the joining surfaces need to be cleaned, non-fat cleaners
experienced by the welder as a result of the welding force applied should be used.
by the welder should be avoided or minimised. The welder
should not be hindered in the necessary advancement of the 9.2 Tacking
connection cables, hoses, and the welding filler. Tacking serves to fix the joining parts together in their intended
position to avoid displacement of the joining parts during welding.
8.1 Equipment Tacking is often carried out by melting the joining surfaces with a
The following equipment represents the minimum requirement for special tacking nozzle or an equivalent nozzle attachment.
carrying out professional welding:
– Hot gas device in accordance with this technical code and 9.3 Hot-gas welding with torch separate from filler rod (WF)
Supplement 2 In hot-gas welding with torch separate from filler rod, the joining
– Flowmeter for welding gas pressure is applied by hand via the welding filler. The welding
filler should be stretched, compressed or twisted as little as
– Fast display, digital temperature meter possible in this process to minimize the occurrence of residual
– Suitable measuring equipment to check displacement / diame- stress in the weld.
ter / thickness At the beginning of a welding pass, it is recommended to slightly
– Suitable equipment storage facilities bevel the tip of the welding filler.
– Scraper, retractable blade, nozzle brush, wire cutting pliers or The nozzle aperture should be directed into the welding zone at
similar an angle of approx. 45° to the base material. The base material
and the welding filler are plasticized with triangular fanning
– Table of welding parameter acc. to Supplement 1 and/or in- motion in the direction of welding. The bevelled welding filler is
structions from the semi-finished products manufacturer then pressed onto the desired point and the fanning motion
– Welding record sheet acc. to Appendix 2 continued in the welding direction.
– Personal protective equipment The joining pressure is applied by hand on the welding filler such
that it then forms a welding string.
– Dust protection for welding filler
During welding, a bow wave of plasticized material spreading in
– Adequate illumination front of the welding filler must be observed, as well as a welding
– Protection against weather as required seam in the form of a uniform double bead on both sides of the
weld string-bead.
– Special cleaner as required (non-swelling, dissolving or contai-
ning fat), lint-free cloths The welding parameters – joining pressure, temperature and the
heat penetration time resulting from the welding speed and the
8.2 Protection against environmental influences material thickness – are to be balanced against each other
(welding parameters – see Supplement 1).
The environmental conditions can have a significant effect on the
welding process and therefore the quality of the joint. The When commencing on a welding string already made or in the
following points should therefore be observed: case of round welds, proceed according to the representation in
Fig. 6. At the end of welding, the welding rod should not be
– The welding area should be protected against the weather twisted off or torn off, but, for example, removed with a knife or
conditions (e.g. moisture, wind, draughts and temperatures be- cutting pliers. After each welding pass the weld should be
low + 5 °C). reworked without scoring using a suitable scraper.
– If the appropriate measures (for example preheating, enclos-
ure in a tent, heating) ensure that an adequate temperature of
the semi-finished products can be maintained for welding, wel-
ding can be carried out at any outside temperature provided
the welder’s manual skill is not impaired. It may be required to
produce test welds under the prevailing conditions as additio- Commencing at the beginning
nal verification. of a weld

– If the joining parts are of an uneven temperature, for example


due to sunshine incident on one side, different storage conditi-
ons etc., the temperature must be equilibrated prior to welding.

9 Welding

9.1 Preparing the joining surfaces and the welding filler


The joining surfaces must not be damaged, oxidized or soiled.
They and the adjacent edges must therefore be mechanically
treated prior to welding.
Mechanical cutting tools, such as scrapers, retractable blades,
mills and drills are suitable for removal. Grinding tools are only Commencing within the weld
permissible if soiling, through the use of grinding equipment and
overheating of the surface, can be avoided. Figure 6. Welding rod positioning.

347
Page 6 to DVS 2207-3

9.4 Hot-gas string-bead welding (WZ) 9.6 Thermal reworking


Residual stress within the weld can be reduced by tempering.
In hot-gas string-bead welding, the welding filler is pressed via The temperature conditions depend on the material and
the nozzle shoe at the end of the draw nozzle into the joining

R&D INTAKE MANIFOLDS


component. The specifications from the semi-finished products
zone. At the start and finish of welds, the same procedure is to be manufacturer are to be observed.
followed as in WF welding, Fig. 2.
9.7 Welding record sheet
The base material is preheated at the beginning of the actual
welding process with the stream of air from main nozzle aperture The welding record sheet also documents the welding conditions
in a fanning motion. The welding filler is then fed into the nozzle and the welding parameters. It forms the basis for the
and is also preheated. As soon as the surfaces of the joining assessment of the weld quality by the welding inspector (cf. DVS
parts are plasticized, the filler is pressed into the prepared 2213 and the sample record sheet in Appendix 2).
welding joint with the tacking tip and the welding machine is
passed along the welding joint under uniform application of
joining pressure. 10 Testing the welded joints

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.

Table 3. Possible testing methods for hot-gas welds.

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

11 Safety instructions DVS 2205 Calculation of thermoplastic tanks and


apparatus
Some materials develop hazardous decomposition products and Part 3 Welded joints

R&D INTAKE MANIFOLDS


poisonous vapours if overheated (for example PVC, PVDF and Part 4 Flanged joints
E-CTFE), others even when welded (for example FEP, MFA,
PFA, PTFE). In accordance with Article 20 of the German Part 5 Rectangular tanks
Hazardous Substances Ordinance (GefStoffV) or according DVS 2206 Testing of components and constructions
national regulations, the company owner must produce operating made of thermoplastic materials
instructions based on the manufacturer’s safety datasheets, DVS 2207-1 Welding of thermoplastics – electro fusion
which show all potential hazards and protective measures welding of pipes made of PE-X with
required. Other specific protective measures are to be defined on pipeline components and sheets made of
a case-by-case basis. PE-HD
The applicable safety regulations pertaining to welding in EX DVS 2207-3 Hot-gas welding of thermoplastics – hot-
protected areas are to be observed and the necessary measures Supplement 1 gas welding with torch separate from filler
are to be agreed with the safety office responsible; see the and string-bead welding of pipes, pipeline
German Workplace Safety Ordinance (BetrSichV) or according components and sheets – welding
national regulations in this regard. parameters
DVS 2207-3 Hot-gas welding of thermoplastics – hot-
Supplement 2 gas welding with torch separate from filler
and string-bead welding of pipes, pipeline
12 Other applicable standards and technical codes components and sheets – welding
equipment requirements
DIN 1910-3 Welding of plastics, processes
DVS 2207-3 Hot-gas welding of thermoplastics – hotgas
DIN 4279 Testing of pressure pipelines for water by Supplement 3 welding with torch separate from filler and
internal pressure – Low density PE-LD (in preparation) string-bead welding of pipes, pipeline
polyethylene pressure pipelines, high components and sheets – welding of fluor
density PE-HD (PE 80 and PE 100) plastics
polyethylene pressure pipelines, Cross-
linked PE-X polyethylene pressure DVS 2207-4 Welding of thermoplastics; extrusion
pipelines, unplasticized polyvinyl chloride welding of pipes, pipe components and
PVC-U pressure pipelines. sheets – Welding processes, requirements
DIN 16960-1 Welding of thermoplastics – principles DVS 2207-5 Welding of thermoplastics; Welding of PE-
pipe jacktets – pipes and pipe components
DIN 32502 Imperfections in plastic welded joints;
classification, terminology, Explanations DVS 2207-11 Welding of thermoplastics – heated tool
welding of pipes, pipeline components and
DIN EN 10204 Metallic products – Types of inspection sheets made of PP
documents
DVS 2207-15 Welding of thermoplastics – heated tool
DIN EN 12943 Filler materials for thermoplastics welding of pipes, pipeline components and
DIN EN 22553 Welded, brazed and soldered joints – sheets made of PVDF
Symbolic representation on drawings DVS 2210-1 Industrial pipelines made of thermoplastics
DIN EN ISO 1043-1 Plastics – symbols and abbreviated terms – planning and execution – above-ground
DVS 2201-2 Testing of semi-finished products of pipe systems
thermoplastics, weldability, test methods – DVS 2211 Filler Materials for thermoplastics – scope,
requirements designation, requirements and tests
DVS 2202-1 Imperfections in thermoplastic welding DVS 2212-1 Examination of plastic welders: Examina-
joints; tion groups I and II
Features, descriptions, evaluation DVS 2213 Plastic welding specialist – Examination
DVS 2203 Testing of welded joints of thermoplastics DVS 2225 Joining of lining membranes made of
Part 1 Test methods – requirements polymer materials in geotechnical and
hydraulic engineering
Part 2 Tensile test
Part 4 Tensile creep test DIN standards may be obtained from Beuth Verlag, Berlin, DVS
technical codes from Verlag für Schweißen und verwandte
Part 5 Technological bending test Verfahren DVS-Verlag GmbH, Düsseldorf.

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-

R&D INTAKE MANIFOLDS


– Valid welding certificate in accordance with DVS 2212-1 tion of the welding process.
– Hot-gas welding equipment with operating instructions – Connect and switch on the welding equipment according to
the operating instructions
– Welding nozzles suitable for the welding job and the wel-
ding filler – Select and fit hot-gas nozzle; set hot-gas flow rate and tem-
perature and check (Supplement 1)
– Flowmeter for welding gas
– Temperature meter with probe to measure the hot-gas and 5. Prepare the weld and joining surfaces (Section 5.8)
the semi-finished product temperature.
– Check weld geometry and shape, define and produce as re-
– Suitable measuring equipment to check displacement, dia- quired
meter, thickness
– Mechanically remove the oxide layer from the joining sur-
– Equipment storage facilities faces with abrasion immediately prior to welding
– Scraper, retractable blade
– Personal protective equipment 6. Tacking the joining surfaces (Section 9.2)
– Dust protection for welding filler – Partial or continuous tacking with tack nozzle
– Cleaning agent
7. Welding (Sections 9.3, 9.4)
– Supplement 1 Welding parameters
– Monitor the welding speed and check uniformity
– Appendix 2 Welding record sheet
– Continuously check the handling of the welding filler and
– Special welding instructions, as required
the draw nozzle and perform necessary corrections

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

Hot-gas welding of sheets and pipes Company logo


Welding record sheet
Project name: Project no.: Weather Protective
measures
Drawing no.: Base material (manufacturer, type, batch, date) form: 1 = sunny 1 = none
Welder: Welding filler (manufacturer, type, batch, date): 2 = dry 2 = screen
Welding certificate no.: / valid until, issued by: Welding equipment (make, type): 3 = precipi- 3 = tent
3 = tation
Welding inspector (2): Nozzle(s): 4 = wind 4 = heating

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

(1) Measured in the middle of the nozzle exit aperture, 5 mm inside


the nozzle Remarks, e.g. adverse conditions
(2) e.g. plastic welding specialist as defined in DVS 2213
R&D INTAKE MANIFOLDS

Date / welder signature Date / welding inspector signature


Page 9 to DVS 2207-3

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

Planned as replacement for April 2005 edition

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

temperature 1) flow 2) with wire 


°C l/min mm/min 3 mm 4 mm

High-density
torch separate from the filler rod (WF)

PE- HD 4) 300 … 320 70 … 90


polyethylene
8 - 10
Polypropylene,
Hot gas welding with the

PP-H; PP-B; PP-R 305 … 315 60 … 85


Types 1, 2 and 3
20 … 25
Unplasticised
PVC-U 330 … 350 110 … 170 8 … 10
polyvinyl chloride
Chlorinated 40 … 50
PVC-C 340 … 360 55 … 85
polyvinyl chloride

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)

PVC-U 350 … 370 45 … 55


polyvinyl chloride
Chlorinated
PVC-C 370 … 390 180 … 220
polyvinyl chloride
20 … 25 30 … 35
Polyvinylidene
PVDF 365 … 385 200 … 250
fluoride

1) Measured 5 mm in the nozzle, in the centre of the nozzle opening.


2) Drawn-in cold air volume at the ambient pressure.
3) Depending on the welding filler material diameter and the welding groove geometry.
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.

DVS, Technical Committee, Working Group “Joining of Plastics”

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
File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-3-Bb2.fm

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

R&D INTAKE MANIFOLDS


welding equipment and accessories Supplement 2

Translation of the German version from April 2005

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,

– the equipment elements are ergonomically designed according – service addresses.


to their intended use and are as light as possible and may be A compilation of potential functional faults is recommended,
operated easily and safely, including possible causes and information on rectification.
– the handle has no preferred direction in relation to the supply
lines and that the nozzle can be fixed in any position, 2.4 Hot-gas supply
– the functional elements are easily accessible for proper Irrespective of the equipment construction, the welding gas
operation and for the necessary cleaning and maintenance supply must ensure that
and that expendable parts are easy to replace, – the welding gas is free of dust, water and oil,
– feed hoses and cables can be extended by the welder with the
– the gas volume remains constant during welding and an air
minimum of effort and do not kink or twist in proper operation, flow matched to the welding job according to DVS 2207-3
– they can be stored safely when welding work is finished or Supplement 1 is provided even if several welding tools are in
during interruptions, continuous operation,

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.

DVS, Technical Committee, Working Group ″Joining of Plastics″

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

R&D INTAKE MANIFOLDS


independent of voltage or air flow fluctuations, nozzle
geometry and differences in ambient temperatures, DIN EN Electrical equipment of industrial machines
– setting of the welding temperature is easy and sensitive and 60204- 1
cannot be inadvertently displaced, EN 61000-3-2 Electromagnetic compatibility (EMC) Part 3-2:
– the output gas volumes fluctuate in a maximum range of ± 5% Limit values – limit values for harmonic current
from the set value, independent of process-related counter- emissions (equipment input currents 16 A per
pressure fluctuations (for example unfavourable nozzle phase)
position). EN 61000-3-3 Electromagnetic compatibility (EMC) Part 3-3:
Limits: Limitation of voltage changes, voltage
For welding torches with integrated air supply it must be ensured
fluctuations and flicker in public low-voltage
that
supply systems, for equipment with rated cur-
– the air suction openings are fitted such that they allow rent 16 A per phase and not subject to condi-
sufficient entry of air at all times for proper use of the tional connection.
equipment (for example no covering with hands), EN 60335-1 Safety for household and similar electrical
– the filter element is easy to change. appliances – Part 1: General requirements
In the case of an external welding gas supply, the temperature of EN 60335-2.45 Safety for household and similar electrical
the gas from the central supply must not exceed 50°C appliances – Part 2-45: Special requirements
VDE 0875 Radio interference suppression of electrical
2.5 Nozzles devices and systems for rated frequencies of 0
For nozzles in hot-gas string-bead welding: to 10 kHz
– The nozzles must match the cross-section of the welding filler DVS 0801 Flow measurement of technical gases for weld-
to be used and must also allow the smooth passage of welding ing, cutting and related procedures
filler taking into account its volume expansion. DVS 2207-3 Hot-gas welding of thermoplastics – hot-gas
string-bead and hot-gas welding with torch
– The leading surface of the nozzle shoe must be polished.
separate from filler rod of pipes, pipeline com-
– The nozzle material must be resistant to oxidation and ponents and sheets – methods, requirements
corrosion. DVS 2207-3 Hot-gas welding of thermoplastics – Hot-gas
– The nozzle shoe must be formed such that its edges do not Supl. 1 welding with torch separate from filler and
score the base material. string-bead welding of pipes, pipeline compo-
nents and sheets – welding parameters
The aforementioned statements apply in principle as well to
pressure rollers for welding soft materials (e.g. soft PVC).

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
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-4\englisch\Jan_08\e2207-4.fm
Erstellt am: 18.01.2005
Zuletzt geändert am: 29.01.2008

March 2008

DVS – DEUTSCHER VERBAND Welding of thermoplastics Extrusion


FÜR SCHWEISSEN UND welding of pipes, piping parts and panels Technical Code
VERWANDTE VERFAHREN E.V. Processes and requirements DVS 2207-4

R&D INTAKE MANIFOLDS Translation of the German version from april 2005

Contents: The technical code can be correspondingly applied to other


materials and material modifications (e.g. electrically conductive).
1 Scope of application It is necessary to pay attention to supplementary instructions
2 Materials from the manufacturers of the semi-finished products.
3 General process description
3.1 Continuous welding process
3.2 Discontinuous welding process 3 General process description
4 Machine variants
4.1 Machine Variant I Extrusion welding is a manual or semi-automatic welding proc-
4.2 Machine Variant II ess. It is performed with a welding filler which consists of wire or
4.3 Machine Variant III granules and is melted and plastified in a plastifying system (ex-
5 Structural design, weld shapes and weld structure truder). A welding shoe shaped according to the weld geometry
6 Requirements serves to press the welding filler into the base material welding
6.1 Requirements on the welding machines and devices groove which is plastified with hot air as a rule. Other heat sourc-
6.2 Requirements on the welding shoes
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

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

This technical code applies to the hot gas extrusion welding


(hereinafter called extrusion welding) of pipes and panels in tank,
apparatus and pipeline construction as well as during the
manufacture of self-supporting collecting pans and of seals on
concrete structures with thermoplastics. It describes the different
processes, indicates the process limits and stipulates
requirements for the quality assurance.
Special instructions for the extrusion welding of sealing sheets in
earthwork construction and water engineering are included in the
DVS 2225-1 and DVS 2225-4 technical codes. Instructions for
the extrusion welding of casing pipes can be found in the
DVS 2207-5 technical code.

2 Materials

This technical code applies to the materials specified in the


DVS 2207-4 technical code, Supplement 1. Figure 1. Diagram for continuous welding with Machine Variant I.

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.

DVS, Technical Committee, Working Group “Joining of Plastics”

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.

welding head. R&D INTAKE MANIFOLDS


The welding zone is preheated by a hot gas fan attached to the
4 Machine variants

3.2 Discontinuous welding process The machines or devices consist of:


For the welding, the plastified welding filler is extracted from the – the plastifying system (extruder) for the plastification of the
extruder section by section with a corresponding quiver, is input welding filler
inserted into welding groove plastified with a hot gas device and – the preheating system for the heating of the joining faces (as a
is pressed in, shaped and smoothed with a press-on tool (Fig. 2). rule, hot air)
– the welding head in order to accommodate the welding shoe
and the preheating system
– the welding shoe in order to input the extrudate into the
welding groove and to shape the surface (alternative to the
quiver and the press-on tool in the case of discontinuous
welding)

4.1 Machine Variant I


Machine or device type in which all the device components form
one unit. As a rule, the welding filler is supplied to the device as
round wire or, in the case of larger devices, also as granules, Fig. 1.

4.2 Machine Variant II


The extruder and the welding head are structurally separate in
the case of this machine type. For continuous welding, both
machine parts are connected with each other by a heated hose
for the welding filler, Fig. 3. For discontinuous welding, the
extrudate is extracted directly from the extruder using
replaceable material nozzles, Fig. 2.
The machines of this type have a high output capacity but are
primarily used in stationary operation due to their size. The
welding filler is usually supplied to the device in granule form.

4.3 Machine Variant III


The machines or devices consist of the welding wire intake
station, the plastifying unit and the preheating system. The
welding filler in wire form is transported into the heating chamber
by the wire feed unit which inputs the plastified welding filler into
the joining zone via the welding shoe, Fig. 4. As a rule, the
devices are smaller and easier to handle than Machine Variants I
Figure 2. Diagram for discontinuous welding with Machine Variant II. and II but also have a lower output capacity.

Figure 3.
Diagram for continuous welding
with Machine Variant II.

356
Page 3 to DVS 2207-4

For materials others than those listed in Appendix 1, it may be


necessary to choose different weld shapes and weld preparation
angles.

R&D INTAKE MANIFOLDS


Desination Sheme Symbol
V- seam
V-seam

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.

5 Structural design, weld shapes and weld structure

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)

– Crossing welds must be in a staggered arrangement. V- and double V-seams


– The distance between the welds should be about three times HV-seams
the width of the top layer but min. 50 mm.
– In the case of butt joints, it is necessary to match the work-
piece thicknesses of connecting ends with different thick-
nesses (DVS 2205).
– A weld shape which guarantees that the cross-section of the
thinner joining part in each case can be connected completely
(e.g. T-joint with a single-bevel butt weld) should be chosen in Angle of seam opering (’’)
the case of accessibility from one side only.
a) Continuous welding
DIN EN 22553 applies to the designation and graphical and
symbolic representation of the welds.
Depth of seams s (mm)

The most important weld shapes are single-V, double-V, single-


bevel and double-bevel butt welds as well as fillet welds.
HV-seam V- and double V-seams
Examples of the execution of welds as well as their symbolic
representation on fabrication drawings are shown on Fig. 5.
As a rule, the welds are manufactured in a single layer or, in
special cases, in multiple layers.
In order to reduce the weld volume and because of the more
uniform distribution of the residual welding stresses, the welds
should, if at all possible, be executed on both sides or with a Angle of seam (’’)
backing layer (double-V butt weld, fillet weld and double-bevel
butt weld). b) Descontinuous welding
The material input into the welding grooves should be minimised
because of the shrinkage stresses arising during the cooling of Figure 6. Recommended weld preparation angles for PE-HD and PP in
the case of single-V and single-bevel butt welds depending on
the welds. It is therefore recommendable to change the weld
the weld depth and the welding process (for other materials, it
preparation angle according to the joining part thickness, Fig. 6. may be necessary to choose different weld preparation angles).
The residual root opening should be max. 1 mm and full-
penetration welding must be ensured.
6 Requirements
The root gap should not exceed 2 mm in the continuous welding
process and 4 mm in the discontinuous welding process. If the 6.1 Requirements on the welding machines and devices
root gap width cannot be complied with for structural or design-
related reasons, appropriate measures must be taken (e.g. using The welding machines and the welding devices must be in a
a backing strip). functioning condition. Their condition and good working order

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

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adjusted to the welding job. part thickness.
Special requirements on the welding machines and the welding The "nose" located on the front part prevents the material from
devices are described in Supplement 2 to this technical code. flowing ahead, is a prerequisite for the generation of the
necessary joining pressure and supports the forward movement
6.2 Requirements on the welding shoes of the welding device. It must correspond to the welding groove
The joining pressure necessary for the welding is applied to the shape but must not touch the welding groove faces during the
joining faces with the welding shoe via the welding filler. At the welding.
same time, the welding shoe shapes and smooths the weld The gap between the nose and the weld sidewalls should be
surface. 1 - 3 mm depending on the weld thickness.
Therefore, the welding shoes must correspond to the welding job, The undercut on the contact surfaces prevents molten base
must be structurally adjusted to the respective weld shapes and material from being pushed away.
thicknesses (Fig. 7), must have smooth, anti-adhesive surfaces
and must be sufficiently temperature-resistant. When press-on tools are used for discontinuous welding, the
above stipulations are applicable correspondingly.

Table 1. Guide values for welding shoe dimensions.

a) Welding shoe for


single-V welds

Seam depth s for V-seams s Pressing length LA


(mm) (mm)
to 15 35
> 15 to 20 45
> 20 to 30 55

6.3 Requirements on the preheating


b) Welding shoe for The preheating must guarantee that the joining faces and the
fillet welds areas of the weld overlap, Fig. 8, are sufficiently plastified even
when the welding groove geometry changes. The welding shoes
and the preheating (nozzle geometry, air volume and hot gas
temperature) must be coordinated.

6.4 Requirements on the materials and their weldability


Semi-finished products and welding fillers (wire and granules)
must be suitable for extrusion welding. One prerequisite for
welded joints which should meet the requirements according to
DVS 2203 is the use of a welding filler of the same type as the
base material but at least of a similar type.
For the semi-crystalline materials (such as PE, PP and PVDF),
reference is made to the melt index as a characteristic parameter
for the weldability. If the melt index (MFR) values of the welding
partners are within the permissible melt index ranges in
DVS 2207-1, -11 and -15, weldability may be assumed in
general. If two semi-finished products in different MFR groups
from these ranges are to be welded with each other, it is
Figure 7. Representations of welding shoe designs. necessary to choose a welding filler whose MFR value is
between that of the combination of semi-finished products. For
As a rule, they are made of polytetrafluoroethylene (PTFE). This PE-HD, PP and PVDF, attention must be paid to the instructions
material possesses the specified properties and is easy to in the scope of application of the DVS 2207-1, 2207-11 and
machine. 2207-15 technical codes. If the melt index is outside the
authorised ranges in the specified technical codes, the welding
The lengths of the press-on zone and the smoothing surface
evidence according to DVS 2203-4 must be provided in the
should not be less than the minimum lengths specified in Table 1.
tensile creep test.
This ensures that the joining pressure acts during a minimum
time and that the necessary bond can thus be produced The following applies to amorphous materials such as PVC:
throughout the joining area (especially the weld root and the weld "Only semi-finished products of the same moulding material type
sidewalls). are weldable."

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

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Only semi-finished products with stipulated quality requirements
changed as well. It is recommended not to use the same extruder
should be welded (e.g. works certificate according to DIN EN
for different materials in practice.
10204).
The welding filler must be dry. If necessary, it must be dried
The welding fillers must meet the requirements according to the
before use (e.g. several hours in an exhaust air oven at
DVS 2211 technical code and DIN EN 12943.
temperatures of approx. 60 - 80°C). Attention must be paid to the
The base and filler materials must be available in a flawless information from the welding filler manufacturer.
processing condition and must be dry and clean.
While the machine is running, the required material temperature
If there are any doubts that the semi-finished products and/or the is checked directly at the material outlet in the middle of the
welding filler are similar (e.g. due to a lack of labelling) or if any strand using the prick sensor of a quick-display temperature
material changes are to be feared due to: gauge.
– improper storage The control measurement of the hot air temperature is taken in
– low joining part temperatures the hot air nozzle between the nozzle outlet plane and a depth of
- soiling 5 mm using a precision probe with a diameter of approx. 1 mm
– ageing (see the instructions in DVS 2207-4, Supplement 2).
– operating influences (media or temperatures) The stipulated air volume must be checked in the case of devices
it is necessary to establish the weldability by means of tests on with an external air supply. It is necessary to ensure the flawless
trial welds. Agreement must be reached with regard to the type function of devices with an internal air supply.
and scope of the tests. Instructions about this are given in the The material and hot gas temperatures must be checked
DVS 2203-1 and 2201-2 technical codes. immediately before the beginning of the welding. Repeat checks
are recommendable in the case of a welding job lasting a longer
6.5 Requirements on the welders time or after interruptions in the work.
Hot gas extrusion welding is a welding process for which not only All the measurements must be taken with regularly checked
comprehensive knowledge with regard to the materials to be measuring instruments (according to DVS 2207-4, Supplement
welded and to the handling of the machines and devices but also 2) and must be documented (Appendix 2).
high skills in the execution are prerequisites.
The welder must have passed a qualification test according to
the DVS 2212-1 technical code, Qualification Test Group II, and 8 Welding preparation
must possess a valid test certificate.
The welding grooves of the joining parts are prepared according
6.6 Requirements on the quality of the welded joints to Section 5.

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

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attention must be paid to the following: necessary to diagonally machine off the already executed ends
– The welding area must be protected from unfavourable of the weld.
weathering influences (such as moisture, formation of
condensation water, wind, draughts and temperatures below
+ 5°C).
– If it is ensured, by taking suitable measures (e.g. preheating,
tenting or heating), that a semi-finished product temperature
sufficient for the welding can be complied with, the welding
may be carried out at any outdoor temperature – provided that
the dexterity of the welder is not hindered. If necessary,
additional evidence must be provided by manufacturing and
testing trial welds in the existing conditions.
– In the case of non-uniformly tempered joining parts (e.g. due to
solar radiation on one side, in the case of different storage
conditions etc.), the temperatures must be equalised before
the welding.

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

10 Testing of the welded joints

A distinction is made between non-destructive and destructive


test procedures. They are listed in Table 2 "Possible test

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procedures" for the most frequent weld shapes.

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
Page 8 to DVS 2207-4

-1 Test procedures – Requirements DVS 2207-4, Welding of thermoplastics – Extrusion welding


-2 Tensile test Supplement 2 of pipes, piping parts and panels –
Requirements on the welding machines and
-4 Tensile creep test welding devices

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-5 Technological bending test DVS 2207-11 Welding of thermoplastics – Heated tool welding
DVS 2205 Calculation of tanks and apparatus made of of pipes, piping parts and panels made of PP
thermoplastics DVS 2207-15 Welding of thermoplastics – Heated tool welding
-3 Welded joints of pipes, piping parts and panels made of PVDF
-4 Flanged joints DVS 2210-1 Industrial piping made of thermoplastics –
-5 Rectangular tanks Planning and execution – Overground pipe
systems
DVS 2206 Testing of components and structures made of
thermoplastics DVS 2211 Welding of thermoplastics – Welding fillers –
Marking, requirements and tests
DVS 2207-1 Welding of thermoplastics – Heated tool welding
of pipes, piping parts and panels made of DVS 2212-1 Qualification testing of plastics welders –
PE-HD Qualification Test Groups I and II – Hot gas
welding with the torch separate from the filler
DVS 2207-3, Welding of thermoplastics – High-speed hot gas rod, high-speed hot gas welding, heated tool
Supplement 1 welding and hot gas welding with the torch butt welding, sleeve welding with an
separate from the filler rod of pipes, piping parts incorporated electric heating element, heated
and panels – Welding parameters tool sleeve welding and hot gas extrusion
DVS 2207-3, Welding of thermoplastics – High-speed hot gas welding
Supplement 2 welding and hot gas welding with the torch DVS 2225 Joining of sealing sheets made of polymer
separate from the filler rod of pipes, piping parts materials in earthwork construction and water
and panels – Requirements on the welding engineering
devices and accessories
DVS 2207-4, Welding of thermoplastics – Extrusion welding DIN standards can be obtained from Beuth Verlag, Berlin and
Supplement 1 of pipes, piping parts and panels – Welding DVS technical codes from Verlag für Schweißen und verwandte
parameters Verfahren DVS-Verlag GmbH, Düsseldorf.

362
Page 9 to DVS 2207-4

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

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– valid welder's certificate
– remove the oxide layer from the joining faces by means of
– hot gas extrusion welding device corresponding to the welding chip-producing machining
job, including the operating instructions
5. Tack the joining parts (Section 9.2)
– possibly hot gas welding device for tacking the joining parts
– execute a partial or continuous root layer with a hot gas
– welding shoes according to the weld shape welding device
– flow meter for welding gas 6. Start up and prepare the welding extruder (Section 7)
– temperature gauge with sensors for measuring the hot gas and – check the supply lines (electricity and air) for any possible
the extrudate as well as the temperature of the semi-finished hindrances to the welding operation
products
– connect and start the extruder according to the operating
– suitable measuring instruments for checking the misalignment, instructions
the diameter and the thickness
– select, adjust and assemble the welding shoe and the hot gas
– storage space for the devices
nozzle according to the weld geometry and the weld shape
– scraper and scraper blade
– extrude the reheated welding filler out of the cylinder
– personal protective equipment
– set and check the parameters (Appendix 1)
– dust protection for the welding wire
– preheat the welding shoe
– cleaning agent
7. Welding (Section 9.3)
– Supplement 1: Welding parameters
–- check that the base material is sufficiently plastified (e.g. by
– Appendix 2: Welding record sheet pricking it with a blunt tool)
– special welding instructions – check the welding speed and monitor the uniformity
2. Check the working conditions and plan the measures
– continuously check the guidance of the welding extruder and
(Section 8.2)
make any corrections needed
– accessibility
– if necessary, prevent any excessively rapid cooling of the weld
– sufficient lighting surface by covering it
– protective tent – bevel the ends of the welds before restarts
– heating – protect the welding filler from contaminations
3. Check the weldability (Section 6.4) 8. Finish-machine the weld (Section 9.4)
– on the semi-finished products and welding fillers, check that – let welded parts cool down sufficiently before unclamping them
the information from the manufacturers is correct and subjecting them to loads
– check the condition and cleanness of the joining partners and – machine off the lateral weld flow and the weld reinforcements
possibly clean them
9. Compile the welding record sheet (Section 9.6)
– if necessary, check the weldability of the joining partners by
means of build-up welding according to DVS 2201-2 or trial –- fill in the welding record sheet (Appendix 2) and carry out the
welds visual inspection according to DVS 2202-1

363
364
Extrusion welding of panels and pipes Company logo

Project: Project no.: Protective


Weathering
measures
Drawing no.: Base material (manufacturer, type, batch, date):
1 = Sunny 1 = None

Welder: Welding filler (manufacturer, type, batch, date):


Page 10 to DVS 2207-4

2 = Dry 2 = Screen

Welding certificate no.: / valid untel Welding machine, make, tpye:


3 = Precipita- 3 = Tent
tion

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
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Date / signature of the welder Date / signature of the welding supervisor


Draft May 2009

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

Planned as replacement for June 2006 edition

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

High-density polyethylene PE-HD 4) 210 … 230 210 … 300 300


Polypropylene, Types 1, 2 and 3 PP-H; PP-B; PP-R 210 … 240 210 … 300 300
Unplasticised polyvinyl chloride PVC-U 190 … 200 330 … 360 300
Impact-resistant polyvinyl chloride PVC-HI 170 … 180 280 … 340 300
Chlorinated polyvinyl chloride PVC-C 195 … 205 300 … 360 300
Polyvinylidene fluoride PVDF 240 … 260 280 … 350 300

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.

DVS, Technical Committee, Working Group “Joining of Plastics”

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
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Erstellt am: 17.01.2008
Zuletzt geändert am: 29.01.2008

March 2008

DVS – DEUTSCHER VERBAND


Welding of thermoplastics
FÜR SCHWEISSEN UND
Extrusion welding Technical Code
VERWANDTE VERFAHREN E.V. of pipes, piping parts and panels DVS 2207-4

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Requirements on the welding machines and welding devices Supplement 2

Translation of the German version from april 2005

Contents: - the preheating of cooled extrudate at the outlet of the material


nozzle is ensured by suitable devices, e.g. baffle nozzle for the
1 Scope of application hot gas flow
2 Requirements
- they can be put down in a stable position at the end of the
2.1 General requirements
welding work or during interruptions in the work
2.2 Marking and documentation
2.3 Safety requirements
2.4 Plastifying system 2.2 Marking and documentation
2.5 Preheating system The following information must be permanently displayed on the
2.6 Welding shoes machines and devices:
2.7 Accessories for discontinuous welding
3 Standards and technical codes which are also applicable – information about the manufacturer and the type
4 Literature – information about the electricity supply, the power input and
the frequency
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

1 Scope of application – identification number


– CE symbol and protection class
This supplement to the DVS 2207-4 technical code describes
general, qualitative and safety-relevant requirements on ma- All the machines and devices are provided with operating and
chines and devices for the extrusion welding of thermoplastics. maintenance instructions which, at least, must include the
following:
It applies to the Machine Variants I, II and III specified in the
DVS 2207-4 technical code and should ensure that the quality of – functional description with operating instructions
the welds which is demanded in the technical code is achieved – information about the application range (power range)
when the devices and machines are operated and handled
properly. – maintenance schedule with information about the test cycles
– service addresses
2 Requirements It is recommendable to compile a list of any possible malfunc-
tions, including any possible causes of defects and information
2.1 General requirements about how to rectify them.
The machines and devices must guarantee that:
2.3 Safety requirements
– the functioning capacity is ensured within the intended temper-
ature utilisation range from - 5°C to + 60°C The machines and devices must not involve any risk of injury
whatsoever for the user when they are utilised properly.
– the storage within a temperature range from - 20°C to + 80°C
does not cause any damage In particular, the following is applicable:
– the mechanical stresses occurring during proper transport and – any surfaces which become hot must be kept as small as pos-
operation do not lead to any disturbances or damage sible and, wherever technically possible, insulated
–- the internal surfaces and the screw have sufficient corrosion – any parts close to the welder's hands must not exceed opera-
protection against externally effective humidity as well as tionally induced temperatures of 40°C, even in the case of
against the planned welding filler or its constituents lengthy utilisation
– the machine and device elements are ergonomically designed –- sharp edges on the machines, devices and accessories are
according to their intended application and handling and can not permissible
be operated easily and safely
The machines and devices must comply with the applicable
– all the components and functional elements must be easily ac- regulations and technical codes.
cessible for the intended operation as well as for the necessary
cleaning and maintenance 2.4 Plastifying system
– the required joining pressure can be applied in the planned The following requirements must be met:
welding positions using corresponding holding jigs and han-
dles Uniform welding filler supply adapted to the screw speed in all the
planned welding positions.
– the design of the supply hoses and cables is flexible and force-
saving for the welder so that it neither kinks nor twists during In order to interrupt the granule supply, a suitable barrier must be
proper operation provided in the corresponding machines or devices.

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.

DVS, Technical Committee, Working Group “Joining of Plastics”

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)

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(air outlet opening) of nozzle
The material output above 1.5 kg/h should be infinitely adjustable (mm) (mm)
on the machine or device with the aid of the screw speed.
Constant speeds are permissible in the case of machines and a b
devices which are used exclusively for discontinuous welding. Up to 15 8 18
A drive cut-off must be effective for the heating-up time of the
16 ... 20 10 23
welding filler which has cooled in the extruder and in the supply
hose. 21 ... 30 12 34
The interruption switch (on/off) for the plastifying system must be 31 ... 40 15 50
arranged in such a way that it can be operated by the welder at
any time. This also applies to the material temperature controller.
maximum welding groove width
The extrudate must be plastified in a completely homogeneous
form and must emerge with a constant material output at a stable
temperature. 2.6 Welding shoes
The material temperature at the material outlet must be dis- The welding shoes must comply with the stipulations in the
played. DVS 2207-4 technical code, Section 6.2.
The temperature fluctuation of the material must not exceed
The safe and secure coupling as well as the easy replacement of
± 3 K (measured in the centre of the material) in continuous
the welding shoe must be guaranteed (this does not apply to
operation and with an unchanged controller setting.
devices which are used exclusively for discontinuous welding).
The deviation between the temperature set on the controller and
the actual outlet temperature must not exceed ± 10 K. 2.7 Accessories for discontinuous welding
The following applies to machines and devices which are used The press-on tools used for discontinuous welding must
exclusively for discontinuous welding: guarantee the most uniform possible input and pressing-on of the
– The material nozzles must be easy to replace. extrudate. The radius of the press-on surface with a bend length
of 120 - 130 mm is approx. 100 mm. The width of the press-on
– The nozzle cross-section must correspond to the weld volume surface corresponds to the weld width. The edges of the press-
to be filled in each case.
on surface must be rounded. If necessary, special press-on tools
are necessary for particular weld geometries.
2.5 Preheating system
The preheating system must guarantee that the weld sidewalls, The quiver consists of a PTFE pipe with a handle which closes
the weld overlap and the weld root are plastified sufficiently. This the pipe on one side. The inside diameter of the pipe is adapted
may be achieved with various systems, e.g. by hot gas heat or to the welding filler to be accommodated.
radiant heat. Because of the practical application, only the
preheating by means of hot gas is dealt with below.
3 Standards and technical codes which are also applicable
– The hot gas temperature is infinitely adjustable, according to
the material to be welded, and is displayed. The temperature DIN EN ISO 12100-1 Safety of machines – Basic terms and
fluctuation at an unchanged controller setting must not exceed general guiding principles for design –
± 10 K. The welding gas temperature must be reached after Part 1: Fundamental terminology and
max. 15 min. methodology
– The hot gas nozzles must be provided with a test borehole DIN EN ISO 12100-2 Safety of machines – Basic terms and
which permits reproducible measurements of the temperature general guiding principles for design –
according to DVS 2207-4. The transferability of the measured Part 2: Technical guiding principles
temperature values to the stipulations in the DVS 2207-4 tech- DIN EN 55014-1 Electromagnetic compatibility – Require-
nical code, Supplement 1 must be guaranteed – if necessary, ments on household appliances, power
by means of conversion tables. tools and similar electrical appliances –
– The volume flow must be min. 300 I/min (cold air volume in- Part 1: Interference emission
take at the ambient pressure) and must be kept constant DIN EN 55014-2 Electromagnetic compatibility – Require-
during the welding operation. ments on household appliances, power
– The heating unit is firmly installed on the welding head or on tools and similar electrical appliances –
the plastifying system. In the case of machines and devices Part 2: Interference immunity
which are used exclusively for discontinuous welding, the heat- DIN EN 60204-1 Safety of machines – Electrical equip-
ing unit is guided independently of the plastifying system. ment of machines – Part 1: General re-
– The hot gas nozzle must guarantee the intensive and uniform quirements
preheating (plastification) of the base material across the DIN EN 61000-3-2 Electromagnetic compatibility (EMC) –
entire weld width – at the lowest possible hot gas temperature. Part 3-2: Limiting values – Limiting val-
Table 1 shows an example of a nozzle geometry. The nozzle ues for harmonic currents (appliance in-
cross-sections specified in the table guarantee the reliable put current: 16 A per conductor)
overlapping of the different weld geometries and weld widths [1]. DIN EN 61000-3-3 Electromagnetic compatibility (EMC) –
In the case of larger welding groove widths, the existing basic Part 3-3: Limiting values – Limitation of
geometry must be correspondingly enlarged to scale. voltage changes, voltage fluctuations
and flickers in public low-voltage supply
In the case of machines and devices which are used for
grids for appliances which have a rated
discontinuous welding, the nozzle must be easy to change.
current of 16 A per conductor and are not
subject to any special connecting condi-
tions

367
Page 3 to DVS 2207-4 Supplement 2

DIN EN 60335-1 Safety of electrical appliances for domes-


tic use and similar purposes – Part 1:
General requirements

R&D INTAKE MANIFOLDS


DIN EN 60335-2-45 Safety of electrical appliances for domes-
tic use and similar purposes – Part 2-45:
Particular requirements on non-station-
ary electrical heating tools and similar
devices
DVS 2207-4 Welding of thermoplastics – Extrusion
welding of pipes, piping parts and panels
– Processes and requirements
DVS 2207-4, Welding of thermoplastics – Extrusion
Supplement 1 welding of pipes, piping parts and panels
– Welding parameters
EC Machine Directive 89/392; 2nd Amendment of 91/368
EEC; 3rd Amendment of 93/44 EEC
VBG 22 Working machines in the chemical, rub-
ber and plastics industries (now only
applicable to stocks of old machines)

4 Literature

[1] Gehde, M.: About the extrusion welding of polypropylene.


Doctoral dissertation, University of Erlangen-Nuremberg, 1993.

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

6.1 Tensile test


6.2 Technological bend test The material to be used for the casing pipe, for sleeves and
6.3 Manual peel test fittings and if necessary the welding filler is PE-HD DIN 8075 –
6.4 Tensile creep test with the strength properties in terms of creep behaviour
6.5 Imperviousness test corresponding to the State of the Art (as dealt with in Section 8.3
7 Requirements imposed on welded joints of this Directive). In order to ensure weldability, the parts to be
7.1 Visual examination welded and if necessary the welding filler materials used must
7.2 Mechanical-technological tests in the short-term test correspond to the melt index groups 005 and/or 0101) to DIN
16776 Part 1.
7.3 Tensile creep test
7.4 Imperviousness test
8 Quality Assurance 4 Design versions of welded joints on PE-HD casing pipes
8.1 Quality Assurance for casing pipes and fittings in the Manu-
facturer's Works Forms of application of welded joints are found as tube/sleeve
8.2 Proofs of Quality for casing pipes and fittings joints and in the manufacture of fittings. The tube/sleeve joints
8.3 Quality Assurance of the welding work are welded on site, welds on fittings are produced both on site
9 Standards, Directives and also in the works.
9.1 Standards
9.2 Directives 4.1 Tube/Sleeve joints
Annex 1 Report Form (Proposal) for electrofusion methods
Annex 2 Report Form (Proposal) for heated plate welding 4.1.1 Heated plate welding (HS)
Annex 3 Report Form (Proposal) for extrusion welding
Heated plate welding2) is used in the works for producing fittings.
Annex 4 Report Form (Proposal) for imperviousness test
For reasons of design this method is not customary for tube/
Annex 5 Test content and implementing internal and external
sleeve joints.
monitoring
Annex 6 Determination of the time factor and a fictitious joining
4.1.2 Extrusion welding (WE)
factor for a welded joint
Annex 7 Stressing of KMR welded sleeves In extrusion welding the two weld shapes V-weld and fillet weld
are produced. Extrusion welding is customary both for the
manufacture of fittings in the works and for tube/sleeve joints.
1 Scope
4.1.2.1 Butt weld with V-weld, Fig. 1.
The Directive applies to all PE-HD welds on components of
plastic casing pipe systems. These include in particular the joints The sleeve tube, which has the same outside diameter as the
of the PE casing pipes and elbows, T-pieces, reducers and casing pipe, is placed slotted in the longitudinal direction over the
special parts with sleeves. The guideline is applicable both to casing pipe. The sleeve tube is fitted with saw cuts on both sides
welds made in the works and for welds which are carried out on and the butt bevel preparation made. Then the circular seams
site. are welded and finally the longitudinal seam. The welding of the
circular seams is done by extrusion welding with a trolley which is
rotated around the tube on a special strap. Particular care must
2 General requirements imposed on welded joints be taken when making the butt region between the circular
seams and the longitudinal seam. Suitable welding shoe shapes
The following general requirements are imposed on the welded for V- welds, matched to the seam shape, must be used (see Fig.
joint: 1).

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.

DVS, Technischer Ausschuß, Arbeitsgruppe "Fügen von Kunststoffen"


in common with Arbeitsgruppe "Schweißen von PE-Mantelrohren" der Arbeitsgemeinschaft Fernwärme – AGFW – e.V.
bei der Vereinigung deutscher Elektrizitätswerke

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

“X” In the application electrofusion is used with integrated heating

R&D INTAKE MANIFOLDS conductors.

4.1.3.1 Sleeve tube/Plate with built-in heating conductors for longi-


tudinal and circumferential welds, Fig. 3
With this method the sleeve tube is made in the works from a
sleeve tube/plate provided with heating conductors. For the
longitudinal seam a supporting element is incorporated. Then the
tube or the plate is placed around the prepared ends of the
casing pipes and secured with external clamping rings. At the
same time the clamping rings serve to apply the compressive
Figure 1. Basic design of a fitted sleeve with V-welds. forces during electrical heating, which are necessary for the
welding. Lap welds are used for the circumferential and
longitudinal seams.
Detail “X” Fillet welds, extrusion
welding with filler 4.1.3.2 Sleeve band with built-in heating conductors for longitudinal
and circumferential seams, Fig. 4
A longitudinally slit sleeve tube is fitted between the ends of the
casing pipes with the same diameter. Over the joint grooves in
the circular butt joint region and on the longitudinal butt joint a
Profile ring “X” band provided with heating conductors is placed and fitted to an
external clamping device during the heating.

Detail “X” Band with heating conductor

Spacer/pressure support

Figure 2. Basic design of a slip-on sleeve with fillet weld. “X”


4.1.2.2 Lapp joint with fillet weld, Fig. 2.
In this case the sleeve tube is not divided. There is no
longitudinal seam. The circular seams are executed as fillet
welds as described under 4.1.2.1. For fixing and centering the
sleeve and for forming a reliable root a profile ring rounded
towards the seam (for example of plywood or plastic) is inserted.
For seam shape see DVS 2209, Fig. 10, or Fig. 5b). Care must
be taken to ensure adequate overlap of the ends of the casing
pipes (make markings).
The execution of the extrusion welding takes place as described
under 4.1.2.1. A welding shoe for this fillet weld design shaped in Figure 4. Basic design of a welding sleeve with sleeve band.

Detail “X” Sleeve tube/plate

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

R&D INTAKE MANIFOLDS


is that the surface areas of casing pipe and sleeve must be conditions, such as moisture, wind and dust, strong solar
prepared and the heating conductor band only applied and fixed radiation and temperatures below + 5°C. The formation of frost
in the sleeve joint on site. Furthermore, the diameter difference and moisture film must be prevented.If welding work has to be
existing between the casing pipe and the sleeve must be formed carried out under unfavourable conditions, suitable protective
by hot forming before the welding process. Sleeve and butt joint measures must be taken in good time, such as for example
shape as in Fig. 3, but without longitudinal seam. covering, preheating of the pipe joints and sleeve parts,
erection of a protective tent, if necessary with heating.
4.1.4 Indirect heated tool welding
– An even temperature must be maintained in all parts to be
In this welding process the heat energy necessary for the welding welded and also around the tube circumference (∆T < 20 °C).
is supplied through the tube joint to the welding plane by
conduction from a heating band placed on the outside of the – The welding areas must be cleaned (in the case of traces of oil
sleeve joint and used as a ring clamping element. As a result the and grease with suitable solvents, for example industrially pure
diameter distance existing between the casing pipe and the spirit), and the surface oxidized by the oxygen of the air must
sleeve tube is overcome during the welding process by shaping be removed, for example by planing, scraping, milling. If wire
the sleeve on to the casing pipe when the material is in the brushes or emery cloth are used care must be taken to ensure
thermoplastic state. that even removal of the surface layer around the
circumference is achieved, no dirt particles are "rubbed in" and
4.2 Welds on fittings abraded residues are thoroughly removed (blowing, brushing
Basically the various designs of bends and T-pieces used are clean etc.). The tools used must be kept clean and free of
mainly manufactured or prepared in the works. Making fittings on grease and must be checked and if necessary cleaned before
site is to be avoided, because the conditions are less favourable. use.
– Sleeve parts with incorporated heating conductors must be
4.2.1 Bends
supplied to the welding site in their packing and before welding
4.2.1.1 Finished bends the surfaces to be welded must be cleaned, for example with
industrially pure spirit.
The PE casing pipe of the bend is manufactured from tube
segments in the manufacturer's works by heated plate welding. – The cleaning and machining of the welding planes or welding
surfaces must take place immediately before the welding. The
4.2.1.2 Assembly bends machined surfaces must be protected against further
In order to equip bends on site with the PE-casing outside the contamination and may not be picked up again. Otherwise
prefabricated angle range also, prefabricated assembly bends repeated machining is necessary.
are used. For this the PE segment bends are longitudinally split – Adequate working space must be made around the welding
on the site, so that the part can be placed around the steel piping. site, so that the particular welding process can be carried out
The longitudinal cut is welded in the site trench. For this purpose reliably.
extrusion welding should be used.
– The tube joints, fittings, sleeve parts, etc., must be supported,
4.2.2 T-pieces aligned and fixed securely in the intended position.
Branches for connecting lines from the main piping are called T- – The welding work must be carried out and monitored by
pieces. The diameter ratios D1 to D2 are usually different. qualified welders (see Section 8.3). It is recommended that
meaningful work reports be prepared concerning the welded
Both T-piece designs with "outward necking" and heated plate
joints (for report form suggestions see Annex) and the joints
butt welding and designs which are produced by extrusion
permanently marked.
welding are usual. Similarly, combined applications of these
welding processes are customary. In special cases the work also – The welded joints may only be subjected to load after cooling
takes place on site, as described under 4.2.1.2 to ambient temperature.
4.2.3 Valves The preparations and conditions specific to each welding process
and the execution of the welding processes are described below.
PE casing pipe constructions of the most varied kind are
necessary for valves to be used in the soil, such as ball valves, 5.1 Heated plate welding (HS)
slide valves, butterfly valves or compensators. These
components are made in the works. The welding methods used This welding method is used in the case of PE casing pipe
for installing them are heated plate butt welding and extrusion exclusively for manufacturing tube bends and other prefabricated
welding. fittings in the works. The preparation and execution of the
method and the requirements imposed on the welding machines
4.2.4 Special fittings used are governed by the stipulations in the Directives DVS 2207
For the PE casing pipe constructions of anchor points, reducers, Part 2 and DVS 2208 Part 1.
end caps and other parts, as far as possible components
prefabricated in the works by extrusion welding or heated plate 5.2 Hot gas extrusion welding (WE)
welding should be used. Of the process variants described in Directive DVS 2209,
Variants II and V are mostly used in modified, partially
mechanized versions.
5 Carrying out the welding process
With process variant II, using a hand instrument, longitudinal
In the PE casing pipe field of applications joints must be made seams on fitted sleeves are welded. Also in the case of repair
both by producing fittings in the works and also in the course of work, if sleeves tubes have to be installed later, i.e. they must be
the pipelaying work under site conditions – usually in trenches. In previously split longitudinally for fitting and welded in the
order to achieve high quality welded joints, in addition to the installation position by butt welding with a V-seam. Furthermore,
special preparations necessary for the individual working these manual process variants are used for auxiliary welds in
methods the following conditions must be created, independently regions near to fittings and the like which cannot or can only with
of the method: difficulty be reached by machines.

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

R&D INTAKE MANIFOLDS


equipped with a suitably matched angular welding shoe – and is – Ejected accumulations must be removed down to "healthy"
carried in a manually operated trolley running on rollers in an weld (notch-free rounded shaving).
orbital frame around the tube circumference. To ensure reliable
guidance and better matching of the equipment speed of
advance to the other welding conditions, steplessly controllable
motor drives must be provided. The welding filler is fed in in wire
form, for example 4 mm diameter, from the supply unit Welding shoe
(encapsulated roll stands, if possible with preheating and drying
system). Melt channel

The heating of the welding zone is done by hot air. Adequate


plastication of the PE material beyond the side wall edges and in
the weld root region requires optimum adjustment of the hot air
nozzle to the joint to be welded (V or fillet welds, curvature of the
weld paths, joint width). The parameters, such as air volume/
temperature and welding speed, must be matched to the filler-
ejection power of the equipment.
The equipment Variant V in the version for casing pipe welding
differs only in the machine side plastication for the welding filler. a) Welding shoe for V-seam: joint opening approx. 60o
This works on the piston principle, in which the filler wire (smaller wall thickness to 80o (greater wall thickness)).
introduced – driven in the infeed region – acts as a consumable
piston to bring about the ejection of the plasticized filler in the x = 0, i. e. without gap, if welding is done without backing.
heated cylinder. All other conditions and functions are as x = 1 – 2 mm, if welding is done with backing.
described above.
In both process variants the plasticized welding filler is brought
Melt channel Welding shoe
into the joint groove by extrusion through the shaping "welding
shoe". In order to achieve adequate welding, i.e. adequate melt
pressure in the welding filler in the critical areas of the seam (root
and upper runoff edge), the welding shoe must have a front
"shoe tip" matched to the joint and adequate overlap length (Fig.
5). For the usual weld thickness in the range of applications up to
approximately 10 mm tube wall thickness an overlap/holding
length of 40mm after the runner is necessary.
The shoe shapes must be matched to the joint shapes depending
on the type of weld (overlapping butt-fillet weld) and the
curvatures to the necessary degree. The lateral sealing surfaces
together with the front "shoe tip" form the clamping for the
welding filler introduced by the extrusion and thus the condition
for the necessary pressure build-up in the weld material. These
Profile ring
sealing surfaces should be approximately 5 mm wide. All
transitions and edges must be carefully rounded, so that during
b) Welding shoe for overlapping butt fillet weld:
welding no plasticized compound is "shaved off" the joint side
The upper edge must also be bevelled with a negative angle
walls causing defects. For extrusion welding see DVS Directive
of up to 15o.
2207 Part 4.
The edges must always be rounded!
For the carrying out of the welding the following are necessary:
– A visible positioning and fixing of the parts to be welded
(casing pipe and tubular sleeve) in the intended butt weld Feed direction
shape; if necessary short tack welds in the weld root.
– Precise centering and adjustment of the orbital frame over the
course of the joint groove; therefore the machining of the joint
surfaces with tool systems must take place in the same frame Welding shoe
setting as the welding.
Melt channel
– Control and tracking systems for continuous adjustment of the
welding unit (direction and position of the welding shoe) and Tip of welding shoe
the hot air nozzle position (central in the median line of the joint
opening).
– Stepless speed adjustment of the welding carriage and control
by intensive observation of the welding point and/or the melt
delivery.
Butt weld side wall of a
– Monitoring of adequate joint heating directly in front of the V-seam in the tube joint
welding unit by penetration tests with blunt tools (thin
screwdriver). c) Welding shoe for V-seam in the middle of the seam
(lingitudinal cut)
– Correct execution of the end regions to be overlapped in the
case of circumferential welds and longitudinal welds. The Figure 5. Schematic drawings for executing weld sheos for extrusion
groove must be adequately bevelled (in the case of welding for V-seams and overlapping butt fillet welds.

372
Page 5 to DVS 2207-5

5.3 Electrofusion *) (HM) - Starting up and monitoring the welding process.


The process variants used in practice are based on sleeves or – Removing the welding pressure only after the welding zone
sleeve plates with heating conductors with 3-sided conductor has cooled down sufficiently to approximately + 90 °C; indicati-
arrangement incorporated in the works (additionally for the ons of the time for this must be taken from the process instruc-

R&D INTAKE MANIFOLDS


longitudinal seam), or use for the particular size inlaid heating
grids prepared in the works, which are mounted and fixed in the
lap joint on the casing pipe.
tions of the manufacturer.
5.3.2 Slip-on sleeve with inlaid heating grid
(cf. also Section 4.1.3.3)
The requirements imposed on the welder in all process variants
essentially relate to careful execution under site conditions. As far as the equipment is concerned, basically for this process
These are in particular: variant the same principles as described under 5.3.1 apply. In the
execution basically the following process-specific jobs must also
– The preparation of the casing pipe joints, be carried out:
– The correct assembly and fixing of the welding sleeves – Determining and marking the welding regions in the joint.
including the clamping and holding systems and – Cleaning and machining both surfaces in the welding regions
– The making of the electrical connections to the welding (casing pipe and tubular sleeve).
equipment. – Adapting the heating grid strip to the tube circumference by ap-
With modern equipment the welding process itself is propriate stretching, positioning of the strip and fixing accor-
automatically controlled on the basis of previous automated ding to the manufacturer's instructions; take note of the alloca-
actual value sensing of the critical initial values (such as tion marking of the heating grid strips!
resistance as a measure of the sleeve nominal diameter, ambient – Assembling the tubular sleeves in the predetermined position.
and component temperature) and automatically controlled as it
– Adapting the slip-on sleeves to the diameter of the casing pipe
progresses on the basis of power consumption measurements.
by hot forming. The sleeve ends are heated evenly to the for-
After the equipment has been basically set the welder has only a
ming temperature over an adequate width in the region of the
supervisory function during the welding process.
heating strips and clamping elements (approx. + 100 °C).
As far as equipment is concerned, with these methods the (Take care when using naked flame; use "soft" liquefied gas
systems must be equipped with measurement value sensing and flame). The adapting of the diameter is done by fixing the clam-
digital recording systems, so that each sleeve joint can be ping members and applying the pressure without delay. The
documented with conclusive parameter and parameter change latter is used after starting the welding process for applying the
reports. joining force.
The other functions and operations are the same as in the works
5.3.1 Tubular sleeves/sleeve plates with built-in heating conductors
sequence previously described.
(cf. Sections 4.1.3.1 and 4.1.3.2)
In respect of the introduction of energy into the joint is concerned, 5.4 Indirect heated tool sleeve welding (–)
the prescribed welding parameters must be matched in particular (cf. Section 4.1.4)
to the wall thicknesses, the semi-finished product and ambient The heat input necessary for the welding of the lap joint on the
temperaures and the material melting characteristics. The sleeve connection takes place indirectly by heat conduction
process must then be controlled with the pressure generating unit through the wall of the sleeve to the welding plane. The metal
for the welding pressure in system coupling. The welder on the heating strip applied to the outside of the sleeve joint is also used
site cannot control the welding process, because with this weld through a hydraulic clamping system as an orbital clamping
shape in the lap joint and with the superstructure formed by the element for applying the joining force for the welding.
pressure generating devices he cannot look into the welding
plane and therefore any controlling influence over the welding According to the system the temperature profile across the
process is out of the question. sleeve wall on the outside of the sleeve has a higher temperature
than the welding point on the inside; the profile of the melt
For reproducible reliable production of high quality welded joints viscosity runs in the same way. Because the clamping ring
according to these process variants welding units with preset presses the sleeve joint over the entire plasticized sleeve wall the
parameters and process controls optimized for the particular heating strip is pressed into the tube wall, i. e. a "notch" is
application are necessary. For the quality of the welded joints the produced by wall thickness reduction in the welding region.
welding and supervisory personnel must correctly and carefully
create the external preconditions on the basis of the stipulations During the welding process at the same time the annular gap
of the process instructions. These are in particular the following existing between the casing pipe and the sleeve tube is closed by
steps: the clamping of the heating strip ring which causes thermoelastic/
plastic material deformation. The external step formation under
– Dimensionally correct marking of the sleeve position and/or the the heating strip position and the wall thickness reduction of the
welding regions. sleeve in the weld region are forced to increase with the size of
– Trimming of the tube joints and fitting supporting sections for the sleeve annular gap. For this reason the use of this process
the longitudinal welds. variant is limited to small casing pipe diameters (at the moment
up to maximum 400 mm).
– Machining of the tube surfaces in the weld regions, taking care
to avoid recontamination when the sleeve is subsequently as- To what extent this "notch formation" which weakens the weld
sembled (clean slip-on sleeves and casing pipes inside and start region is acceptable from a strength point of view must be
outside beforehand). demonstrated for the particular application.
The energy supply of the welding equipment must be
– Positioning and fixing of the tubular sleeves or sleeve plates -
programmed to the tube size and to the semi-finished product
in the predetermined position with rigid straps.
and ambient temperatures. As far as the application of pressure
– Setting up the pressure generating devices and clamps. is concerned, the annular clamping system must be
synchronized with the heating process. The corresponding
– Making the electrical connections, and the pressure connec-
information must be taken from the process instructions of the
tions and control connections, followed by examination to
system manufacturer.
avoid confusion, and function monitoring of the welding ma-
chine. The weld preparation and the other operations are subject to the

*) DIN 1910 Part 3: “Sleeve welding with incorporated electric heating element”

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Joining weld Joining weld

R&D INTAKE MANIFOLDS


Specimen Shape 1
(Strip specimen) Specimen Shape 2
(Shoulder specimen)

Figure 6. Specimen shapes for the tensile tests.

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.

5.5 Hot gas welding (W)


The force at the moment the specimen tears must be recorded. If
the specimen should neck, this yield stress is the reference
The method is described in Directive DVS 2207 Part 3. With the stress (FB). Tests during which the specimens tear in the
method of hot gas welding with filler, for example hot gas string- clamping region should be disregarded and must be repeated.
bead welding with welding wire – generally lower long-term weld
strengths are achieved than with the welding methods described 6.1.2 Evaluation
above. This is all the more so, if the welding work has to be
carried out under difficult conditions; on sites and mostly in For the welded specimens FV and the unwelded specimens
trenches in the case of circumferential welds. (reference specimens) FB the short term joining factor fz = FV/FB
is determined from the mean values of the tearing force, in the
For these reasons hot gas welding should not be used on lines case of different specimen dimensions, from the stresses
with PE-casing pipes. referred to the specimen cross-section.
If because of local circumstances this method cannot be avoided
in exceptional cases, particular care must be taken during 6.2 Technological bending test
execution. The requirements of DVS 2203 Part 1 must be For assessing the execution of the weld the technological
fulfilled. bending test in combination with other tests can be used. The
bending angle and the fracture photomicrograph give an
indication of the deformability of the joint and thus of the quality of
6 Testing the welded joints the execution.
For the testing of welded joints the test methods described in the The bending test is carried out on the basis of the Directive DVS
following can be used, taking into account the requirements 2203 Part 5 and/or DIN 50 121. The bead is machined away in
imposed and/or the conclusions required. the region where the bending punch is applied. The edges on the
tensile stressed side must be broken. Six welded specimens are
The results of the short term tests however can only be tested. The tensile stress is applied both to the root and to the
transferred to the long term behaviour of the welded fabrication to overlay of the welded joint (3 specimens each).
a limited extent. Specific demonstrations of the long term
behaviour are only possible by means of long term tests. Information about the shape and the dimensions of the
specimens and the test arrangements is contained in Table 2.
Generally the specimens must be manufactured by sawing,
milling or water jet cutting (not stamping).
Table 2. Dimensions for the test arrangement for the technological
6.1 Tensile test bending test (from DVS 2203 Part 5).

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°.

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Fig. 8 until fracture or until the free ends of the specimen come
into contact with the bar.

R&D INTAKE MANIFOLDS a)

b)

Figure 8. Diagrammatic representation of the manual test.


“X”
6.3 Manual peel test
The manual peel test is a simple, indicative workshop test carried
out by hand, which can also be carried out on site. This test is
intended in particular for lap welded joints, for example
c) electrofusion-welds, which cannot be directly tested using the
technological bending test as per Section 6.2.

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

Figure 7. Diagrammatic representation of the mechanical test and the


planes of action in the technological bending test (examples):
a) V-weld, root as tension side a) Plastic jacket pipe b)
b) V-weld, rear of weld under tension; during the test at a
bending angle of approximately 90o,
Figure 9. Illustration of the specimens for the manual peel test;
c) and d) die arrangement for the lap welded joint with fillet
a) strip specimen before the test
weld (WE). 3 specimens each with the weld root (c) and
b) joint ends bent upwards for the peel test.
the joint side wall edges (d) under tension.

6.2.2 Evaluation 6.3.2 Evaluation

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
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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

R&D INTAKE MANIFOLDS


6.4.1 Execution tensile creep joining factor – referred to a particular stress on the
The tensile creep test is carried out in accordance with DVS 2203 reference curve B – is calculated from the curve obtained for the
Part 4 or DIN 53 444 (Fig.10). The welded joints are tested in welded specimen: see examples in Fig.11.
accordance with the actual execution. Alternatively, the ong-term joining factor can be referred to one
test stress on the reference specimen. The joining factor
determined must then be identified, with indication of this test
dial gauge stress (for example σ4(B)), see Fig.12.
Simplified method for minimum proof of a required long-term
joining factor
To reduce the complexity of the test the proof can be limited to
one stress level in each case using the following method, see
Fig.13.
For example:
– Test stress for the basic material (reference specimens)
σB = 4 N/mm2
specimen – Test stress for the weld specimens with for example fs = 0.8
σS = fs ∙ σB = 0.8 ∙ 4 N/mm2 = 3.2 N/mm2.
test medium
If the weld specimens reach at least the same mean time-to-
tank test weight failure as the base material, at least the required long-term
joining factor is demonstrated (yes/no statement).
With this test no conclusion about the stress-related strength
behaviour is possible.

6.5 Imperviousness test


Figure 10. Test set-up for the tensile creep test (on the basis of DVS Normally a positive pressure test with compressed air at approx
2203 Part 4). 0.2 to 0.3 bar is carried out. After a test duration of at least 10
minutes after coating the welds with a harmless foaming aqueous
For the shapes and dimensions of the specimens the specimen solution (for example a modern biologically degradable
shapes (Fig.6) indicated in Section 6.1 "Tensile Test" with Table household detergent in the lowest concentration) no leaks must
1 are applicable. For this test the use of the same specimens is be visible (bubble formation).
recommended. The joint position lies in the middle of the
specimen, the longitudinal axis of which must lie in the direction
of the tensile force. 7 Requirements imposed on welded joints
The specimen must be made without notches and if necessary
The welded joints on PE-HD casing pipes and fittings must – just
retouched after visual examination (for example grinding in the
like the tubes – reliably withstand the stresses occurring in
longitudinal direction). In the tensile creep test the duration until
operation over the design duration of stress.
fracture of the specimen and, if necessary, the increase in
elongation with time are determined. As a rule welded joints on PE-tubes do not achieve the same
material strength as the unwelded casing pipe. The piping
The specimens are stressed at constant temperature (± 1°C) with planning and design must indicate the weld qualities achievable
uniformly steady tensile force (± 1%) and constant ambient with the welding methods used. The required weld qualities must
conditions. be guaranteed by suitable measures and test methods.
In order to ensure even concentration of the wetting agent, it Therefore corresponding requirements must be imposed on the
must be circulated continuously in the test bath. The bath welded joints.
concentration of the test medium must be monitored by control In the Directive DVS 2203 Part 1 requirements imposed on
measurements – in its spatial distribution also – (for example by plastic welded joints are described for certain moulding
residue determination by evaporation). Evaporated water must compounds and welding methods, as are applied mainly in tank,
be topped up by adding demineralized water (deionate) vessel and piping construction. In these fields of application the
continuously (level control). plane butt joint without transition is used and welded.
After reaching the bath temperature the specimens are In the case of lines with PE-casing pipes the multiple lap joint is
vigourously stressed with the test force but without impact in the also often used in special process variants, however from a test
test bath, the force being maintained constant during the test. point of view and also in respect of the requirements imposed it
The duration of loading is calculated from the moment the test cannot be immediately treated and assessed. Otherwise the
force is reached and recorded by built-in dial gauges. requirements of the Directive quoted apply.
In order to determine the gradient of the creep curve (straight
7.1 Visual test
lines in double logarithmic form), the tests are carried out under
at least 2 stresses (for example 4 and 3 N/mm2). At least 6 In the visual test the defect-free execution of the welded joint
welded and 6 unwelded specimens are tested for each stress. must be demonstrated by visual examination. In combination with
The mean value is calculated as the geometric mean of the destructive tests the weld cross-section and fracture surfaces
individual values. must also be assessed. Typical test features are:

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.

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– 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

R&D INTAKE MANIFOLDS


Defect descriptions and evaluation references are also given in
– shape and uniformity of the weld formation DIN 32 502 and DVS 2202 Part 1.
Stress (N/mm2)

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)

S = weld specimen; σ4 and σ3


B = reference specimen; σ4

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).

Welding method Tensile creep


joining factor fs
Heated plate welding 0.8
V-weld extrusion welding 0.6
Extrusion welding on the lap joint with fillet
weld 0.5*)
Electrofusion in the lap joint 0.5*)
Bending angle

*) At present values from approximately fs = 0.4 are accepted. This low


value is permitted in order to take into account the falsification of the
tensile test due to the superimposed bending stresses, increased
inherent stresses and notch effects, etc.

7.3 Tensile creep test

In the tests as per Section 6.4, for correctly executed joints on


casing pipes at least the long-term joining factors "fs" required in
Table 4 must be demonstrated.
For the tubular semi-finished products (casing pipe and tubular
sleeves), under the same test conditions as in Section 6.4 for the
test stress 4.0 N/mm2, a minimum time-to-failure of 1500 hours is
required for the geometric mean value from at least 6 individual
specimen results, see Draft Standard DIN EN 253.
Specimen thickness
This single-point requirement in the creep diagram (+ 80 °C)
HS = Heated plate welding applies subject to the condition that the tube moulding material
LE = Light beam welding by extrusion of filler material basically satisfies at least the creep requirements in the internal
WE = Hot gas welding by extrusion of filler material pressure test according to the creep diagram used as the basis
WF = Hot gas welding with torch separate from filler rod
WZ = Hot gas string-bead welding for DIN 8075.

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.

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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

R&D INTAKE MANIFOLDS


destructive long term tests, the quality assurance must be based method. For the methods WZ and HS DVS 2212 Part 1 and Part
on indices, identity and reproducibility proofs. 2 apply to extrusion welding.
Therefore, for the quality assurance of welding work in the case The execution of the welding work in the manufacturer's works
of joints in PE-HD casing pipe and fittings, in addition to the use (prefabrication of fittings) and – in particular – on the site under
of moulding compounds and tube products with fixed indications difficult conditions in pipe trenches, must be supervised by a
of product qualities, qualification requirements must be imposed qualified responsible welding inspector of the manufacturer's
on the skilled welding personnel and minimum requirements on works.
the equipment and workplace arrangements of the contracting The welding inspector must supervise in particular
companies.
– The use of suitable welding equipment and accessories in a
8.1 Quality assurance for casing pipes and fittings in the functionally reliable condition,
manufacturer's works – The correct arrangement and preparation of the joints
The measures for quality assurance in the manufacturer's works – The qualified execution of the welding processes in accor-
are normally divided into two. According to DIN 18 200, a dance with the particular prescribed methods (Manufacturer's
distinction is made between internal and outside supervision: instructions, DVS Directives, etc.) if necessary using suitable
– Internal supervision protective measures (protection against weather, etc),
Tests by professionals of the manufacturer's works based on – Adequate recording of the welds (for suggested report forms
established test and work instructions. see Annex) with welder identification and documentation of the
– Outside supervision joints in accordance with what is stated in the manufacturer's
These are used to permit the regular checking of the equip- specifications and DVS Directives relating to the method.
ment and operations of the internal works inspectors, their do- Finally, he carries out
cumentation and test procedures by outside supervisors. For
the application described here, as a rule the outside supervi- – The visual examination of the finished welded joints for defect-
sion is carried out and administered by suitable independent free execution and
plastics test centres and experts as per DIN 18 200. As a rule – The imperviousness test
outside supervision dates are observed and certified twice per
and prepares a test report on these.
year. The results of the supervision inspections must be docu-
mented and the test reports of the outside inspector included in The welding inspector is responsible to and reports to the
the manufacturer's documentation. Employer/the Site Management.
For the execution of the welding work done by the Employer,
8.2 Proof of quality for casing pipes and fittings
outside supervision is recommended on a random basis.
For the casing pipes and fittings used tests must be carried out in
accordance with the basic standards, moulding compound and
moulding guidelines already in existence for the products or 9 Standards, Directives
according to a product-specific test and supervision program.
The test results obtained must be specified and documented, 9.1 Standards
contrasted with the established requirements. DIN EN 253 Preinsulated bonded pipe systems for underground
The content of the test must be based on: (Draft) hot water networks – Pipe assembly of steel
service pipes, polyurethane thermal insulation and
– DIN EN 253, 448, 488 and 489 for PE-HD casing pipe materi- outer casing of high density polyethylene.
als DIN EN 448 Preinsulated bonded pipe systems for underground
– DIN 8074/75 applied rationally, in particular in respect of the (Draft) hot water networks – Fitting assemblies of steel
long-term tests. In the case of the larger tube diameters with service pipes, polyurethane thermal insulation and
smaller wall thicknesses tensile creep tests are preferable to outer casing of high density polyethylene.
the otherwise customary long-term internal pressure tests in DIN EN 488 Preinsulated bonded pipe systems for underground
this respect. For the minimum time-to-time failure rates the (Draft) hot water networks – Steel valve assembly of steel
requirements under Section 7.3 apply. service pipes, polyurethane thermal insulation and
The proofs of quality must be produced by the manufacturing outer casing of high density polyethylene.
works at least in the form of "Works Certificates" as per 2.2, DIN DIN EN 489 Preinsulated bonded pipe systems for underground
50049. For the content of the tests and the application of internal (Draft) hot water networks – Joint assembly steel service
or outside supervision, see Annex 5. pipes, polyurethane thermal insulation and outer
casing of high density polyethylene.
8.3 Quality assurance of the welding work DIN 1910 Welding, Welding of plastics, methods
Process tests must be demonstrated by the contracting Part 3
companies and skilled workers for the welding method applied DIN 8074 Tubes of high density polyethylene (PE-HD),
(proof by the manufacturing company that it is in a position, with dimensions
its skilled personnel and the physical equipment of the company,
to execute the welding work correctly and reproducibly in DIN 8075 Tubes of high density polyethylene (PE-HD),
accordance with the high requirements imposed. general quality requirements, testing

5) Training centres for PE welders:


– Süddeutsches Kunststoff-Zentrum, Frankfurter Straße 15-17, D-97082 Würzburg
– Training centres under supervision of the Institut für Kunststoffverarbeitung at Aachen
University of Technology, Pontstraße 49, D-52056 Aachen
6) Examination centres:
- the Training Centres mentioned under 5) and
- the TÜV Plastic Test Centres; for information: Association of the Technical Supervision Societies, Kurfürstenstrasse 56, D-45038 Essen.

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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

Order No.: Welder:

BV/Section: Welding machine No.:

Section No.: of: Power source: … Mains … Generator

Sleeve No. Type Section Date Ambient Weather Weather Displays Sleeve Remarks
temperature protection
(°C)
A B C

Tent

Sunny
Wind
Time
Temperature

Sleeve initial temperature (oC)

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.

R&D INTAKE MANIFOLDS


Page 13 to DVS 2207-5

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

Make: 1 = sunny 1 = none


Page 14 to DVS 2207-5

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.

R&D INTAKE MANIFOLDS

Example: (10,5+10,7) (10,5+0,7) (10,5+10,7)


1 25.5.92 160Ø14,6 10,5 220 ± 5 21,2/ 11,2/ 21,2/ 130/ <10/8 ≈ 10/12 >20/20 ≈ 20 24 2 None

Signature of welder: Date and signature of the welding inspector:

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

Annex 3: Report form (proposal) for extrusion welding

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

Order No.: Drawing No.:

Contracting Company:

Welder (Name, Reference):

Process/Equipment

Process variants: Welding shoe No.:

Welding equipment (make):

Weld shape (e. g. DVS 2205):

Material

Material to be welded:

Semi-finished product shape, thickness (mm):

Welding filler:

Welding Conditions

Hot air temperature (°C): Air volume (l/min):

Cylinder heating (°C): Compound temperature (°C):

Hose heating: Welding speed (mm/min):

Remarks:

Date/signature Date/signature
Welder Welding supervisor

383
Page 16 to DVS 2207-5

Annex 4: Report form (proposal) for imperviousness test

This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS


Imperviousness Test
Acceptance Order No.

Project:

Building section/line section No.:

Sleeve No. Positive pressure Welder Tested and accepted Date


VL RL 0.2 bar Name Signature

Remarks:

384
Page 17 to DVS 2207-5

Annex 5: Content of test and organization of internal and outside supervision


This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS


This Annex to the Directive contains the content of the test for the
Quality Assurance of PE casing pipe and tubular sleeves and
corresponding sleeve plates, Table A5-1. The content of the test
– DIN 8075 (05/87)
– DIN 16 963 Part 5 (10/89)
for the Quality Assurance of welded joints in fittings and sleeve – GKR Guideline R 9.3.17 (05/92)
joints (welding in the works and on site) is also specified; Table
A5-2. It isbased on the requirements of the official product In Tables A5-1 and A5-2 recommendations for a Quality
standards and guidelines: Assurance Certificate are given. In the list of obligations of the
– DIN EN 253 (4th draft revision; issued on 1.11.1991 in the TC contractual partners special stipulations can be imposed
107) concerning the tests to be carried out, the scope and frequency.
– DIN EN 448 (pr EN; issued on 1.11.1991 in the TC 107)

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.

Serial Application Tests Execution as per Requirements as per/ Test/frequency


Item standard, Section values
No. in:
DIN EN DVS Type of tests On On suitability internal outside
253 2207-5 FM HZ test supervision supervision
Page 18 to DVS 2207-5

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.

Serial Application Tests Execution as per Requirements as per/ Test/frequency


Item standard, Section values
No. in:
DIN EN DVS Type of tests On On suitability internal outside
253 2207-5 FM HZ test supervision supervision
2 Condition and dimensions
2.1 5.2.3 – Surface condition × DIN 8075 DIN 8075
DIN EN 253 DIN EN 253, Section 4.2.2.4
GKR-Guideline R 9.3.17 GKR-Guideline R 9.3.17
Unacceptable features Continuous
inspection during
2.2 5.2.2 – Dimensional stability × DIN EN 253 DIN EN 253, Section 4.2.2.3 production
GKR-Guideline R 9.3.17 Execution of the In general twice
tests described per year1)
see permissible limits of
deviation
2.3 5.2.4 – Hot storage × DIN EN 253 DIN EN 253, Section 4.2.2.6 Once per week
GKR-Guideline R 9.3.17 GKR-Guideline R 9.3.17
Deformation ≤ 3%
3 Mechanical tests
3.1 4.2.2.5 – Elongation at tear in the × DVS 2203-2 DIN EN 253, Section 4.2.2.5 Once per week Generally twice
tensile test ISO/DIS 6259, Section 1.2 GKR Guideline R 9.3.17 per year1)
DIN 53 455
≤ 350%
Test speed = 100 mm/min
3.2 5.2.5 – Long-term internal ×3) (×) DIN 8075 DIN EN 253, Section 4.2.1.4 Once per week, Generally twice
pressure test ISO 1167 if stipulated in per year, if
Execution of the
detail stipulated in
tests described
detail1)
3.3 5.2.6 6.4 Tensile creep test in the × × DVS 2203-4 DIN EN 253, Section 4.2.2.7 Four times per Generally twice
wetting agent bath (ISO/DIS 6259 Section GKR-Guideline R 9.3.17 year per year1)
1.2)
> 1500 h in the water bath with
2% wetting agent at 80°C;
= 4.0 N/mm2

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

HZ = result on the semi-finished product. FM = result on the moulding compound (pellets)


3) As type test on the extruded specimen tube and as alternative to the tensile creep test in product supervision.
x Execution of the test described.
(X) Execution, if stipulated in detail
a Per machine, dimension, type of compound, or per per production run
b At least per type of compound, machine and group diameter once per year.
Page 19 to DVS 2207-5

387
388
Table A5-2. Monitoring tests on welded joints (works and site welds)

Consecutive Application standard, Type of tests Execution as per Requirements Test/frequency


item No. Section in: as per
Process Workshop welds Site welds
DIN EN DVS 2207-5 tests welding outside welding outside
253 (448) supervisor supervision supervisor supervision
Page 20 to DVS 2207-5

1 – 7.1 Visual examination Visual inspection DVS 2207-5, 100% 100%


Section 7.1
2 – 6.1 Short-term tensile test DVS 2203-2 DVS 2207-5,
DN 53 455 Section 7.2 As part of the As part of the
3 – 6.2 Technological bending DIN 2203-5 DVS 2207-5, welder and welder and
test DIN 2207-5, Section 6.2.1 Section 7.2 Execution work work
In general In general
of the examinationsb) examinationsb)
4 – 6.3 anual peel test DIN 2207-5, Section 6.3.1 DVS 2207-5, twice per twice per
tests
(alternative to Item 3) Section 6.3.2 year1) year1)
described
5 – 6.4 Tensile creep test in DVS 2203-4 DVS 2207-5, Four times per
wetting agent bath DVS 2207-5, Section 6.4 Section 7.3 yeara)
DIN 53 444
6 – 6.5 Imperviousness test DVS 2207-5, Section 6.5 DVS 2207-5, 10 ... 20% 100%
Section 7.4

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.

R&D INTAKE MANIFOLDS


If creep tests are only carried out under one test stress (for 2. The slope of the curve of the single-axis tensile creep test cor-
example where σ = 4.0 N/mm2), from the results for the base responds in its slope to the curves of the multi-axis long-term
material and the welding specimens only the ratio of the internal pressure tests to DIN 8075; shift of position only on
evaluated times-to-failure (geometrical mean value "XG") can be the time axis.
formed and as the time factor
3. The slope of the curves of welded specimens corresponds to
x G(S) the slope of the base material specimens (parallel trend). Ex-
f s(t) = ------------- perience has shown that this is only applicable to high quality
x G(B)
butt joints!
be specified.
In the example in Fig.A6-1 the fictitious joining factor is
This time factor is not identical with the joint factor (fs) calculated
from the significance ratio of the stresses. =
f′ s ( σ ) =
2,0/4,0 0,5
If nevertheless – in the absence of basic curves for the tube
material from tensile creep tests – a comparison factor is formed The time factor from the results of the tensile creep test works out
by including known long-term internal pressure curves (for at
example the minimum value curves from DIN 8075) for PE-HD
tubes, this is based on the following assumed conditions: =
fs ( t ) =
67/1500 0,045
1. The long-term internal pressure curves of the casing pipes
correspond in their slope to the minimum curves of DIN 8075. This fictitious joining factor cannot be used as a calculation value.
Comparative stress in N/mm2 is the long-term internal pressure test

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

Annex 7: Stressing of welding sleeves in plastic jacket pipes


This Annex is only for information and is not a binding part of this Directive.

R&D INTAKE MANIFOLDS


Like the PE-casing pipes, the welding sleeves are exposed to The calculations have been carried out taking into account the
mechanical loads. The stresses are caused by relaxation with temperature, using values of E (σ = 0.75 N/mm2
and 1 N/mm²).
– friction in the subsoil
The following conclusions should be drawn:
– possible drag of the sleeve and
– With the usual plastic jacket pipes applications axial stresses
– restricted elongation due to temperature. of max 2 N/mm2 are to be expected in the sleeve wall.
Because the level of the mechanical stresses has a critical – In extreme cases stresses of up to 4.5 N/mm2 are also possi-
influence on the working life of the joint, the stresses occurring ble.
are estimated for 3 different cases of loading. The significant
loads are in each case the stresses in the axial direction. – The effect of the drag on the axial stress is small.
Estimates: – sheath friction σR = µ ∙ p -– In the case of the traffic loads, the "parking SLW 60" load re-
presents the most unfavourable stress. Because of the disper-
– drag σSt sion of the load coming from the wheel loads with depth, this
– restricted elongation due load represents the critical load for the sleeve joint when there
– to temperature σT = αT ∆T E is little cover above it. The probability that an SLW 60 will park
over a sleeve is however very remote, because the axle load of
Calculation assumptions: DN 250, Da = 400mm, t = 6 mm an SLW 60 is twice the maximum possible according to the
Case 1: Fitted welding sleeve without drag, Road Traffic Authorization Order.
hü = 60 cm in the expansion buffer, µ = 0.25 – Expansion pads reduce both the sheath friction and the drag
Case 2: Welding sleeve with high drag, loads and increase the stress due to restricted thermal expan-
hü = 60 cm in the sand bed, µ = 0.5 sion. In all, however, the stress-relieving effect predominates.
This occurs in particular with high mechanical stress (for ex-
Case 3: High drag, parking heavy truck with 60 t ample depth of cover or traffic loads).
(called: SLW 60),
This information is at present under discussion in the specialist
hü = 1.5 m in the sand bed, µ = 0.5.
circles. The calculations based on other hypotheses and
The results of the guide calculations should be taken from Table assumptions lead to different results, but are of the same order of
A7-1. magnitude.

Table A7-1. Axial stresses in the sleeve wall.

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

DVS – DEUTSCHER VERBAND Welding of Thermoplastics Directive D


Welding of PE Casing Pipes DVS 2207-5
FÜR SCHWEISSEN UND
Supplement 1 V
VERWANDTE VERFAHREN E.V. – Fittings and Isolating Valves – (July 1997) S 
R&D INTAKE MANIFOLDS
Content: 2 Material and semi-finished products

1 Scope PE-HD in accordance with paragraph 4.2 of DIN EN 253 must be


2 Material and semi-finished products used as a material for fittings to be made by welded joints.
3 Carrying out the welding process
3.1 Preparation and requirements for carrying out the process In order to ensure suitability for welding, the mass flow rate of the
3.1.1 Inspection of the condition of the heating tools and air materials to be welded must satisfy the requirements of DIN
supply EN 253, paragraph 4.2.1.2. This means that the mass flow rate
3.1.2 Operating test of the equipment and machines used (MFR 190/5) of the materials to be welded may not differ by more
3.1.3 Work and workplace than 0.5 g/10 minutes.
3.2 Heated plate welding (HS)
3.2.1 Equipment requirements PE-HD in accordance with DIN 8075 must be used as welding
3.2.2 Preparation of the welded material / joint sub-faces filler under paragraph 7.3 of DVS 2207-5, with state of the art
strength properties in respect of its creep behaviour, depending
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

3.2.3 Welding process


3.3 Hot gas extrusion welding (WE) upon the welding method used.
3.3.1 Equipment requirements Only qualifying tubes with appropriate, informative test
3.3.2 Preparation of the welded material / joint sub-faces certificates under or on the basis of DIN EN 253, or moulding
3.3.3 Welding process materials in accordance with DVS 2207-5, may be used as semi-
3.4 Hot gas string bead welding (WZ) finished products.
4. Testing welded joints
4.1 Non-destructive testing methods – visual inspection
4.2 Destructive testing methods
3 Carrying out the welding process
4.2.1 Tensile test
4.2.2 Technological bend test
4.2.3 Tensile creep test The following welding processes are used for producing PE
4.3 Imperviousness test casing pipe fittings:
5 Requirements on the welded joints In the factory:
5.1 Visual inspection
5.1.1 Indications of good HS welded joints – Heated plate welding (HS) for segmental construction or in
5.1.2 Indications of good WE welded joints conjunction with “outward necked” pipes;
5.1.3 Indications of good WZ welded joints
5.2 Requirements for the tensile test – Continuous and intermittent hot gas extrusion welding (WE)
5.3 Requirements for the technological bend test (DVS 2209-1), possibly with a root pass produced by hot-gas
5.4 Requirements for the tensile creep test string-bead welding (WZ), if necessary.
5.5 Requirements for the imperviousness test
If production on site is necessary, e.g. for modifications, repairs,
6 Quality assurance
etc:
7 Standards and directives
– Hot gas extrusion welding and

1 Scope – Under exceptional circumstances – restricted access, etc –


hot gas string-bead welding.
This Supplement to Directive DVS 2207-5 applies to all PE-HD
In addition to the process stipulations, characteristics and
factory and site casing pipe welded joints on segmental bonded
requirements in Directive DVS 2207-5 for welding PE casing
prefabricated fittings (elbows, T-pieces, adapters and anchor
pipes, predominantly in site production, the following stipulations
points) in accordance with DIN EN 448 and underground
must be observed in the production of fittings.
isolating valves within the scope of plastic casing pipe systems
for district heating networks in accordance with DIN EN 488. Only suitable, calibrated and regularly-maintained machines and
The HS (heated plate) welding method must be used for factory equipment may be used to execute welds. The appropriate
casing pipe joints and the WE (hot gas extrusion) method in working instructions – process and parameter stipulations – must
exceptional and special cases. be available at the workplace: see also DVS 2208-1 and DVS
2209-2.
Site casing pipe joints must be made using the WE method and
the WZ (hot gas string-bead) method in exceptional and special Welds must only be made by qualified welders certificated for the
cases. process under Directive DVS 2212.

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.

A working out of the common DVS-/AGFW-working group “Schweißen von PE-Mantelrohren”

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-

R&D INTAKE MANIFOLDS


lism of the clamped, machined pipe faces
3.1.1 Inspection of the condition of the heating tools and air supply (a) By bending and beaming up the equipment guides and
jigs1)
The proper condition of the heating tools and energy media must (b) Deviations from the plane-parallelism of the machined
be verified at appropriate intervals before and during the work. faces when clamped with minimal contact pressure
– Superficial condition (PTFE coating) of the heated plates; between the ends of the pipes pushed together.

– 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]

3.2 Heated plate welding ≤ 0.4 ≤ 355

3.2.1 Equipment requirements ≤ 0.5 400 ≤ 560

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

R&D INTAKE MANIFOLDS


ends of the weld and other problem areas with the welding Directive DVS 2207-5.
tool, and with the hand plunger in insufficiently accessible ar- Note on table 1 of Directive 2207-5:
eas.
If the dimensions of the test specimen cannot be maintained for
– In the intermittent process, face heating must be undertaken design reasons, smaller dimensions (specimen length) may be
carefully and inspected (penetration tests). The welding filler selected, provided that the remaining specifications are fulfilled.
material must be introduced directly into the welding area and An appropriate conversion of machine speed to the same
pressed in and down with the plunger for a sufficient period. specimen deformation speed must be made (c.f. Fig. 2).
– Remachining the edges of the weld (removing weld flashes),
without damaging the surfaces of the pipe and with minimal External mitre
scraping depths of ≤ 0.1 x s, but ≤ 1 mm.
Abutment plane
Working instructions and process directives must be observed. (upper edge)

3.4 Hot gas string-bead welding


The process is described in Directive DVS 2207-3. In general,
only lower long-term weld strengths are achieved in the hot gas
welding process with the introduction of welding filler, e.g. hot Internal
mitre
gas string-bead welding with a welding rod, than in the process
described above. This is all the more applicable if the welding
has to be carried out under difficult conditions, e.g. on site and in
trenches. Figure 3. Location for sampling from segmented elbows
a) Specimen from the abutment plane for the tensile test
For these reasons, hot gas welding should not be used for PE b) Specimen from the internal and external mitre for the
casing pipes or the production of fittings, or only used under technological bend test.
exceptional circumstances. Should this process nevertheless be
integrated into production, e.g. for root passes or in inaccessible In the case of segmental prefabricated fittings, particularly those
joint face positions, the requirements of DVS 2207-3 must be with a large diameter, one (or, if necessary, two) test specimens
fulfilled. with reasonable leg coils may be taken from the abutment area
and on the diagonal of the weld to the axis of the specimen, c.f.
Fig. 3.
4 Testing welded joints
4.2.2 Technological bend test
The tests described below may be used to test welded joints, The technological bend test is conducted in accordance with
taking account of the existing requirements. A decision on the paragraph 6.2 of Directive DVS 2207-5. The dimensions of the
applicability and informative content of individual test procedures specimen must be selected in accordance with table 2 therein.
or combinations thereof must be made on the basis of the When testing specimens from the outer or inner mitre of a
circumstances of each individual case. segmental elbow (see Fig. 2), the excess of deformation angle
Reference is made to Directive DVS 2207-5, paragraph 6, in “α” achieved in the test above the existing angle of the specimen
respect of the informative content of individual test procedures. “β” must be regarded as the result.
In the case of mounted discharge pipe T-pieces with a fillet weld,
4.1 Non-destructive test methods – Visual inspection specimens are taken, tested and analysed in accordance with
In general, visual inspection is the only non-destructive test Fig. 3.
applied to PE casing pipes. All welded joints are inspected for
visible errors in execution and external indications of internal 4.2.3 Tensile creep test
defects in execution. The tensile creep test is implemented and evaluated in
accordance with paragraph 6.4 of Directive 2207-5. The
Radiographs and ultrasound tests are not customary within the
specimen geometry is identical to that in the tensile test.
scope of this Directive. Should such test processes be used for
corresponding welding processes, weld shapes and weld The component strength of fittings may also be verified in an
dimensions under exceptional circumstances, Directive DVS internal pressure creep test in water, analogous to the
2206 must be consulted. stipulations in DIN 16963-5. Apertures in fittings must then be

L fKurz
V Kurz = V Normal × ----------------------
L fNormal

LfNormal = Specimen length in accordance with DVS 2203-2,


table 1
LfKurz = Shortened specimen length
VNormal = Machine feed for specimen length Lf;
Guide setting for PE-HD under DVS 2203-2, table 3
= 50 mm/min
VKurz = Machine speed for shortened specimen length

Figure 2. Example of a shortened specimen from a prefabricated fitting.

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

R&D INTAKE MANIFOLDS


An imperviousness test must be carried out using compressed air
at approximately 0.2 to 0.3 bar. No leaks (bubbles) must be
visible one minute after coating the welds with a harmless
foaming aqueous solution (e.g. a modern biodegradable
domestic washing-up liquid in the lowest possible concentration).
Should there be any doubt or dispute, the pressure must be
maintained for ≥ 10 minutes. Figure 5. Extrusion weld with well-formed cap and good root penetration
(in accordance with DVS 2206).

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.

5.1.1 Indications of good HS welded joints


Crucial features of good HS welded joints on visual inspection Figure 6. Hot-gas welded butt joint with diagram of welding filler
are (Fig. 4): principle
a) Well-filled weld without backing run (weld structure e.g.
one ∅ = 3 mm + one ∅ = 4 mm + twice ∅ = 4 mm)
b) Weld with inadmissible root gap notches – non-penetrative
root.

– Even, slightly reinforced cap with straight passes;


– Flat transitions between the individual passes and continuous
joint edge coverage;
– Process-specific double bead on both sides, each pass without
Figure 4. Good bead formation in heated plate welding. indications of burning
– Minimal face offset
– Even formation of a double bead throughout the entire length
of the weld/circumference of the pipe (inside and outside); – Notch-free weld penetration with slight sag. Root suck-back is
inadmissible.
– Individual beads as symmetrical as possible, rounded shape,
not pressed into a peak by excessive joint pressure; – Similarly evident “heat delustering” on both sides of the weld
as an indication of the even application of heat.
– Root of the central groove outside the cross-section of the
pipe, double bead width in the approximate vicinity of the pipe 5.2 Requirements for the tensile test
wall;
The requirements of Directive DVS 2207-5, paragraph 7.2 and
– Minimum face offset. table 3, apply.

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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

R&D INTAKE MANIFOLDS


5.4 Requirements for the tensile creep test
and outer casing of polyethylen.
The requirements of Directive DVS 2207-5, paragraph 7.3 and
table 4, apply, with the exception of the footnote. DIN EN 448 Preinsulated bonded pipe systems for directly
burried hot water networks – Fitting assemblies for
5.5 Requirements for the imperviousness test steel service pipes, polyurethane thermal insulation
and outer casing of polyethylene.
The independent impervious test on factory mass-produced
fittings may be waived, if the following requirements are fulfilled: DIN EN 488 Preinsulated bonded pipe systems for directly
burried hot water networks – Steel valve assembly
– Use of certifiably qualified, quality-assured semi-finished prod- for steel service pipes, polyurethane thermal
ucts and similarly certificated welding fillers, if applicable; insulation and outer casing of polyurethane.
– Certified welding process with qualified, regularly-serviced DIN 8075 Polyethylene (PE) pipes – PE 63, PE 80, PE 100,
welding tools; PE-HD – General quality requirements, testing
– Use of qualified, certified welders under DVS 2212-1 and –2, DIN 16776-1 Polyethylene (PE) moulding components,
under similarly qualified, certified supervision (e.g. under DVS classification and description
2213 and 2214); DIN 16963-5 Pipe joints and components of polyethylene (PE)
– Compliance with test certificates under Directive DVS 2207-5, for pipes under pressure, PE 80 and PE 100 – Part
table A 5-2, pos. 1 to 5. 5: General quality requirements, testing
In the case of individual production, particularly the production of DVS 2202-1 Imperfections in thermoplastic welding joints –
fittings or valve jacket casings on site, they must be subjected to Features, description, evaluations
an imperviousness test at excess air pressure in accordance with DVS 2203-1 Testing of welded joints of thermoplastics – Test
paragraph 4.3, after installation in the pipe system and prior to methods, requirements
filling with foam: see also Directive DVS 2207-5, paragraph 6.5. DVS 2203-2 Testing of welded joints of thermoplastics – Tensile
No leaks, atypical deformation or other inadmissible changes test
may take place.
DVS 2203-4 Testing of welded joints of thermoplastics plates
and tubes – Tensile creep test
6 Quality assurance DVS 2203-5 Testing of welded joints of thermoplastics plates
and tubes – Technological bend test
Directive DVS 2207-5, paragraph 6, must be applied analogously DVS 2206 Testing of components and constructions made of
to quality assurance. thermoplastic materials
This particularly affects the following, if possible on the basis of DVS 2207-1 Welding of thermoplastics, Heated tool welding of
an ISO 9000 ff. quality assurance/quality management system: pipes, pipeline, components and sheets made from
– Effective quality assurance measures for the factory produc- PE-HD
tion of casing pipe fittings within the scope of factory produc- DVS 2207-3 Hot gas welding of thermoplastic polymers; panels
tion; and pipes
– The use of approved, regularly-maintained machines and DVS 2207-4 Welding of thermoplastics, Extrusion welding –
equipment subjected to certified regular operating tests panels and pipes
– The use of qualified welders with examination certificates in DVS 2207-5 Welding of thermoplastics – Welding of PE casing
the welding process used under DVS 2212-1 and –2, under pipes – Tubes and tubular components
qualified supervision (e.g. under DVS 2213 and DVS2214); DVS 2208-1 Welding of thermoplastics – Machines and devices
– Specimen tests after machine setting and at regular inter- for the heated tool welding of pipes, pipeline
vals during production under DVS 2207-5, Annex 5, table A components and sheets
5-2. DVS 2209-1 Welding of thermoplastics – extrusion welding;
– Final testing/visual inspection of all the welded fittings. procedures, characteristics
– Quality certification of semi-finished products and welding filler DVS 2209-2 Welding of thermoplastics – Hot gas extrusion
materials welding – Requirements for welding machines and
tools
– Documentation of certificates and test results for welding work.
DVS 2212-1 Examination of plastic welders – Group I – Hot gas
welding with torch separate from filler rod (WF), hot
gas string-bead welding (WZ), heated tool butt
welding (HS)
DVS 2212-2 Examination of plastic welders – Examination
group II – Hot gas extrusion welding (WE)
DVS 2213 Specialist for plastic welding – Examination
DVS 2214 Regulations for the examination of the specialist for
plastic welding

396
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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

R&D INTAKE MANIFOLDS


Methods – Equipment – Parameters

Content: parallelism of the surfaces to be joined. The joining areas have to


be heated up without contacting the heating tool yet maintaining
1 Scope a defined distance in order to achieve a thermoplastic condition
2 General description of methods (heating up). After reaching a plasticised state the radiant heated
3 Requirements on welding equipment tool butt is removed (adjusting) and the components are joined
3.1 General under pressure (joining). The welding joint has to be cooled down
3.2 Special requirements for distance control whilst retaining the joining pressure in the finished joining
4 Radiant heated tools position.
4.1 Radiators
The following joining methods are distinguished at heated tool
4.1.1 Types of radiators
butt welding machines with radiant heating:
4.1.2 Temperature exactness
5 Welding, procedure and parameters – Welding with joining pressure control: the joining pressure is
5.1 General requirements adjusted and kept constant by the machine.
5.2 Measures before welding
– Welding with joining distance limitation: the joining distance is
5.2.1 Welding requirements
limited with adjustable distance bolts.
5.2.2 Cleaning
5.3 Preparation of the components to be welded – Welding with combined joining pressure control and joining
5.4 Welding procedure distance limitation: the joining distance is limited by machine
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

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.

DVS, Technical Committee, Working Group “Joining of Plastics”

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.

4.1.1 Types of radiators


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The following types of radiators are usual:
Within the scope of the quality assurance it is recommended to
produce and test samples of joints before beginning and during
the welding works.
– Short-wave or bright radiators (wave range up to 1,6 µm) Every welder has to be trained. The intended application range
– Medium-wave radiators (wave range > 1,6 up to 3,5 µm) may be decisive for the kind of qualification. The welding exam
– Long-wave or dark radiator (wave range > 3,5 µm) certificate according to DVS 2212-1 in the groups I-4 res. I-8 in
conjunction with the complementing training certificate on non-
The general structure of radiators is that a filament is embedded contact heated tool butt welding issued by an authorized training
in a metallic or ceramic mass which can be heated up to a institute or by the particular machine manufacturer is valid as
temperature of 1000 °C with the wire. An infrared radiation (IR) is qualification proof.
created.
5.2 Measures before welding
4.1.2 Temperature exactness
The temperature deviations measured on the heated tool 5.2.1 Welding requirements
opposite to the temperature adjustment result from technically The welding zone must be protected against bad weather
limited inexactness (regulator deviation and temperature influences (e. g. moisture and temperatures below + 5 °C res.
distribution on the active surface), installation position of the tool higher than + 40 °C). If it is ensured by suitable measures (e. g.
(e. g. natural convection, shielding effects) and environmental preheating, tent, heating) that a component temperature
influences (e. g. draught). sufficient for welding can be kept – as far as the welder is not
hindered in his handling – work may be carried out at any outside
Table 1. Maximum allowed technically limited temperature temperature. If necessary, an additional proof must be provided
deviations. by carrying out sample welds under the mentioned conditions,
see section 6.
Heated tools for pipes Heated tools
If the semi-finished product is heated up unevenly under
and fittings for sheets
influence of sunshine, a temperature compensation in the area of
Active surface < 250 ≥ 250... ≤ 2000 independent the welding joint can be reached by covering. A cooling down
[cm²] during the welding process by uncontrolled draught has to be
avoided. During the welding of pipes the pipe ends have to be
Regulator 3 3 3 closed.
deviation [°C]
The joining areas of the parts to be welded may not be damaged
Temperature 5 7 8 and have to be free of contaminations (e. g. dirt, oil, shavings).
distribution on
active surface [°C] The welding process may only be started with a stable heated
tool temperature according to manufacturer instructions. This has
Technically limited 8 10 11 to be guaranteed by adequate measures, e. g. timed lock, lock of
total deviation [°C] menu prompt, etc. In order to guarantee an exact temperature
distribution on the heated tool surface, the heated tool in neutral
position should be stored in a suitable protection device.
Since each heated tool has its own radiation characteristic the
tool and machine must be adjusted (calibrated) to each other. 5.2.2 Cleaning
This results in different heated tool surface temperatures with the
same input temperature adjusted on the machine. This has to be The surfaces to be joined should be clean and free of grease and
considered during the measurement of the heated tool only similarly clean tools and heated tools are to be utilised if a
temperature. perfect welding joint is to result.
The measurements are done at an ambient temperature of 23
5.2.2.1 Cleaning agents
± 2 °C and a reference temperature which is within the operating
range of the machine. The use of cleaning agents is mentioned in the manufacturer’s
instructions.
Since the heated tools could have high temperatures, the
measurement has to be done with an adequate measuring The paper for cleaning must be clean, unused, absorbent, non-
device. With the use of non-contact measuring devices (dark fraying and non-coloured.
radiators), a measuring spot diameter of maximum 20 mm has to
be kept. 5.2.2.2 Cleaning of the heated tool
The heated tool may not be cleaned in heated up condition
because of the high heated tool temperatures. Contaminations
5 Welding, procedure and parameters have to be removed from the cold heated tool whereby the
manufacturer’s instructions have to be considered.
With the heated tool butt welding method with radiator heating,
the welding parameters depend on the system. In the following 5.2.2.3 Cleaning of joining areas
the method parameters and method indications for the welding
with joining pressure and joining distance limitation are given. Before shaving the joining areas it has to be ensured that the
used tools and components are clean and free of grease in the
welding zone, if necessary cleaning agents should be used.
5.1 General requirements
The quality of welding joints depends on the qualification of the 5.3 Preparation of components to be welded
welders, suitability of the used machines, devices and
The nominal wall thicknesses of the parts to be welded must
components as well as the compliance of welding guidelines. The
correspond in the joining area.
welding joint can be tested and inspected by destructive and/or
visual methods. During clamping the components to be welded must be aligned in

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]

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The joining areas have to be planed with a clean and grease-free
tool directly before welding, so that they are plane parallel in up to 3,0 <3 <3
clamped condition. The maximum deviation of plan parallelism of > 3,0 up to 7,0 3 3
joining areas must be ≤ 0,3 mm.
> 7,0 up to 15,0 4 4
The misalignment has to be checked simultaneously with the
control of the gap width. The misalignment of joining areas has > 15,0 5 5
an essential influence to the strength of the welding joint. A
minimum misalignment should be reached. The allowed gap of
0,1 x wall thickness may not be exceeded. A larger misalignment
means a quality reduction.
The treated welding areas should be neither contaminated nor Bead notch
touched by hand. Any additional cleaning is not necessary Pipe surface,
and means no quality improvement. Shavings which have outside
fallen into the welding areas have to be removed without
contamination. If contamination happens after treatment, e. g. by K-size
touch with hands, the welding areas can be treated with a
cleaning agent in the event that an additional shaving is
technically impossible.

5.4 Welding procedure

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

With the joining pressure limitation, the joining pressure must be


5.4.2 Heating up
kept until the end of the cooling time. The material specific joining
Alignment is not done. pressures are indicated by the manufacturer.
The heated tool is put in heating up position and the components
to be welded are brought together. The distance of the 5.4.4.2 Distance controlled joining
components to be welded to the heated tool is usually adjusted
with distance bolts. A plasticised zone in the joining are is created The joining distance is calculated starting with the contact of the
during heating up. The decisive influences are radiation source, parts to be welded. The material specific joining distances are
radiator temperature, component material, distance to indicated by the manufacturer.
component, start-up time (see table 2), heating up time.
The heating up parameters have to be chosen so that a minimum 5.4.4.3 Distance-/Pressure controlled joining
plasticised zone depending from the material is created without
causing a thermal destruction on the surface. The joining distance is calculated starting with the contact of the
parts to be welded. After the joining distance is reached the
General valid parameters cannot be indicated due to major joining pressure is measured. After falling below a limit value it is
differences in the reflecting behaviour of different heated tool changed to joining pressure and kept until the end of the cooling
surface as well as the variety of influence factors and their time.
combination with each other. Experiences have shown that
plasticised zone thicknesses of 10 – 20 % result in good welding
joint strengths of the materials welded with this method. 5.4.5 Cooling
In general the welding parameters have to be chosen by the The cooling process must be done completed whilst maintaining
manufacturer so that the requirements according to DVS 2203-1 the complete joining distance/joining pressure. The cooling times
are fulfilled. depend on the wall thickness and are indicated by the
manufacturer. Increased mechanical loads during or directly after
5.4.3 Changeover re-clamping are only allowed after corresponding elongated
cooling phase.
After the heating up the heated tool is extended and the
components to be welded are joined together quickly until directly
before the contact. The changeover time should be as short as 5.5 Safety indications
possible (see table 2) as otherwise the plasticised zones would
cool down and the welding joint quality would be influenced With the decomposition of fluorpolymers (PVDF, PFA, E-CTFE)
negatively. toxic vapours appear. This is the reason why the contact
between the high tempered heated tool and the parts to be
5.4.4 Joining welded has to be avoided. This is also valid for shavings incurred
by planing.
The areas to be welded should meet with a speed of nearly zero.
Different bead sizes are created by heat convection and gravity
influence on the total circumference of pipes. In addition, melt 6 Testing of welded joints
viscosity differences, e. g. existing between pipe and fitting, have
an influence to the bead size.
Non-destructive and destructive tests can be used for testing
The K-size (distance between the lowest point of the bead notch welded joints. These methods are listed in table 3. Tests and
(notch ground) and the surface of the component to be welded, sampling should be done by spot checks during the welding
picture 1, must be higher than 0. works – depending from agreement.

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,

R&D INTAKE MANIFOLDS


evaluation
Visual test DVS 2202-1 DVS 2203 Testing of welded joints out of thermoplastics;
Radiation test Statement about e. g. holes, not about quality -1 – Test methods - Requirements
is possible -2 – Tensile test
Tensile test DVS 2203-2, short-term factor. Factors acc. to -4 – Long-term tensile test
DVS 2203-1, supplement 1, table 1 -5 – Technologic bending test
DVS 2203-4, long-term factor. Factors acc. to DVS 2207 Welding of thermoplastics;
DVS 2203-1, supplement 2, table 1 -11 – Heated tool welding of pipes, pipeline
Technologic DVS 2203-5. components and sheets out of PP
bending test Minimum bending angle acc. to DVS 2203-1, -15 – Heated tool welding of pipes, pipeline
supplement 3, pictures 2 to 4 components and sheets out of PVDF
Minimum bending angle acc. to DVS 2203-1, DVS 2208-1 Welding of thermoplastics; Machines and
supplement 3, pictures 8 to 10 devices for heated tool welding of pipes, pipe-
Long-term Length of each pipe piece acc. to DIN 16963, line components and sheets
internal table 6 DVS 2212-1 Exam of plastic welders; test group I-4 res. I-8
pressure test PVDF acc. to ISO 10931-2, section 7.2, table 5 draft
EG-machine Technical Code 89/392 (2. revision 91/368/EWG,
PP acc. to DIN 16 963-5, table 4, sections 3. revision 93/44)
5.4.3.1 and 6.4
BGV A2 (VBG 4) Electric equipment and production facilities
Not meaningful for long-term welding factor VBG 5 Pressure operated engines
> 0,5
VBG 22 Engines of chemical industry, rubber and
plastics industry
Reliability regulation
7 Standards and Technical Codes

7.1 Standards 8 Explanations


DIN 8077 Pipes out of polypropylene (PP); PP-H
100, PP-B 80, PP-R 80; Dimensions The draft has been established according to the latest state-of-
the-art. It follows to the content of the Technical Codes DVS
DIN 8078 Pipes out of polypropylene (PP); PP-H 2208-1, DVS 2207-11 and 2207-15.
(Type 1), PP-B (Type 2), PP-R (type 3);
General quality requirements, Testing
DIN 16962-5 Pipe joints and pipeline components for Appendix: Indications for machine control
pressure pipelines out of polypropylene
(PP); PP-H (type 1), PP-B 80, PP-R 80; – Visual check regarding damages
General quality requirements, Testing
– Operating test
ISO 10931-2 Plastics piping system for industrial
applications – Polyvinylidene fluoride – Control of clamping device according to DVS 2208-1, sections
(PVDF); Pipes 4.1 and 4.2
DIN EN ISO 15013 Extruded sheets out of polypropylene – Control of guiding elements according to DVS 2208-1, sections
(PP); Requirements and test methods; 4.1 and 4.2
Sheet group 1.1 / 2.1 / 3.1 – Control of device for welding joint preparation regarding cutting
DIN EN 292- 1 Safety of machines performance and plane parallelism according to DVS 2208-1,
DIN EN 292- 2 Fundamental terms, general design section 4.1
principles – Control of heated tool regarding damages, plane parallelism,
DIN EN 60204- 1 Electric equipment of machines easy operation and floating suspension of positioning and
removing res. set down devices according to section 4 and
DIN EN 294 Safety distances against reaching of
DVS 2208-1, sections 4.1 and 4.2
dangerous areas
– Control of heated tool regarding temperature exactness
DIN EN 418 Emergency stop
according to 4.1.2
DIN VDE 0100 Regulations for installation of power
sets with nominal voltages up to 1000 – Check of control and regulation equipment for pressure and
Volt time with minimum and maximum diameter res. with minimum
and maximum sheet thickness and joint length according to
DIN VDE 0105 Part 1 Regulations for the operation of power section 3
sets; General regulations
– Check of scale and display indication with applied pressure on
DIN VDE 281 Part 1 PVC-power lines the joining area by means of load cells at pressure controlled
DIN VDE 0551 Regulation for safety transformers machines. This is done at pipe machines on the smallest,
(German edition of EN 60742) average and largest diameter, each with the highest pressure
DIN VDE 0700 Part 1 Safety of electric equipment for the rating and at sheet machines on the smallest, average and
domestic use and similar purposes; largest sheet thickness and maximum joint length.
General requirements – Check of the distance measuring system according to
DIN VDE 0700 Part 30 Mobile electric heating tools manufacturer’s indication for distance controlled machines
DIN VDE 0721 Regulations for industrial electro – Check of reliability according to DVS 2208-1, section 2.7
heating equipment – Record of results in the test protocol, see example

400
Page 5 to DVS 2207-6

Appendix

Test protocol for heated tool butt welding machines (pipeline components)

Product/Manufacture R&D INTAKE MANIFOLDS Type


Machine/Serial number Dimension range*
Heated tool serial number * also valid for required heated tools

Date of last check

 Personal safety and reliability Test result Evaluation


Current supply cable incl. plug
Tools and operating devices
Condition and density of the hydraulic system (if existing)
Visual and acoustic control devices
Emergency function (if not existing, input = 0)

 Clamping device and guiding elements


Gap measuring Gap difference mm
Condition of clamping elements and surfaces
Condition of guiding elements
Condition of slides

 Chip removing tools


Condition of cutting elements
Chip condition Chip thickness mm
Plan parallelism of joining areas after treatment
Condition of joining areas after treatment

 Radiant heated tools Preset temperature °C


Plan parallelism Deviation* mm
Temperature distribution Deviation* °C
Temperature exactness Deviation* °C
Surface condition
Operational test (for the indicated dimension range)
Joining pressure control / Joining distance Deviation* %/mm
Reading accuracy joining pressure Deviation* %
(manometric pressure) (if applicable)

Joining pressure build-up time / Joining distance Deviation* %


* (deviation from reference value)

Reference values acc. to DVS

 Operation manual (if missing, input = 0)

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

Date of check: Testing authority with stamp and signature:

Auditor:

401
Page 6 to DVS 2207-6

Test protocol for heated tool butt welding machines (sheets)

Product/Manufacture Type
Machine/Serial number
Heated tool serial number R&D INTAKE MANIFOLDS Dimension range*
* also valid for required heated tools

Date of last check

 Personal safety and reliability Test result Evaluation


Current supply cable incl. plug
Tools and operating devices
Condition and density of the hydraulic/pneumatic system (if existing)
Visual and acoustic control devices
Emergency function (if not existing, input = 0)

 Clamping device and guiding elements


Condition of clamping elements and surfaces
Condition of guiding elements
Condition of slides
Table misalignment mm

 Elevating spar
Plan parallelism
Straightness and alignment
Elevation adjustment

 Radiant heated tools Preset temperature °C


Plan parallelism Deviation* mm
Elevation adjustment in working position
Temperature distribution Deviation* °C
Temperature exactness regarding set value Deviation* °C
Surface condition
Operational test (for the indicated dimension range)
Joining pressure control / Joining distance Deviation* %/mm
Reading accuracy joining pressure Deviation* %
(manometric pressure) (if applicable)

Joining pressure build-up time / Joining distance Deviation* %


* (deviation from reference value)

Reference values acc. to DVS

 Operation manual (if missing, input = 0)

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

Date of check: Testing authority with stamp and signature:

Auditor:

402
Material
Protocol form for non-contact heated tool butt welding of sheets Sheet of
Customer Executive company Welding equipment:

Name of order Name of welder Identification no. Label:


Type:
No. of order Name of company of the welding supervisor Machine No.:
Year of construction:
Weld no. Date Sheet Measured Joining Start-up Heating-up Changeover Joining Joining Cooling time Environ- Notes
thickness heated tool pressure time time time pressure distance under joining mental
temperature (machine build-up pressure temperature
table) time
mm C min/max N s s s s mm min C
R&D INTAKE MANIFOLDS

Welder signature: Date and signature of welding supervisor:


1) controlled by the machine
2) pressure controlled machines: according to the indications of the manufacturer res. from machine tests plus movement pressure res. force
3) distance controlled machines: according to the indications of the manufacturer
4) the measured values have to be entered
Page 7 to DVS 2207-6

403
404
Protocol form for non-contact heated tool butt welding of pipes and pipeline  aboveground Material Sheet of
components  buried

Customer Executive company Welding machine: Weather: Precautions:


1 = sunny 1 = none
Label: 2 = dry 2 = umbrella
Name of order Name of welder Ident-no.
Type: 3 = rain or snow 3 = tent
Page 8 to DVS 2207-6

Machine No.: 4 = wind 4 = heating


No. of order Name of company of the welding supervisor Year of construction:
Multiple selections: order as above (e.g. 3 4 = rain and wind)
Weld no. Date Pipe Measured Movement Joining Start-up Heating-up Changeover Joining Joining Cooling time Environ- Key no. Notes
dimension heated tool pressure pressure time time time pressure distance under joining mental
∅dxs temperature (machine build-up pressure temperature Weather Precautions
table) time
mm C min/max N N s s s s mm min C
R&D INTAKE MANIFOLDS

Welder signature:: Date and signature of welding supervisor


1) controlled by the machine
2) pressure controlled machines: according to the indications of the manufacturer res. from machine tests plus movement pressure res. force
3) distance controlled machines: according to the indications of the manufacturer
4) the measured values have to be entered
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-11\englisch\e2207-11.fm
Erstellt am: 21.09.2008
Zuletzt geändert am: 09.10.2008

December 2008

DVS – DEUTSCHER VERBAND Welding of thermoplastics


FÜR SCHWEISSEN UND Heated tool welding of pipes, piping parts and Technical Code
VERWANDTE VERFAHREN E.V. panels made of PP DVS 2207-11

R&D INTAKE MANIFOLDS Translation of the German edition from August 2008

Contents: 2 General requirements

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

4.1.2 Preparation for the welding


4.1.3 Execution of the welding Every welder must be trained and must possess a valid
5 Sleeve welding with an incorporated electric heating qualification certificate. The planned area of application may
element determine the type of the qualification. DVS 2212-1 applies to the
heated tool butt welding of panels as well as to pipeline
5.1 Process description
construction.
5.2 Welding device
5.3 Preparation for the welding The machines and jigs used for the welding must comply with the
requirements in DVS 2208-1.
5.4 Execution of the welding
6 Heated tool sleeve welding
6.1 Process description 3 Measures before the welding
6.2 Welding jigs
6.3 Preparation for the welding 3.1 Prerequisites for the welding
6.4 Execution of the welding The immediate welding area must be protected from un-
7 Testing of the welded joints favourable weathering influences (e. g. wind or the action of
8 Standards, technical codes and guidelines which are also moisture). If suitable measures (e. g. preheating, tenting or
applicable heating) ensure conditions permissible for the welding, the work
9 Explanations may be carried out at any outdoor temperature – provided that
Appendix: the dexterity of the welder is not hindered (see the explanations).
Processing instructions (short versions) If necessary, additional evidence must be provided by manu-
Welding record sheets facturing trial welds in the specified conditions (see Section 7).
If the semi-finished product is heated non-uniformly due to solar
radiation, the temperatures must be equalised by covering the
1 Scope of application area of the welding point in good time. It is necessary to avoid
any draught-induced cooling during the welding operation. When
This technical code applies to the heated tool butt welding of pipes are welded, the pipe ends must be closed in addition.
panels according to DIN EN ISO 15013 and to the heated tool PP pipes from the ring coil are oval and curved immediately after
butt welding, heated tool sleeve welding and sleeve welding with the unrolling. The pipe end to be welded must be straightened
an incorporated electric heating element of pipes and fittings before the welding, e. g. by means of careful heating-up with the
which are made of PP-H, PP-B and PP-R polypropylenes aid of a hot gas device and/or using a suitable clamping or round
according to DIN 8077, DIN 8078 and DIN 16962 and serve to pressing jig.
transport gases, liquids and solids.
The joining faces of the parts to be welded must not be damaged
Paying attention to the following instructions, it may be assumed and must be free from contaminations (e. g. dirt, grease and
that a melt flow rate MFR1) 190/5 of 0.4 - 1.0 g/10 min is suitable. chips).
This range roughly corresponds to the melt flow rate MFR 230/
2.16 of 0.2 - 0.6 g/10 min. 3.2 Cleaning
In the case of deviating melt flow rates, the proof of suitability For the manufacture of flawless welded joints, it is decisively
must be provided in the tensile creep test according to important that not only the joining faces but also the tools and the
DVS 2203-4 or Supplement 1. heated tools are clean and free from grease.

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.

DVS, Technical Committee, Working Group "Joining of Plastics"

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

3.2.1 Cleaning agents 4.1.2 Preparation for the welding


The cleaning fluid or cloths which have already been moistened The heated tool temperature necessary for the welding must be
with it in the factory and are kept in a lockable plastic box must checked before the beginning of the welding work. This is carried

R&D INTAKE MANIFOLDS


consist of a solvent with 100% vaporisation, e. g. of 99 parts out, for example, with a quick-display temperature gauge for
ethanol with a degree of purity of 99.8% and one part MEK surface measurements with a contact area > 10 mm. The control
(methyl ethyl ketone, denaturation). Agents tested according to measurement must be taken within the heated tool area
DVGW VP 603 comply with this stipulation. The use of spirit may corresponding to the semi-finished product. So that a thermal
lead to a quality reduction because of the water contained in it. equilibrium can occur, the heated tool may be used, at the
earliest, ten minutes after the nominal temperature has been
The paper for the cleaning must be clean, unused, absorbent,
reached.
non-fraying and undyed. Ensure subsequent extraction.
For optimum welds, it is necessary to clean the heated tool
3.2.2 Cleaning of the heated tools according to Section 3.2.2 before every welding operation. The
The heated tools must be cleaned with paper before every anti-adhesive coating or covering of the heated tool must be
welding operation. No residues of cleaning agents or paper may undamaged in the working area.
remain on the heated tool. The respective joining forces or joining pressures must be
stipulated for the machines to be used. These may refer, for
3.2.3 Cleaning of the joining faces example, to information from the manufacturer or to calculated or
Before the chip-producing machining of the joining faces, it must measured values. In the case of pipe welding, it is also necessary
be ensured that the utilised tools and the workpieces are clean to read the movement force or movement pressure arising during
and free from grease beyond the welding area. If necessary, the slow movement of the workpiece off the display instrument of the
cleaning must be carried out with a cleaning agent. welding machine and to add this to the previously determined
joining force or to the joining pressure. Preference should be
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
If the surface is soiled after the chip-producing machining (e. g. match in the joining region.
because of contact with the welder's hands), the welding faces Pipes and fittings must be aligned axially before they are
must be treated with a cleaning agent if an additional chip- clamped in the welding machine. The easy longitudinal mobility
producing machining operation is not possible for process-related of the part to be welded on must be ensured, for example, using
reasons. adjustable dollies or a swinging suspension.
Immediately before the welding, the faces to be joined must be
4 Heated tool butt welding subjected to chip-producing machining with a clean and grease-
free tool so that they have parallel faces in the clamped condition.
4.1 Heated tool butt welding of pipes, piping parts, fittings The permissible gap widths under the alignment pressure are
and panels shown in Table 1.
4.1.1 Process description Table 1. Maximum gap widths between the machined welding faces.
During heated tool butt welding, the joining faces of the parts to
be welded are aligned to the heated tool under pressure Pipe outside diameter d Gap width Panel width
(alignment), are subsequently heated up to the welding mm mm mm
temperature at a reduced pressure (heating-up) and, when the ≤ 355 0.5
heated tool has been removed (changeover), are joined together
under pressure (joining). Figure 1 shows the principle of the 400 ... < 630 1.0 ≤ 1,500
process. 630 ... < 800 1.3 > 1,500 ≤ 2,000
preparation 800 ... ≤ 1,000 1.5 > 2,000 ≤ 2,300
> 1,000 2.0 > 2,300 ≤ 3,000

The misalignment must be checked at the same time as the gap


width. The misalignment of the joining faces in relation to each
other must not exceed the permissible dimension of 0.1 x wall
thickness on the outside of the pipe or on the panel. A larger
pipe heated tool pipe 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
heating-up
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.
welding joint 4.1.3 Execution of the welding
In the case of heated tool butt welding, the faces to be joined are
heated up to the welding temperature using a heated tool and,
when the heated tool has been removed, are joined together
under pressure. The heated tool temperature is 210 ± 10°C. In
principle, it is necessary to strive for the upper temperature with
lower wall thicknesses and for the lower temperature with higher
Figure 1. Principle of heated tool butt welding using the example of wall thicknesses. The step-by-step sequence of the welding
pipes. operation is illustrated on Figure 2.

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

R&D INTAKE MANIFOLDS


A mechanical load on the joint is permissible, at the earliest, after
the end of the cooling process. For this purpose, the full joining
heating-up pressure must be maintained during the cooling time at the
pressure ambient temperature (see Table 2, Column 5).
time Subject to the following prerequisites, it is permitted to shorten

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.

R&D INTAKE MANIFOLDS


The joining faces (i.e. the surface of the pipe and the inside of the
fitting) overlap, are heated up to the welding temperature by
electrical energy with the aid of resistance wires positioned in the
In the area of the welding zone, the complete surface of the pipe
or of the pipe spigot on the fitting must be subjected to chip-
producing machining. A rotating peeling device with constant wall
fitting (heater spiral) and are welded in this way (see Figure 4). thickness removal of approx. 0.2 mm should be used. Attention
machined must be paid to the formation of a small annular gap!
joining faces
The pipe end must be deburred on the inside and outside. Chips
must be removed without touching the joining face.

The fitting may only be removed from the protective packaging


immediately before the assembly.

insert If the machined pipe surface is contaminated after the chip-


fitting depth pipe producing machining, this must be cleaned according to Section
3.2.3. In this respect, it must be ensured that no contamination is
rubbed into the welding zone. The joining face of the fitting must
be cleaned according to Section 3.2.3.

It must be possible to check the insert depth of the pipe either


with a mark to be applied or using a suitable jig. The fitting must
not be tilted or pushed on to the pipe end with force (low-stress
joining plane assembly). The saddle piece must be tightly clamped on the pipe
with the aid of a suitable jig according to the information from the
manufacturer.
Figure 4. Sleeve welding with an incorporated electric heating element
(principle). The contact bushes for the connection of the welding cable must
be easily accessible.
5.2 Welding device
It is only allowed to use welding devices which are adapted to the The fitting and the pipe must be at the same temperature level
parts to be welded. Preference should be given to automatic before the welding. In the case of welding devices with automatic
welding devices – if at all possible, with recording. The welding temperature compensation, it must be ensured that the recorded
device must supply the welding parameters required for the fitting ambient temperature corresponds to the conditions at the
to be welded in each case, e. g. welding time, amperage and location of the welding. If necessary, the welding device as well
voltage. The device must be switched off automatically as soon as the pipe and the fitting must be protected from (for example)
as the necessary heat quantity has been supplied to the welding direct solar radiation.
zone.
5.4 Execution of the welding
5.3 Preparation for the welding
The correct insert depth must be checked on the basis of the
For the manufacture of flawless welded joints, decisive mark. If necessary, suitable measures or jigs must be used in
significance is attached to clean surfaces and to stress-free order to prevent any changes in the positions of the components
installation. The assembly of fittings is facilitated by the selection to be welded.
of pipes with restricted diameter tolerances according to
DIN 8077. Cables serve to connect the welding device with the fitting to be
For axial pipe joints, the pipes must, if necessary, be cut off at a welded. The welding cables must be attached in a weight-
right angle with a suitable tool. In the case of conical collapsing of relieved form. The contact faces must be clean. As a rule, the
the cut edge of the pipe, the unmachined pipe must exhibit the nom- welding device acquires the fitting data required for the welding
inal diameter d at the planned insert depth, at least in the region of by reading in a component-specific bar code. The displayed data
the heater spiral (Figure 5). If necessary, the pipe end must be (e. g. dimensions) must coincide with the component data. After
shortened correspondingly immediately before the welding. the welding operation has started, this proceeds automatically.
The welding duration is usually displayed by the welding device.
Just like the other data displayed by the device, it must also be
indicated on the welding record sheet unless the data is stored.

Pay attention to error messages! For example if the power supply


is interrupted, a prematurely terminated welding operation can be
repeated on one occasion in so far as there are no defects on the
fitting or on the welding device (error message) and the fitting
still allowed wrong manufacturer permits this. It is necessary to wait for the entire
cooling time before carrying out the welding once again.

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.

For a short version of the processing instructions, see the


Figure 5. Conical collapsing of the pipe end. appendix.

408
Page 5 to DVS 2207-11

6 Heated tool sleeve welding

6.1 Process description

R&D INTAKE MANIFOLDS


In the case of heated tool sleeve welding (see Figure 6), the pipe approx
and the fitting are welded in an overlap. The pipe end and the
fitting are heated up to the welding temperature with the aid of
sleeve-shaped and spigot-shaped heated tools and are
subsequently welded.
The heated tools and the fittings are dimensionally coordinated in
such a way that a joining pressures builds up during the joining.
Heated-tool-sleeve-welded joints with a pipe diameter up to
50 mm can be executed manually. In the case of diameters as
from 63 mm, the level of the joining force necessitates the use of
a welding jig. Figure 7. Bevelling of the pipe end.
preparation heated tool
Table 3. Dimensions for the pipe bevel and the insert depth.

Pipe outside diameter d Pipe bevel b Insert depth l


[mm] [mm] [mm]
16 13
20 14
25 16
heated spigot 2
fitting heated sleeve pipe 32 18
40 20
heating-up
50 23
63 27
75 31
90 3 35
110 41
welded joint
125 46

Before the beginning of the welding, the welding temperature of


250 - 270°C at the heated tools must be checked according to
Section 4.1.2.
The heated bush and the heated spigot must be free from
Figure 6. Heated tool sleeve welding (principle). contaminations and must be cleaned according to Section 3.2.2
before every welding operation. The anti-adhesive coating of the
6.2 Welding jigs heated spigot and the heated bush must be undamaged in the
welding area.
The heated tools are heated electrically and are coated anti-
adhesively. 6.4 Execution of the welding
6.3 Preparation for the welding For the heating-up, the fitting and the pipe are quickly and axially
pushed on to the tools attached to the heated tool as far as the
The fitting must be cleaned on the inside and the pipe on the stop in the case of machine welding or as far as the mark in the
outside according to Section 3.2. The joining faces of the parts to case of manual welding and are fixed. It is imperative to
be welded must be machined immediately before the beginning prevent the front face of the pipe from bumping into the end
of the welding. The pipe end must be bevelled according to of the heated bush. The heating-up time according to the time
Figure 7 and Table 3. The joining face of the pipe must be indicated in Table 4, Column 2 begins thereafter.
machined according to the information from the fitting supplier. In
the case of manual welds, the insert depth must then be marked When the heating-up time has elapsed, the fitting and the pipe
on the pipe end at the distance l according to Table 3. must be pulled off the heated tools with a jolt and must be pushed
together immediately as far as the stop or the mark without any
twisting (max. changeover time: see Table 4, Column 3).
In the case of manual welding, the joined parts must be kept in a
fixed position according to the time indicated in Table 4, Column
4. The joint may only be subjected to the stresses of the further
laying work when the cooling time (Table 4, Column 5) has
elapsed.

409
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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

R&D INTAKE MANIFOLDS


Heating-up Changeover Cooling
Heated tool temperature 250 - 270°C
Pipe outside
Changeover time Cooling time
diameter d
Heating-up time for Heating-up time for (maximum time)
SDR2) 11, SDR 7.4 and SDR 66 SDR2) 17 and SDR 17.6
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 10
30
75 30 15 8 6
90 40 22 40
110 50 30 50
10 8
125 60 35 60
Because the wall thickness is too low, the welding process is not recommendable.
Standard Dimension Ratio ~ d/s (ratio of the outside diameter to the wall thickness).

For a short version of the processing instructions, see the appendix.

7 Testing of the welded joints

Various test procedures are applied for the individual welding


processes. A distinction is made between non-destructive and
destructive test procedures. They are listed in Table 5.
Depending on the agreement, checking and sampling operations
should be carried out on a random basis during the welding work.

Table 5. Test procedures for welded joints.

Sleeve welding with an incorpo-


Heated tool butt welding Heated tool sleeve welding
Test procedure rated electric heating element
Panels, pipes and fittings Pipes and fittings
Fittings
DVS 2202-1 DVS 2202-1
DVS 2202-1 Table 3 Table 2
Visual inspection
Table 1 The machining of the pipe surface must be visible beyond the
welding area.
Radiographic and
Applicable. Statement possible, for example, about voids, not about quality.
ultrasonic tests
DVS 2203-2
Tensile test Short-time tensile welding factor Not applicable
DVS 2203-1, Supplement 1

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

Sleeve welding with an incorpo-


Heated tool butt welding Heated tool sleeve welding
Test procedure rated electric heating element
Panels, pipes and fittings Pipes and fittings
Fittings

R&D INTAKE MANIFOLDS


DVS 2203-6, Supplement 1
Torsion shear test Not applicable
Also as a site test for pipe wall thicknesses ≥ 4 mm.
DVS 2203-6, Supplement 1
Radial peeling test Not applicable
Site test for pipe wall thicknesses ≥ 4 mm
DIN EN 12814-4, Section 8
Compression test Not applicable
Also suitable as a site test
Peel decohesion Not applicable
Not applicable DIN EN 12814-4, Section 7
test

8 Standards, technical codes and guidelines which are 9 Explanations


also applicable
The technical code was adjusted to the state of the art with
DIN 8077 Pipes made of polypropylene (PP); PP-H, regard to improved cleaning agents and to the development of
PP-B, PP-R and PP-RCT; dimensions larger piping parts. Non-contact heated tool welding is dealt with
DIN 8078 Pipes made of polypropylene (PP); PP-H, in DVS 2207-6.
PP-B, PP-R and PP-RCT; general quality The welding of thermoplastics at ambient temperatures < 5°C is
requirements and testing generally considered to be problematical. This relates not so
DIN EN 12814-4 Testing of welded joints between thermo- much to the material-specific properties of the plastic but, to a
plastics; Part 4: Peeling test greater extent, to the restricted dexterity of the welder. Therefore,
the prerequisite for open-air welding at any outdoor temperatures
DIN EN ISO 15013 Extruded panels made of polypropylene
(PP); requirements and test procedures is an environment which enables the welding personnel to
perform the individual work steps without any quality-reducing
DIN EN ISO15494 Plastic piping systems for industrial appli- influences. In this respect, it is necessary to pay attention to the
cations; polybutene (PB), polyethylene information from the manufacturers and to the dew point curve.
(PE) and polypropylene (PP); requirements The parts to be joined must exhibit an identical temperature level.
on piping parts and on the piping system; Trial welds must be produced and tested.
metric series
With regard to the condition of the pipe end, it must be ensured
DIN 16962 Pipe joints and piping parts for pressure that, within the framework of the welding preparations, any white
piping made of polypropylene (PP) frost, ice and moisture are removed from the area of the joining
DVGW VP 603 Test basis for cleaning agents and their re- zone (≥ 0.5 x fitting length) by supplying heat (e. g. hot gas
ceptacles for the preparation of welded device). Fittings must be stored in closed, frost-free rooms and
joints between polyethylene pipes may only be transported to the welding location in the number
DVS 2202-1 Defects in welded joints between thermo- required in each case.
plastics; characteristics, description and At present, a qualitative evaluation of sleeve-welded joints in the
evaluation internal pressure creep test is possible to an inadequate extent
DVS 2203-1 Testing of welded joints between thermo- only. In conjunction with the tensile creep test, an initial approach
plastics; test procedures – requirements is included in DVS 2203-6, Supplement 1 and in DVS 2207-15,
for explanations for Section 6.
Supplement 1 Requirements in the tensile test
Supplement 2 Requirements in the tensile creep test
Supplement 3 Requirements in the technological bending
test, bending angle / bending path
DVS 2203-2 -, tensile test
DVS 2203-4 -, tensile creep test
DVS 2203-4, -, tensile creep test; testing of sleeve-weld-
Supplement 1 ed joints between pipes
DVS 2203-5 Technological bending test
DVS 2203-6, Testing of joints between polymer materi-
Supplement 1 als; torsion shear and radial peeling tests
for joints manufactured by means of sleeve
welding with an incorporated electric heat-
ing element and heated tool sleeve welding
DVS 2208-1 Welding of thermoplastics; machines and
devices for the heated tool welding of
pipes, piping parts and panels
DVS 2212-1 Qualification testing of plastics welders;
Qualification Test Groups I and II
DVS 2207-15 Welding of thermoplastics; heated tool
welding of pipes, piping parts and panels
made of PVDF
Betr.Sich.V Operational Safety Ordinance

411
Page 8 to DVS 2207-11

Appendix: Processing instructions (short versions)

Re. 4.1 Heated tool butt welding of pipes, piping parts, 4. Guarantee the roundness of the pipes using round pressing

R&D INTAKE MANIFOLDS


fittings and panels clamps, permissible out-of-roundness: ≤ 1.5%, max. 3 mm.
Processing instructions (short version) 5. Clean the joining faces beyond the welding area with a
cleaning agent according to Sections 3.2.1 and 3.2.3 with
1. Create permissible working conditions, e. g. welding tent.
unused, absorbent, non-fraying and non-dyed paper.
2. Connect the welding device to the mains or to the alternating Machine the pipe surface in the welding area, if at all
current generator and check its function. possible with a rotating peeling device and wall thickness
3. Align and clamp the parts to be welded, e. g. with dollies. removal of approx. 0.2 mm. Remove the chips without
touching the pipe surface.
4. Close the pipe ends against draughts.
6. Clean the machined pipe surface (in so far as it is
5. Clean the joining faces beyond the welding area with a
contaminated subsequently) and, if necessary, also the
cleaning agent according to Sections 3.2.1 and 3.2.3 with inside of the fitting according to the information from the
unused, absorbent, non-fraying and non-dyed paper.
manufacturer with a cleaning agent according to Sections
Machine the joining faces, in the case of pipes using a plane
3.2.1 and 3.2.3 with unused, absorbent, non-fraying and
(for example).
non-dyed paper and ensure extraction.
6. Take out the plane in the case of a pipe welding machine.
7. Push the pipes into the fitting and check the insert depth with
7. Remove the chips from the welding area without touching a mark or using a suitable jig. Prevent any change in the
the joining faces. position of the pipe.
8. Check the plane parallelism by moving the joining faces 8. Connect the cables to the fitting in a weight-relieved form.
together (max. gap width according to Table 1).
9. Input the welding data (e. g. using a bar code reading pen),
9. Check the misalignment (max. 0.1 x wall thickness). check the displays on the device and start the welding
10. Check the heated tool temperature (210 ± 10°C). process.
11. Clean the heated tool with a cleaning agent according to 10. Check the correct welding sequence on the welding device
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fraying (e. g. by checking the display and, if present, the welding
and non-dyed paper and ensure extraction. indicators). Pay attention to error messages.
12. Determine the movement pressure or the movement force 11. Detach the cables from the fitting.
before every welding operation and make a note of it on the
welding record sheet. 12. Unclamping of the welded parts when the cooling time
according to the information from the manufacturer has
13. Determine the setting values for the alignment, heating-up elapsed. Remove the utilised holding jigs.
and joining pressures.
13. Complete the welding record sheet unless there was any
14. Stipulate the guide values according to Table 2. automatic recording.
15. Move the heated tool into the welding position.
16. Align the faces to the heated tool until a bead arises Re. 6 Heated tool sleeve welding
(according to Table 2, Column 2). Processing instructions (short version)
17. Heating-up at a reduced pressure ≤ 0.01 N/mm², heating-up 1. Create permissible working conditions, e. g. welding tent.
time according to Table 2, Column 3.
2. Connect the welding device to the mains or to the alternating
18. At the end of the heating-up, detach the joining faces to be current generator and check its function.
welded from the heated tool and move this out of the welding
position. 3. Clean the heated tools with a cleaning agent according to
Sections 3.2.1 and 3.2.3 with unused, absorbent, non-fraying
19. Within the changeover time (Table 2, Column 4), quickly and non-dyed paper.
move together the faces to be welded until they almost
touch. The faces must come into contact at a speed of nearly 4. Check the welding temperature (250 - 270°C).
zero. Immediately afterwards, build up the joining pressure 5. Clean all the non-machined joining faces with a cleaning
with a linear rise in the build-up time (Table 2, Column 5). agent according to Sections 3.2.1 and 3.2.3 with unused,
20. A bead must exist after the joining at a pressure of absorbent, non-fraying and non-dyed paper and ensure
0.10 N/mm². According to Figure 4, K must be > 0 at every extraction.
point. 6. Bevel the pipe end cut off at a right angle according to Figure
21. Cooling under the joining pressure according to Table 2, 7 and Table 3 or machine it according to the information from
Column 5. the fitting manufacturer. If necessary, mark the insert depth.
22. Unclamping of the welded parts when the cooling time has 7. Simultaneously push the fitting and the pipe on to the heated
elapsed. In the case of workshop work, see the joining in spigot or into the heated bush as far as the stop or the mark.
Section 4.1.3. Do not bump the pipe end into the end of the heated bush.
23. Complete the welding record sheet. 8. Comply with the heating-up time according to Table 4,
Column 2.
Re. 5 Sleeve welding with an incorporated electric
heating element 9. Pull the fitting and the pipe off the heated tools with a jolt,
immediately push them together as far as the mark or the
Processing instructions (short version) stop (for max. changeover time: see Table 4, Column 3) and
1. Create permissible working conditions, e. g. welding tent. fix them in this position (see Table 4, Column 4).
2. Connect the welding device to the mains or to the alternating 10. Let the joint cool down. Only subject the welded joint to
current generator and check its function. mechanical loads when the cooling time according to Table
4, Column 5 has elapsed.
3. Deburr the outside of the pipe end cut off at a right angle. In
the case of excessively pronounced collapsing of the pipe 11. Complete the welding record sheet
end, shorten the pipe. See Figure 5.

412
Welding record sheet for the heated tool welding  above ground Material Page of

of pipes  underground

Constructor Executing company Welding device: Weather conditions: Protection mesures:

1 = sun 1 = none

Order description Name of welder ID-No. Manufacturer: 2 = dry 2 = umbrella

Type: 3 = rain or snow 3 = tent

No. of Order Name and company of welding supervisor Machine-No.: 4 = wind 4 = heating

Year built: I several Conditions apply, order of numbers as above


(e. g. 34 = rain and wind)

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

Welder signature: Date and signature of welding supervisor:

From control-interval, frequency see section 4.2.


Values from manufacturer of welding machine or from machine-check plus moving pressure.
Insert measured values.

413
Page 9 to DVS 2207-11
414
Welding record sheet for heated tool butt welding of panels Material Sheet of

Building sponsor Executing company Welding device:

Order (description) Name of welder ID-number Manufacturer:


Page 10 to DVS 2207-11

Type:

Number of order Name and company of supervisor Number of machine:

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]

Signature of welder: Date and signature of supervisor:

From control-interval, frequence see chapt. 4.2.


R&D INTAKE MANIFOLDS

Values from manufacturer of welding machine or from machine-check.


Measured values.
Welding record sheet for electrofusion welding o above ground Material Page of

of pipes and fittings o underground

Building sponsor Executing company Welding device: Weather conditions Protection

1 = sun 1 = none

Order (description) Name of welder ID-number Manufacturer: 2 = dry 2 = umbrella

Type: 3 = rain or snow 3 = tent

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

Signature of welder: Date and signature of supervisor:

Values on agreement. A = Manufacturers sign B = Fitting identification


Measured values. 1 = Socket 2 = Elbow 3 = Tee 4 = Reducer
5 = Saddle 6 = Cap 7 = Transition piece

415
Page 11 to DVS 2207-11
416
Welding record sheet for heated tool socket welding o above ground Material Page of

of pipes and fittings o underground

Building sponsor Executing company Welding device: Weather conditions Protection

1 = sun 1 = none
Page 12 to DVS 2207-11

Order (description) Name of welder ID-number Manufacturer: 2 = dry 2 = umbrella

Type: 3 = rain or snow 3 = tent

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

Signature of welder: Date and signature of supervisor:

Values on agreement. A = Manufacturers sign B = Fitting identification


Measured values. 1 = Socket 2 = Elbow 3 = Tee 4 = Reducer
5 = Saddle 6 = Cap 7 = Transition piece
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-12\e2207-12.fm
Erstellt am: 15.10.2008
Zuletzt geändert am: 16.10.2008

January 2009

DVS – DEUTSCHER VERBAND Welding of thermoplastics


FÜR SCHWEISSEN UND Heated tool welding of pipes, piping parts Technical Code
VERWANDTE VERFAHREN E.V. and panels made of PVC-U DVS 2207-12

R&D INTAKE MANIFOLDS Translation of the German edition from December 2006

Contents: heated tool butt welding of panels as well as to pipeline


construction.
1 Scope of application
The machines and jigs used for the welding must comply with the
2 General requirements
requirements in DVS 2208-1.
3 Measures before the welding
3.1 Prerequisites for the welding
3.2 Cleaning 3 Measures before the welding
3.2.1Cleaning agents
3.2.2Cleaning of the heated tools 3.1 Prerequisites for the welding
3.2.3Cleaning of the joining faces
4 Heated tool butt welding of pipes, piping parts, fittings and The immediate welding area must be protected from
panels unfavourable weathering influences (e. g. wind or the action of
4.1 Process description moisture). If suitable measures (e. g. preheating, tenting or
4.2 Preparation for the welding heating) ensure conditions permissible for the welding, the work
may be carried out at any outdoor temperature – provided that
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

4.3 Execution of the welding


5 Testing of the welded joints the dexterity of the welder is not hindered (see the explanations).
6 Standards, technical codes and guidelines which are also If necessary, additional evidence must be provided by manufacturing
applicable trial welds in the specified conditions (see Section 5).
7 Explanations If the semi-finished product is heated non-uniformly due to solar
Appendix: Processing instructions (short versions) radiation, the temperatures must be equalised by covering the
Welding record sheets area of the welding point in good time. It is necessary to avoid
any draught-induced cooling during the welding operation. When
1 Scope of application pipes are welded, the pipe ends must be closed in addition.
The joining faces of the parts to be welded must not be damaged
This technical code applies to the heated tool butt welding of and must be free from contaminations (e. g. dirt, grease and
panels according to DIN EN ISO 1163-1 for the fabrication of chips).
tanks and construction elements as well as of pipes and fittings
which are made of PVC-U and serve to transport gases, liquids 3.2 Cleaning
and solids.
For the manufacture of flawless welded joints, it is decisively
Paying attention to the following instructions and on the basis of important that not only the joining faces but also the tools and the
the practical experience, it may be assumed that panels heated tools are clean and free from grease.
according to ISO 11833-1, Group 2 and DIN 16927 as well as
pipes and fittings according to DIN 8061 and DIN 8062 are 3.2.1 Cleaning agents
suitable. If necessary, reference may be made to the data sheets
of the suppliers of the semi-finished products – in cases of doubt, The cleaning fluid or cloths which have already been moistened
Works Certificate 2.1 according to DIN EN 10204. with it in the factory and are kept in a lockable plastic box must
consist of a solvent with 100 % vaporisation, e. g. of 99 parts
ethanol with a degree of purity of 99.8 % and one part MEK
2 General requirements (methyl ethyl ketone, denaturation). Agents tested according to
DVGW VP 603 comply with this stipulation. The use of spirit may
The quality of the welded joints is dependent on the qualification lead to a quality reduction because of the water contained in it.
of the welders, on the suitability of the utilised machines and jigs
The paper for the cleaning must be clean, unused, absorbent,
as well as on the compliance with the technical codes for
non-fraying and undyed.
welding. The weld can be tested using non-destructive and/or
destructive procedures.
3.2.2 Cleaning of the heated tools
The welding work must be monitored. The contracting parties The heated tools must be cleaned with a cleaning cloth or paper
must reach agreement on the type and scope of the monitoring. It
before every welding operation. No residues of cleaning agents
is recommended to document the process data on welding
or paper may remain on the heated tool. Ensure subsequent
record sheets (for a specimen, see the appendix) or on data
extraction.
carriers.
Within the framework of the quality assurance, it is recommended 3.2.3 Cleaning of the joining faces
to manufacture and test trial welds in the given working Before the chip-producing machining of the joining faces, it must
conditions before commencing and during the welding work.
be ensured that the utilised tools and the workpieces are clean
Every welder must be trained and must possess a valid and free from grease beyond the welding area. If necessary, the
qualification certificate. The planned area of application may cleaning must be carried out with a cleaning agent. Ensure
determine the type of the qualification. DVS 2212-1 applies to the subsequent extraction.

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.

DVS, Technical Committee, Working Group "Joining of Plastics"

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

R&D INTAKE MANIFOLDS


match in the joining region.
If the surface is soiled after the chip-producing machining (e. g.
because of contact with the welder's hands), the welding faces Pipes and fittings must be aligned axially before they are
must be treated with a cleaning agent if an additional chip- clamped in the welding machine. The easy longitudinal mobility
producing machining operation is not possible for process-related of the part to be welded on must be ensured, for example, using
reasons. adjustable dollies or a swinging suspension.
Immediately before the welding, the faces to be joined must be
subjected to chip-producing machining with a clean and grease-
4 Heated tool butt welding of pipes, piping parts, fittings free tool so that they have parallel faces in the clamped condition.
and panels The permissible gap widths under the alignment pressure are
shown in Table 1.
4.1 Process description
During heated tool butt welding, the faces of the parts to be Table 1. TMaximum gap widths between the machined welding
welded are aligned to the heated tool under pressure (alignment), faces.
are subsequently heated up to the welding temperature at a
reduced pressure (heating-up) and, when the heated tool has Pipe outside diameter d Gap width Panel width
been removed (changeover), are joined together under pressure mm mm mm
(joining). Figure 1 shows the principle of the process. ≤ 63 0.5 –
preparation > 63 ... ≤ 110 1.0 ≤ 1,500
> 110 ... ≤ 225 1.3 > 1,500 ≤ 2,000
> 225 ... ≤ 400 1.5 > 2,000 ≤ 2,300
– 2.0 > 2,300 ≤ 3,000

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.

4.3 Execution of the welding


Figure 1. Principle of heated tool butt welding using the example of In the case of heated tool butt welding, the faces to be joined are
pipes.
heated up to the welding temperature using a heated tool and,
when the heated tool has been removed, are joined together
4.2 Preparation for the welding under pressure. The heated tool temperature is 230 ± 8°C. The
The heated tool temperature necessary for the welding must be step-by-step sequence of the welding operation is illustrated on
checked before the beginning of the welding work. This is carried Figure 2.
out, for example, with a quick-display temperature gauge for
surface measurements with a contact area with an edge length of
approx. 10 mm. The control measurement must be taken within Pressure
the heated tool area corresponding to the semi-finished product.
So that a thermal equilibrium can occur, the heated tool may be Alignment pressure Joining pressure
used, at the earliest, ten minutes after the nominal temperature 0.60
has been reached.
For optimum welds, it is necessary to clean the heated tool Heating-up
according to Section 3.2.2 before every welding operation. The pressure
0.01
anti-adhesive coating or covering of the heated tool must be Time
Changeover time

undamaged in the working area.


The respective joining forces or joining pressures must be Heating-up time Cooling time
stipulated for the machines to be used. These may refer, for Alignment Joining pressure build-up time
example, to information from the manufacturer or to calculated or time
Total joining time
measured values. In the case of pipe welding, it is also necessary
to read the movement force or movement pressure arising during Total welding time
slow movement of the workpiece off the display instrument of the
welding machine and to add this to the previously determined
joining force or to the joining pressure. Preference should be Figure 2. Process steps in heated tool butt welding.

418
Page 3 to DVS 2207-12

Alignment A mechanical load on the joint is permissible, at the earliest, after


the end of the cooling process. For this purpose, the full joining
In this respect, the joining faces to be welded are pressed on to pressure must be maintained during the cooling time at the
the heated tool until the entire faces are in contact with the ambient temperature (see Table 2, Column 5).

R&D INTAKE MANIFOLDS


heated tool with parallel faces. This can be recognised by the
formation of the beads. The alignment is finished when the bead A uniform double bead must exist after the joining. The bead
heights around the entire pipe circumference or on the entire top formation provides orientation with regard to the uniformity of the
side of the panel have reached the values specified in Table 2, welds with each other. Different bead formations may be caused
Column 2. The bead heights are regarded as an indicator that the by the different types of flow behaviour of the joined materials.
whole area of the joining faces is in contact with the heated tool. On the basis of the experience with the commercially available
The alignment pressure of 0.60 N/mm² is effective throughout the semi-finished PVC-U products according to the standards, it may
alignment operation. be assumed that these are weldable even if this may lead to
asymmetric welding beads. K must always be > 0 (see Figure 3).
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 Figure 3. Bead formation in the case of heated tool butt welding
should be kept as short as possible (see Table 2, Column 4) (principle using the example of a pipe).
since the plastified faces would otherwise cool down. This would
exert a detrimental influence on the weld quality. For a short version of the processing instructions, see the appendix.
Joining
The faces to be welded should come into contact at a speed of 5 Testing of the welded joints
nearly zero. The required joining pressure is applied, if at all
possible, with a linear rise. The times necessary for this purpose Various test procedures are applied for the individual welding
are shown in Table 2, Column 5. The joining pressure is processes. A distinction is made between non-destructive and
0.60 ± 0.01 N/mm². The low melt viscosity demands exact control destructive test procedures. They are listed in Table 3.
of the joining pressure build-up in order to obtain a sufficient Depending on the agreement, checking and sampling operations
melting zone depth. should be carried out on a random basis during the welding work.

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

R&D INTAKE MANIFOLDS


DVS 2202-1 Defects in welded joints between thermoplastics
Visual DVS 2202-1, Table 1 – Characteristics, description and evaluation
inspection DVS 2203-1 Testing of welded joints between thermo-
Radiographic DVS 2206 applicable; plastics; test procedures – requirements
and ultrasonic Statement possible, for example, about voids, Supplement 1 Requirements in the tensile test
tests not about quality Supplement 2 Requirements in the tensile creep test
Tensile test DVS 2203-2; Supplement 3 Requirements in the technological bending test,
bending angle / bending path
Short-time tensile welding factor according to
DVS 2203-1, Supplement 1 DVS 2203-2 –, tensile test
DVS 2203-4 –, tensile creep test
Tensile creep DVS 2203-4;
test DVS 2203-5 –, technological bending test
Tensile creep welding factor according to
DVS 2206 Testing of components and structures made of
DVS 2203-1, Supplement 2
thermoplastics
Technological DVS 2203-5; DVS 2208-1 Welding of thermoplastics – Machines and
bending test Minimum bending angle according to devices for the heated tool butt welding of
DVS 2203-1, Supplement 3, Figs. 5 and 6 pipes, piping parts and panels
Minimum bending path according to DVS 2212-1 Qualification testing of plastics welders –
DVS 2203-1, Supplement 3, Figs. 11 and 12 Qualification Test Groups I and II
DVGW VP 603 Provisional test basis for cleaning agents and
Internal With reference to DIN 16963-5, Section their receptacles for the preparation of welded
pressure 5.4.3.1; length of each pipe piece according to joints between polyethylene pipes
creep test Table 6
Betr.Sich.V Operational Safety Ordinance
Testing temperature: 60°C, testing stress:
11.3 N/mm², creep rupture time: ≥ 200 hours
Not meaningful for long-time tensile welding 7 Explanations
factor > 0.5
The technical code was elaborated according to the state of the
art.
6 Standards, technical codes and guidelines which are
The welding of thermoplastics at ambient temperatures below
also applicable
5°C is generally considered to be problematical. This relates not
ISO 11833-1 Plastics – Panels made of unplasticised poly- so much to the material-specific properties of the plastic but, to a
vinyl chloride – Panels with a thickness greater greater extent, to the restricted dexterity of the welder. Therefore,
than 1 mm the prerequisite for open-air welding at any outdoor temperatures
is an environment which enables the welding personnel to
DIN EN ISO Plastics – Unplasticised polyvinyl chloride perform the individual work steps without any quality-reducing
1163-1 (PVC-U) moulding materials – Designation influences. In this respect, it is necessary to pay attention to the
system and basis for specifications information from the manufacturers and to the dew point curve.
DIN EN 10204 Metallic products – Types of test certificates The parts to be joined must exhibit an identical temperature level.
DIN 8061 Pipes made of unplasticised polyvinyl chloride – Trial welds must be produced and tested.
General quality requirements With regard to the condition of the pipe ends, it must be ensured
DIN 8062 Pipes made of unplasticised polyvinyl chloride – that, within the framework of the welding preparations, any white
Dimensions frost, ice and moisture are removed from the area of the joining
zone (≥ 0.5 x fitting length) by supplying heat (e. g. hot gas
DIN 16927 Panels made of unplasticised polyvinyl chloride
device). Fittings must be stored in closed, frost-free rooms and
– Technical terms of delivery
may only be transported to the welding location in the number
required in each case.

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.

1. R&D INTAKE MANIFOLDS


Processing instructions (short version)
Create permissible working conditions, e. g. welding tent.
16. Move the heated tool into the welding position.

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

Welder signature: Date and signature of welding supervisor:

From control-interval, frequency see section 4.2.


Values from manufacturer of welding machine or from machine-check.
Insert measured values.
Welding record sheet for the heated tool welding  above ground Material Page of

of pipes  underground

Constructor Executing company Welding device: Weather conditions: Protection mesures:

1 = sun 1 = none

Order description Name of welder ID-No. Manufacturer: 2 = dry 2 = umbrella

Type: 3 = rain or snow 3 = tent

No. of Order Name and company of welding supervisor Machine-No.: 4 = wind 4 = heating

Year built: If several Conditions apply, order of numbers as above


(e. g. 34 = rain and wind)

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

Welder signature: Date and signature of welding supervisor:

From control-interval, frequency see section 4.2.


Values from manufacturer of welding machine or from machine-check plus moving pressure.
Insert measured values.

423
Page 7 to DVS 2207-12
November 2012

DVS – DEUTSCHER VERBAND Welding of thermoplastics –


FÜR SCHWEISSEN UND Heated tool welding of pipes, piping parts Technical Code
VERWANDTE VERFAHREN E.V. and panels made of PVC-C DVS 2207-13
R&D INTAKE MANIFOLDS
Contents: The welding work must be monitored. The contracting parties
must reach agreement on the type and scope of the monitoring. It
1 Scope of application is recommended to document the process data on welding record
2 General requirements sheets (for specimens, see the appendix) or on data carriers.
3 Measures before the welding
Within the framework of the quality assurance, it is recommended
3.1 Prerequisites for the welding
to manufacture and test trial welds in the given working conditions
3.2 Cleaning
before commencing and during the welding work.
3.2.1 Cleaning agents
3.2.2 Cleaning of the heated tools Every welder must be trained and must possess a valid qualifica-
3.2.3 Cleaning of the joining faces tion certificate according to the DVS 2212-1 guideline for PVC-U
4 Heated tool butt welding in the WZ and WF processes as well as, at present, an HS pro-
4.1 Process description cess with another material (requirements for PVC-C are under
4.2 Preparation for the welding preparation). The planned area of application may determine the
4.3 Execution of the welding type of the qualification.
4.3.1 Heated tool temperature
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

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.

DVS, Technical Committee, Working Group "Joining of Plastics"

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.

3.2.2 Cleaning of the heated tools


R&D INTAKE MANIFOLDS face measurements. The control measurement must be taken in
the working area of the heated tool for the corresponding semi-
finished product. So that a thermal equilibrium can occur, the
The heated tools must be cleaned with cleaning cloths or paper heated tool may be utilised, at the earliest, ten minutes after the
before every welding operation. No residues of the cleaning agent nominal temperature has been reached. It is recommended to
or of the paper may remain on the heated tool. Ensure subsequent record the temperature measurement at several positions in the
extraction. heated tool area used for the welding operation concerned in order
to check the uniformity of the temperature distribution.
3.2.3 Cleaning of the joining faces In order to achieve optimum welds, it is necessary to clean the
Before the chip-producing machining of the joining faces, it must heated tool with absorbent, non-fraying and non-dyed paper before
be ensured that the utilised tools and the workpieces are clean every welding operation. The anti-adhesive coating or covering of
and free from grease beyond the welding area. If necessary, the the heated tool must be undamaged in the working area.
cleaning must be carried out with a cleaning agent. Ensure sub-
sequent extraction. The respective joining forces or joining pressures must be stipu-
lated for the machines to be utilised. These may refer, for example,
The joining faces must be machined immediately before the be- to information from the manufacturer or to calculated or measured
ginning of the welding. values. In the case of pipe welding, it is also necessary to read
Immediately before the welding, the faces to be joined must be the movement force or movement pressure arising during slow
subjected to chip-producing machining with a clean and grease- movement of the workpiece off the display instrument of the
free tool so that they have parallel faces in the clamped condition. welding machine and to add this to the previously determined
In the case of fresh saw cuts, it is not necessary to mechanically joining force or to the joining pressure.
clean the welding faces of panels. It is urgently advised not to In the joining area, the nominal wall thicknesses of the parts to be
perform any cleaning with chemical agents or solvents. welded must be within the tolerances in DIN EN ISO 15013 for
Any chips which may be present must be removed without touch- plates and in DIN 8079 or DIN EN ISO 15493 for pipes.
ing the joining faces.
Pipes and fittings must be aligned axially before they are clamped
in the welding machine. The easy longitudinal mobility of the part
4 Heated tool butt welding to be welded on must be ensured, for example, using adjustable
dollies or a swinging suspension.
4.1 Process description The permissible gap widths a of the parts to be joined before the
In the case of heated tool butt welding, the joining faces of the alignment are shown in Table 1.
parts to be welded are aligned at the heated tool under pressure
(alignment), are subsequently heated at a reduced pressure Table 1. Maximum gap widths between the machined welding faces.
(heating-up) and, when the heated tool has been removed
(changeover), are joined under pressure (joining). Fig. 1 shows Panel width Pipe diameter Da Gap width
[mm] [mm] [mm]
the principle of the process.
–  63 0.25
All the welds must be executed with machines and devices which
satisfy the requirements according to the DVS 2208-1 technical  1,500 > 63 to  110 0.50
code. > 1,500 to  2,000 > 110 to  225 0.70
> 2,000 to  2,300 > 225 to  400 0.80
Preparation > 2,300 to  3,000 1.00

The misalignment must be checked at the same time as the gap


width. The misalignment of the joining faces in relation to each
other must not exceed the permissible dimension of 0.1 x wall
Pipe Pipe thickness s on the outside of the pipe or on the panel. If the mis-
Heated tool alignment is > 0.1 x s, this results in a distinct quality reduction
which substantially restricts the load-bearing capacity of the welded
joint due to the notch sensitivity of the PVC-C. In this case, an
Heating-up evaluation should be carried out according to the DVS 2202-1
technical code taking account of the requirements on the welded
joint and of the structure.
The machined welding faces must not be either soiled or touched
by the welder's hands since another cleaning operation according
Bead caused by the heating-up
to Section 3.2.3 would otherwise be necessary.
If piping parts are welded, it must be ensured that any chips
Welded joint which have fallen into the pipe are removed after the planing opera-
tion without soiling the welding faces.

4.3 Execution of the welding

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

Alignment time Heating-up time Cooling time

Changeover time Joining pressure build-up time

Figure 2. Process steps in the case of heated tool butt welding.

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

R&D INTAKE MANIFOLDS


Nominal wall Alignment Heating-up Changeover Joining
thickness s
Bead height Pressure nearly Joining pressure Cooling time
(at the heated tool at the end zero, build-up time = 2 x wall thickness
of the alignment time) p = 0.01 N/mm² under joining pressure
(minimum pressure for the p = 0.50 N/mm² ± 0.01 N/mm²
alignment: (minimum values)
p = 0.50 N/mm² ± 0.01 N/mm²)
[mm] [mm] [s] [s] [min]
2 28 4
3 0.5 42 6
4 56 8
6 86 12
8 1.0 122 16
2s 4
10 168 20
12 222 24
15 294 30
1.5
20 392 40
25 490 50

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

DIN EN ISO Plastics – Panels made of unplasticised poly-


11833 vinyl chloride – Types, dimensions and proper-
ties
DIN EN ISO Plastics – Extruded panels made of polypro-
15013 pylene (PP) – Requirements and testing
Figure 4. Bead formation in the case of heated tool butt welding, K must DIN EN ISO Plastic piping systems for industrial applica-
always be greater than zero (principle using the example of a 15493 tions – Acrylonitrile butadiene styrene (ABS),
pipe weld). unplasticised polyvinyl chloride (PVC-U) and
chlorinated polyvinyl chloride (PVC-C) – Re-
quirements on piping parts and the piping
5 Testing of the welded joints system; metric series
DIN EN ISO Plastic piping systems for hot and cold water
Various test procedures are applied for the individual welding plumbing – Chlorinated polyvinyl chloride
15877
processes. A distinction is made between non-destructive and (PVC-C)
destructive test procedures. They are listed in Table 3. Depend-
ing on the agreement, testing and sampling operations should be DIN 8079 Pipes made of chlorinated polyvinyl chloride
carried out on a random basis during the welding work. (PVC-C) – Dimensions

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

R&D INTAKE MANIFOLDS


chloride) (PVC) compounds and chlorinated current generator and check its function.
poly(vinyl chloride) (CPVC) compounds
3. Align and clamp the parts to be welded, e.g. with dollies.
DVS 2202-1 Defects in welded joints between thermoplas-
tics; characteristics, description and evalua- 4. At the opposite pipe ends, close the pipes to be welded
technical code against draughts.
tion
DVS 2203-1 Testing of welded joints between thermoplas- 5. Machine the joining faces, in the case of pipes using a plane
tics; test procedures – requirements (for example). It is urgently advised not to use any chemical
technical code
cleaning agents or solvents.
DVS 2203-2 Testing of welded joints between thermoplas-
tics; tensile test 6. Take out the plane in the case of a pipe welding machine.
technical code
Testing of welded joints between thermoplas- 7. Remove the chips from the welding area without touching the
DVS 2203-4 welding faces (clean, grease-free brooms, paintbrushes, paper
technical code tics; tensile creep test
cloths or dry, oil-free compressed air).
DVS 2203-5 Testing of welded joints between thermoplas-
8. Check that the joining faces are parallel by moving them
technical code tics; technological bending test
together (max. gap width according to Table 1).
DVS 2205-1 Calculation of tanks and apparatus made of 9. Check the misalignment (max. 0.1 x wall thickness).
technical code, thermoplastics – Reduction coefficients A1
for moulding materials made of PVC-C 10. Check the heated tool temperature (e.g. 230 ± 4°C).
Supplement 9
Calculation of tanks and apparatus made of 11. Clean the heated tool with absorbent, non-fraying and non-
DVS 2205-1 dyed paper.
technical code, thermoplastics – Creep curves for pipes
Supplement 11 made of PVC-C 12. Read the movement pressure or the movement force off the
pipe welding machine and make a note of it on the welding
DVS 2206-1 Non-destructive testing of tanks, apparatus record sheet.
technical code and piping made of thermoplastics; dimen-
sional checking and visual inspection 13. Stipulate the setting values for the alignment, heating-up and
joining pressures.
DVS 2208-1 Welding of thermoplastics – Machines and
technical code devices for the heated tool welding of pipes, 14. Calculate the guide values (heating-up and cooling times)
piping parts and panels according to Table 2.
DVS 2212-1 Qualification testing of plastics welders; 15. Move the heated tool into the welding position.
guideline Qualification Test Groups I and II
16. Align the faces to the heated tool at a pressure of 0.50 N/mm²
BetrSichV Operational safety ordinance until a bead arises (according to Table 2, Column 2).
DVGW VP 603 Cleaning agents for welded joints between PE 17. Heating-up at a reduced pressure < 0.01 N/mm², heating-up
pipes in the gas and water sectors time according to Table 2, Column 3.
18. At the end of the heating-up, detach the joining faces to be
welded from the heated tool and remove this from the
7 Explanation welding plane.

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

Title of the order Name of the welder Code no. Make:

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]

Signature of the welder: Date and signature of the welding supervisor:


R&D INTAKE MANIFOLDS

1) From the control interval, frequency according to Section 4.2.


2) According to information from the manufacturer of the welding machine or from the machine test.
3) The measured values must be entered.

429
430
Record sheet for the heated tool butt welding  Overground Material Sheet of

of piping parts  Underground


Building owner Executing company Welding machine: Weather Protective measures

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 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

Signature of the welder: Date and signature of the welding supervisor:

1) From the control interval, frequency according to Section 4.2.


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.
Page 7 to DVS 2207-13
April 2009

DVS – DEUTSCHER VERBAND Welding of thermoplastics –


FÜR SCHWEISSEN UND Welding by bending using a heated tool Technical Code
VERWANDTE VERFAHREN E.V. for panels made of PP and PE DVS 2207-14

R&D INTAKE MANIFOLDS


Contents: panel to be folded at an angle is put on a flat, thermally insulating
support and the wedge-shaped heated tool is placed on the fold-
1 Scope of application ing position (see Fig. 1).
2 Process description
3 General requirements Heated tool
4 Measures before the welding
4.1 Prerequisites for the welding
4.2 Cleaning
4.2.1 Cleaning agents
4.2.2 Cleaning of the heated tool
4.2.3 Cleaning of the folding zone
4.3 Checking of the heated tool temperature
5 Execution of the welding
5.1 Alignment
5.2 Heating-up
5.3 Changeover and joining
Figure 1. Welding by bending using a heated tool with heating on one
5.4 Cooling
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

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

This technical code applies to welding by bending using a heated


tool for panels made of polypropylene1) (PP-H, PP-B and PP-R)
according to DIN EN ISO 15013 and for panels made of PE1)
according to DIN EN ISO 14632.
Paying attention to the instructions in this technical code, weld-
ability may be assumed within the melt flow rates MFR2) 190/5
named below:
1 0.4 –1.0 g/10 min (PP) – approximately corresponds to the
melt flow rate MFR2) 230/2.16 of 0.2 – 0.6 g/10 min
2 0.3 –1.7 g/10 min or 0.2 – 0.7 g/10 min (PE)
The main areas of application for welding by bending using a Lower
heated tool are in tank and apparatus construction as well as in heated tool
ventilation and air conditioning technology. DVS 2207-1 and
DVS 2207-11 are technical codes which are also applicable. Figure 2. Welding by bending using a heated tool with heating on both
sides (principle).

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.

DVS, Technical Committee, Working Group "Joining of Plastics"

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

R&D INTAKE MANIFOLDS


In order to be able to apply the joining pressure, the bevel angle receptacle (e.g. plastic box). In so far as paper is utilised for the
of the heated tool must be smaller than the folding angle. A bevel cleaning, this must be clean, unused, absorbent, non-fraying and
angle of α = 87° ± 1° is recommended for rectangular folds and undyed. Ensure subsequent extraction.
α = 57° ± 1° for folds of 60°. After the folding, the panel must be
The use of spirit may lead to a quality reduction in the welded
fixed for the duration of the cooling time.
joint because of the water contained in it.
The process can be applied accordingly to the PVDF material.
Panels made of PVC-U and PVC-C are predominantly heated 4.2.2 Cleaning of the heated tool
and bent without any contact.
For optimum fold welds, it is necessary to clean the heated tool
according to Section 4.2.1 before every welding operation, partic-
ularly if the material is changed. No residues of cleaning agents
3 General requirements or paper may remain on the heated tool. The anti-adhesive coat-
ing or covering of the heated tool must be undamaged in the
The quality of the welds is influenced by the qualification of the working area.
welder, by the suitability of the utilised machines and jigs as well
as by the process parameters. The quality of welds executed by 4.2.3 Cleaning of the folding zone
bending using a heated tool can be investigated with the aid of
destructive test procedures. The folding zone must be cleaned immediately before the weld-
ing. The cleaning must be carried out beyond the welding area
The welding work must be monitored. The contracting parties with a cleaning agent according to Section 4.2.1. If the folding
must reach agreement on the type and scope of the monitoring. zone is soiled once again (e.g. because of contact with the weld-
Within the framework of the quality assurance, it is appropriate to er's hands), the area concerned must be recleaned.
have trial welds manufactured before the beginning and during
the welding work and to test these. The process data of the weld- 4.3 Checking of the heated tool temperature
ing work must be entered on welding record sheets without delay
(for a specimen, see the appendix) or must be documented on The heated tool temperature necessary for the welding must be
data carriers. checked before the beginning of the welding work. This is carried
out, for example, with a quick-display temperature gauge for sur-
The welders must be trained and must possess a valid qualifica- face measurements whose sensor exhibits a contact area
tion certificate. The type and scope of the qualification are deter- > 10 mm. The control measurement must be taken at the bevels
mined by the area of application in which the welder is active. in the case of the upper heated tool and on the front face of the
Welding by bending using a heated tool is assigned to the heated lower heated tool. So that a thermal equilibrium can occur, the
tool butt welding of panels to which the plastics welder qualifica- heated tool may be used, at the earliest, ten minutes after the
tion test according to DVS 2212-1 applies. nominal temperature has been reached.
The machines and jigs used for the welding must comply with the
requirements in DVS 2208-1. Requirements extending beyond Table 1. Heated tool temperature.
these are described in this technical code.
PE-HD PP

4 Measures before the welding Upper heated tool1) 210 ± 10 °C


Lower heated tool2) ∼ 130 °C ∼ 140 °C
4.1 Prerequisites for the welding
1) In the case of low wall thicknesses and PE 100, choose the higher
The folding area must be undamaged and must be protected temperature.
from unfavourable ambient influences such as cold, draughts, the
2) Dependent on the design of the machine. Preliminary tests are
action of moisture and similar influences. If suitable measures advisable. It must be possible to bend the panel without any great
(e.g. protected workplace and drying of the folding zone) ensure resistance.
conditions permissible for the welding, the work may be carried
out at any ambient temperature – provided that the dexterity of
the welder is not hindered. If necessary, additional evidence must
be provided by manufacturing trial welds under the ambient influ- 5 Execution of the welding
ences to be expected (see Section 8).
5.1 Alignment
If the panel to be folded was heated non-uniformly due to solar
radiation, the temperatures must be equalised in the area of the At the beginning of the welding operation, the folding zone is
folding zone in good time before the welding. It is necessary to heated up to the welding temperature using the upper heated tool
avoid any abrupt cooling during the welding operation, e.g. due to in the case of heating on one side or using two heated tools in the
draughts. case of heating on both sides. Pressure or the dead weight of the
upper heated tool results in a wedge-shaped recess in the panel.
This is designated as alignment. The alignment operation is
4.2 Cleaning
concluded when the heated tool has penetrated into the panel by
For the manufacture of flawless welded joints, it is essentially 0.7 x wall thickness (see Fig. 1 and Fig. 2).
important that not only the folding zone but also the tools and the
heated tools are clean and free from grease. Wherever neces- 5.2 Heating-up
sary, the zones affected by soiling must be cleaned using a suita-
When the penetration depth has been reached, the joining zone
ble cleaning agent.
is heated up on both sides of the heated tool in order to plastify
the joining faces. Guide values for the heating-up times, depend-
4.2.1 Cleaning agents
ing on the nominal wall thickness of the panel, are included in
The cleaning agent, a cleaning fluid is most suitable, must DVS 2207-1, Table 2, Column 3 for PE and in DVS 2207-11,
consist of a solvent with 100 % vaporisation, e.g. of 99 parts Table 2, Column 3 for PP. Optimum results are obtained when
ethanol with a degree of purity of 99.8 % and one part MEK these heating-up times are shortened by 20 %.

432
Page 3 to DVS 2207-14

5.3 Changeover and joining


After the heating-up, the heated tool must be taken or swivelled
out without damaging or soiling the plastified joining faces. The
folding operation must be carried out immediately thereafter Clamp

R&D INTAKE MANIFOLDS


since the plastified joining faces may otherwise cool down.
The changeover time (the time between the detachment of the
heated tool from the joining faces and the end of the folding oper-
ation) influences the quality and load-bearing capacity of the
welded joint. Guide values for the changeover times are included
in DVS 2207-1, Table 2, Column 4 for PE and in DVS 2207-11, Steel T section
Table 2, Column 4 for PP.

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

Figure 4. Testing of welds executed by bending using a heated tool


(principle).

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.

The evaluation may only be made by correspondingly trained


6 Testing of the welded joints specialist personnel. The results must be summarised in a test
report. If the test results are diffuse, the test must be repeated. If
necessary, additional test procedures must be used.
No special test procedures are available for the testing of welds
executed by bending using a heated tool. It is therefore recom-
mended to perform the testing with reference to DVS 2207-25.
Depending on the agreement, checking and sampling operations 7 Literature
should be carried out on a random basis during the welding work.
DIN EN ISO 1872-1 Polyethylene moulding materials, designa-
tion systems and basis for specifications
6.1 Specimen preparation
DIN EN ISO 14632 Extruded panels made of polyethylene
At least six uniformly distributed specimens must be taken from a (PE-HD); requirements and test proce-
weld executed by bending using a heated tool and must be dures
prepared according to the information on Fig. 4. The legs of the DIN EN ISO 15013 Extruded panels made of polypropylene
angular test specimen are trimmed to a length of 7 x wall thick- (PP); requirements and test procedures
ness with a suitable tool and the edges are broken with a scraper
(see Fig. 4). The width of the specimens [b] should comply with DVGW VP 603 Test basis for cleaning agents and their
DVS 2203-5, Table 1. receptacles for the preparation of welded
joints between polyethylene pipes
6.2 Execution of the testing DVS 2202-1 Defects in welded joints between thermo-
plastics; characteristics, description and
A jig according to Fig. 4 must be used for executing the test. The assessment
testing speeds are 50 mm/min for specimens made of PE and DVS 2203-5 Testing of welded joints between panels
PP-R and 20 mm/min for specimens made of PP-H and PP-B. and pipes made of thermoplastics; techno-
The tests relate to the deformation behaviour of the joint until an logical bending test
incipient crack or a fracture arises in the joining plane. If neces-
sary, the specimen can be deformed until the bead comes into DVS 2207-1 Welding of thermoplastics; heated tool
contact with the support (polished steel plate) without the occur- welding of pipes, piping parts and panels
rence of any incipient cracks or fractures. made of PE-HD
DVS 2207-11 Welding of thermoplastics; heated tool
welding of pipes, piping parts and panels
made of PP

433
Page 4 to DVS 2207-14

DVS 2207-25 Welding of thermoplastics; heated tool 8 Explanations


welding of window sections made of PVC-U
DVS 2208-1 Welding of thermoplastics; machines and The technical code corresponds to the current state of the art.
devices for the heated tool welding of The recommendations must be varied according to the machine

R&D INTAKE MANIFOLDS


pipes, piping parts and panels design.
DVS 2212-1 Qualification testing of plastics welders; The welding of thermoplastics at ambient temperatures < 5°C is
Qualification Test Groups I and II generally considered to be problematical. This relates not so
much to the material-specific properties of the plastic but, to a
Betr.Sich.V Operational Safety Ordinance greater extent, to the restricted dexterity of the welder. In this
respect, it is necessary to pay attention to the information from
the manufacturers and to the dew point curve. Trial welds must
be produced and tested if necessary.

434
Material Sheet of
Record sheet for welding by bending using a heated tool for panels
Building owner Executing company Welding machine

Title of the order Name of the welder Code no. Make

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]

Signature of the welder: Date and signature of the welding supervisor:


R&D INTAKE MANIFOLDS

1) From the control interval


2) According to information from the manufacturer of the welding machine or from the machine test
3) The measured values must be entered
4) Not possible with all machines
Page 5 to DVS 2207-14

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

DVS – DEUTSCHER VERBAND Welding of thermoplastics


FÜR SCHWEISSEN UND Heated tool welding of pipes, Technical Code
VERWANDTE VERFAHREN E.V. piping parts and panels made of PVDF DVS 2207-15

R&D INTAKE MANIFOLDS Translation of the German version from december 2005

Contents: is recommended to document the process data in welding record


sheets (for specimen, see appendix) or on data carriers.
1 Scope of application Within the framework of the quality assurance, it is recommended
2 General requirements to manufacture and test trial welds in the given working
3 Measures before the welding conditions before commencing and during the welding work.
3.1 Prerequisites for the welding
3.2 Cleaning Every welder must be trained and must possess a valid
3.2.1 Cleaning agents qualification certificate. The planned area of application may
3.2.2 Cleaning of the heated tools determine the type of the qualification. DVS 2212-1 applies to the
3.2.3 Cleaning of the joining faces heated tool butt welding of panels as well as to pipeline
4 Heated tool butt welding of pipes, piping parts, fittings and construction. A supplementary certificate of proficiency must be
panels provided for pipes with an outside diameter > 225 mm as well as
4.1 Process description for heated tool sleeve welding.
4.2 Preparation for the welding
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

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.

3.2.1 Cleaning agents


2 General requirements The cleaning fluid or cloths which have already been moistened
with it in the factory and are kept in a lockable plastic box must
The quality of the welded joints is dependent on the qualification consist of a solvent with 100 % vaporisation, e. g. of 99 parts
of the welders, on the suitability of the utilised machines and jigs ethanol with a degree of purity of 99.8 % and one part MEK
as well as on the compliance with the technical codes for (methyl ethyl ketone, denaturation). Agents tested according to
welding. The weld can be tested using non-destructive and/or DVGW VP 603 comply with this stipulation. The use of spirit may
destructive procedures. lead to a quality reduction because of the water contained in it.
The welding work must be monitored. The contracting parties The paper for the cleaning must be clean, unused, absorbent,
must reach agreement on the type and scope of the monitoring. It non-fraying and undyed. Ensure subsequent extraction.

old designation for melt index: 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.

DVS, Technical Committee, Working Group “Joining of Plastics”

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

R&D INTAKE MANIFOLDS


remain on the heated tool. clamped in the welding machine. The easy longitudinal mobility
of the part to be welded on must be ensured, for example, using
3.2.3 Cleaning of the joining faces adjustable dollies or a swinging suspension.
Before the chip-producing machining of the joining faces, it must Immediately before the welding, the faces to be joined must be
be ensured that the utilised tools and the workpieces are clean subjected to chip-producing machining with a clean and grease-
and free from grease beyond the welding area. If necessary, the free tool so that they have parallel faces in the clamped condition.
cleaning must be carried out with a cleaning agent. The permissible gap widths under the alignment pressure are
The joining faces must be machined immediately before the shown in Table 1.
beginning of the welding.
Any chips must be removed without touching the joining faces. Table 1. Maximum gap widths between the machined welding faces.

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.

4.3 Execution of the welding


Figure 1.
Principle of heated tool In the case of heated tool butt welding, the faces to be joined are
butt welding using the heated up to the welding temperature using a heated tool and,
example of pipes. when the heated tool has been removed, are joined together
under pressure. The heated tool temperature is 240 8°C. The
4.2 Preparation for the welding step-by-step sequence of the welding operation is illustrated on
Fig. 2.
The heated tool temperature necessary for the welding must be
checked before the beginning of the welding work. This is carried
out, for example, with a quick-display temperature gauge for
surface measurements with a contact area of approx. 10 mm.
The control measurement must be taken within the heated tool
area corresponding to the semi-finished product. So that a
thermal equilibrium can occur, the heated tool may be used, at
the earliest, ten minutes after the nominal temperature has been
reached.
For optimum welds, it is necessary to clean the heated tool
according to Section 3.2.2 before every welding operation. The
anti-adhesive coating or covering of the heated tool must be
undamaged in the working area.
The respective joining forces or joining pressures must be
stipulated for the machines to be used. These may refer, for
example, to information from the manufacturer or to calculated or
measured values. In the case of pipe welding, it is also necessary
to read the movement force or movement pressure arising during
Figure 2. Process steps in heated tool butt welding.
slow movement of the workpiece off the display instrument of the
welding machine and to add this to the previously determined
Alignment
joining force or to the joining pressure. Preference should be
given to electronically controlled machines – if at all possible, In this respect, the joining faces to be welded are pressed on to
with recording. the heated tool until the entire faces are in contact with the

437
Page 3 to DVS 2207-15

heated tool with parallel faces. This can be recognised by the


formation of the beads. The alignment is finished when the bead
heights around the entire pipe circumference or on the entire top
side of the panel have reached the values specified in Table 2,

R&D INTAKE MANIFOLDS


Column 2. The bead heights are regarded as an indicator that the
whole area of the joining faces is in contact with the heated tool.
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. Figure 3. Bead formation in the case of heated tool butt welding (principle
using the example of a pipe).
Changeover
After the heating-up, the joining faces must be detached from the
heated tool which must be taken out without damaging or soiling 5 Heated tool sleeve welding
the heated joining faces. The joining faces must then be moved
together quickly until they almost touch. The changeover time 5.1 Process description
should be kept as short as possible (see Table 2, Column 4)
In the case of heated tool sleeve welding (see Fig. 4), the pipe
since the plastified faces would otherwise cool down. This would
and the fitting are welded in an overlap. The pipe end and the
exert a detrimental influence on the weld quality.
fitting are heated up to the welding temperature with the aid of
Joining sleeve-shaped and spigot-shaped heated tools and are
The faces to be welded should come into contact at a speed of subsequently welded.
nearly zero. The required joining pressure is applied, if at all
possible, with a linear rise. The times necessary for this purpose
are shown in Table 2, Column 5. The joining pressure is
0.10 ± 0.01 N/mm². The low melt viscosity demands exact control
of the joining pressure build-up in order to obtain a sufficient
melting zone depth.
A mechanical load on the joint is permissible, at the earliest, after
the end of the cooling process. For this purpose, the full joining
pressure must be maintained during the cooling time at the
ambient temperature (see Table 2, Column 5).
A uniform double bead must exist after the joining. The bead
formation gives an orientation about the uniformity of the welds in
relation to each other. Different bead formations may be caused
by various types of flow behaviour of the joined materials. The
weldability may be assumed from the experience with the
commercially available semi-finished PVDF products in the
specified MFR range, even if this may lead to asymmetric
welding beads. K must always be > 0 (see Fig. 3).
For a short version of the processing instructions, see the
appendix. Figure 4. Heated tool sleeve welding (principle).

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

3.5 ... 5.5 0.5 75 ... 95 3 4 ... 5 6 ... 8.5

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

R&D INTAKE MANIFOLDS


set stop in the case of machine welding or as far as the mark in
from 50 mm, the level of the joining force necessitates the use of
the case of manual welding and are fixed. It is imperative to
a welding jig.
prevent the front face of the pipe from bumping into the end
of the heated bush. The heating-up time according to the time
5.2 Welding jigs indicated in Table 4, Column 3 begins thereafter.
The heated tools are heated electrically and are coated anti- When the heating-up time has elapsed, the fitting and the pipe
adhesively. must be pulled off the heated tools with a jolt and must be pushed
together immediately as far as the stop or the mark without any
5.3 Preparation for the welding twisting (max. changeover time: see Table 4, Column 4).
The fitting must be cleaned on the inside and the pipe on the In the case of manual welding, the joined parts must be kept in a
outside according to Section 3.2. The joining faces of the parts to fixed position according to the time indicated in Table 4, Column
be welded must be machined immediately before the beginning 5. The joint may only be subjected to the stresses of the further
of the welding. The pipe end must be bevelled according to Fig. 5 laying work when the cooling time (Table 4, Column 6) has
and Table 3. The joining face of the pipe must be machined elapsed.
according to the information from the fitting supplier. In the case
of manual welds, the insert depth must then be marked on the For a short version of the processing instructions, see the
pipe end at the distance I according to Table 3. appendix.

6 Testing of the welded joints

Various test procedures are applied for the individual welding


processes. A distinction is made between non-destructive and
destructive test procedures. They are listed in Table 5.
Depending on the agreement, checking and sampling operations
should be carried out on a random basis during the welding work.

7 Standards and technical codes which are also applicable

ISO 10931 Plastics piping systems for industrial applica-


tions – Polyvinylidene fluorides (PVDF)
Figure 5. Bevelling of the pipe end. DIN EN 10931, Plastics piping systems for industrial applica-
draft tions – Polyvinylidene fluorides – Require-
Table 3. Dimensions for the pipe bevel and the insert depth. ments on piping parts and the piping system
DIN EN 10204 Metallic products – Types of test certificates
Pipe outside diameter d Pipe bevel b Insert depth l
[mm] [mm] [mm] DIN EN 12814-4 Testing of welded joints between thermoplas-
tics – Part 4: Peeling test
16 13 DVS 2202-1 Defects in welded joints between thermoplas-
20 14 tics- Characteristics, description and evalua-
tion
25 16
2 DVS 2203-1 Testing of welded joints between panels and
32 18 pipes made of thermoplastics – Test proce-
dures – Requirements
40 20
Supplement 1 Requirements in the tensile test
50 23 Supplement 2 Requirements in the tensile creep test
63 27 Supplement 3 Requirements in the technological bending
test – Bending angle / bending path
75 31
3 -2 - Tensile test
90 35
-4 - Tensile creep test
110 41 -4, - Tensile creep test – Testing of sleeve-weld-
Supplement 1 ed joints between pipes
Before the beginning of the welding, the welding temperature of -5 Technological bending test
250 - 270°C at the heated tools must be checked according to DVS 2208-1 Welding of thermoplastics – Machines and
Section 4.2. devices for the heated tool butt welding of
The heated bush and the heated spigot must be free from pipes, piping parts and panels
contaminations and must be cleaned according to Section 3.2.2 DVS 2212-1 Qualification testing of plastics welders –
before every welding operation. The anti-adhesive coating of the Qualification Test Groups I and II
heated spigot and the heated bush must be undamaged in the DVGW VP 603 Provisional test basis for cleaning agents and
welding area. their receptacles for the preparation of welded
joints between polyethylene pipes
BetrSichV Operational Safety Ordinance

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

R&D INTAKE MANIFOLDS


Pipe outside Pipe wall Heating-up Changeover Cooling
diameter d thickness min. Heated tool temperature 250 - 270°C Changeover time Cooling time
Heating-up time (maximum time)
Fixed Total
[s] [min]
[mm] [mm] [s] [s]
16 1.5 4
20 6 6 2
1.9
25 8
4
32 10
2.4
40 12 12 4
50 18
63 20
75 3 22 18 6
6
90 25
110 30 24 8

Table 5. Test procedures for welded joints.

Test procedure Heated tool butt welding Heated tool sleeve welding
Panels, pipes and fittings Pipes and fittings

Visual inspection DVS 2202-1, Table 1 DVS 2202-1, Table 2

Radiographic Applicable
and ultrasonic tests Statement possible, for example, about voids, not about quality

Tensile test DVS 2203-2 Not applicable


Short-time tensile welding factor
DVS 2203-1, Supplement 1

Tensile creep test DVS 2203-4 DVS 2203-4, Supplement 1


Tensile creep rupture
welding factor
DVS 2203-1, Supplement 2

Technological DVS 2203-5 Not applicable


bending test Minimum bending angle according
to DVS 2203-1, Supplement 3, Fig. 4
Minimum bending path according
to DVS 2203-1, Supplement 3, Fig. 10

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

Torsion shear test Not applicable See appendix


Also as a site test for pipe wall thicknesses ≥ 3 mm

Radial Not applicable See appendix


peeling test Also as a site test for pipe wall thicknesses ≥ 3 mm

ompression test Not applicable DIN EN 12814-4, Section 8


Also suitable as a site test

8 Explanations Trial welds must be produced and tested.

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.

R&D INTAKE MANIFOLDS


3. Align and clamp the parts to be welded, e. g. with dollies. 8. Comply with the heating-up time according to Table 4, Col-
4. Close the pipe ends against draughts. umn 3.

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.

Separation behaviour Appearance and characteristics Evaluation

High separating forces, tough fracture, over 80 % Extremely structured fracture pattern with plastic deformation and stretching No or slight defects

R&D INTAKE MANIFOLDS


of the welding face (ductile)

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.

Figure 8. Force introduction during the radial peeling test.

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

Title of the order Name of the welder Code no. Make:

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

[mm] [ C] [ C] [bar] [bar] [bar] [s] [s] [s] [min] [ C]

Signature of the welder: Date and signature of the welding supervisor:


R&D INTAKE MANIFOLDS

From the control interval, frequency according to Section.


According to information from the manufacture of the welding machine or from the machine test.
The measured values must be entered.

443
444
Record sheet for the heated tool butt welding  Overground Material Sheet Of

of piping parts  Underground

Building owner Executing company Welding machine:

Weathering: Protective measures:

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

(e. g. 34 = rain and wind)

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

Signature of the welder: Date and signature of the welding supervisor:

From the control interval, frequency according to Section.


According to information from the manufacture of the welding machine or from the machine test plus movement pressure or force.
The measured values must be entered.
Page 9 to DVS 2207-15
Record sheet for the heated tool sleeve  Overground Material Sheet Of

welding of piping parts  Underground

Building owner Executing company Welding machine:

Weathering: Protective measures:

1 = Sunny 1 = None
Page 10 to DVS 2207-15

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 Machine no.:
supervisor 4 = Wind 4 = Heating
Year of construction:
In the case of multiple designations, sequence of the numbers as above

(e. g. 34 = rain and wind)

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

[mm] [ C] [ C] [s] [s] [s] [min] [ C]

Signature of the welder: Date and signature of the welding supervisor:


R&D INTAKE MANIFOLDS

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

DVS – DEUTSCHER VERBAND Welding of thermoplastics


FÜR SCHWEISSEN UND Heated tool welding of pipes and piping parts Technical Code
VERWANDTE VERFAHREN E.V. made of Polyamide 12 DVS 2207-16

R&D INTAKE MANIFOLDS


Contents: Every welder must be trained and must possess a valid qualifica-
tion certificate. The planned area of application may determine
1 Scope of application the type of the qualification. DVS 2212-1 applies to heated tool
2 General requirements butt welding and sleeve welding with an incorporated heating
3 Measures before the welding element in pipeline construction.
3.1 Prerequisites for the welding
3.2 Cleaning The machines and jigs used for the welding must comply with the
3.2.1 Cleaning agents requirements in DVS 2208-1.
3.2.2 Cleaning of the heated tools
3.2.3 Cleaning of the joining faces
4 Heated tool butt welding
4.1 Heated tool butt welding of pipes, piping parts and fittings 3 Measures before the welding
4.1.1 Process description
4.1.2 Preparation for the welding 3.1 Prerequisites for the welding
4.1.3 Execution of the welding
5 Sleeve welding with an incorporated heating element The immediate welding area must be protected from unfavourable
weathering influences (e. g. wind or the action of moisture). If
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

5.1 Process description


5.2 Welding device suitable measures (e. g. preheating, tenting or heating) ensure
5.3 Preparation for the welding conditions permissible for the welding, the work may be carried
5.4 Execution of the welding out at any outdoor temperature – provided that the dexterity of
6 Testing of the welded joints the welder is not hindered (see the explanations). If necessary,
7 Standards, technical codes and guidelines which are also additional evidence must be provided by manufacturing trial
applicable welds in the specified conditions (see Table 2).
8 Explanations
Appendix: If the semi-finished product is heated non-uniformly due to solar
Processing instructions (short versions) radiation, the temperatures must be equalised by covering the
Welding record sheets area of the welding point in good time. It is necessary to avoid
any cooling during the welding operation, e. g. due to draughts.
When pipes are welded, the pipe ends must be closed in addi-
1 Scope of application tion.

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

2 General requirements For the manufacture of flawless welded joints, it is decisively


important that not only the joining faces but also the tools and the
The quality of the welded joints is dependent on the qualification heated tools are clean and free from grease.
of the welders, on the suitability of the utilised machines and jigs
as well as on the compliance with the technical codes and the 3.2.1 Cleaning agents
guidelines for the welding. The weld can be tested using non-
destructive and/or destructive procedures. The cleaning fluid or cloths which have already been moistened
The welding work must be monitored. The contracting parties with it in the factory and are kept in a lockable plastic box must
must reach agreement on the type and scope of the monitoring. It consist of a solvent with 100% vaporisation, e. g. of 99 parts
is recommended to document the process data on welding ethanol with a degree of purity of 99.8% and one part MEK
record sheets (for a specimen, see the appendix) or on data (methyl ethyl ketone, denaturation). Agents tested according to
carriers. DVGW VP 603 comply with this stipulation. The use of spirit
leads to a quality reduction because of the water contained in it.
Within the framework of the quality assurance, it is recommended
to manufacture and test trial welds in the given working condi- The paper for the cleaning must be clean, unused, absorbent,
tions before commencing and during the welding work. non-fraying and undyed. Ensure subsequent extraction.

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.

DVS, Technical Committee, Working Group “Fügen von Kunststoffen”

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

R&D INTAKE MANIFOLDS


may remain on the heated tool.
given to electronically controlled machines – if at all possible,
with recording.
3.2.3 Cleaning of the joining faces
The nominal wall thicknesses of the parts to be welded must
Before the chip-producing machining of the joining faces, it must
match in the joining area.
be ensured that the utilised tools and the workpieces are clean
and free from grease beyond the welding area. If necessary, the Pipes and fittings must be aligned axially before they are
cleaning must be carried out with a cleaning agent. clamped in the welding machine. The easy longitudinal mobility
of the part to be welded on must be ensured, for example, using
The joining faces must be machined immediately before the
adjustable dollies or a swinging suspension.
beginning of the welding.
Immediately before the welding, the faces to be joined must be
Any chips must be removed without touching the joining faces.
subjected to chip-producing machining with a clean and grease-
If the surface is soiled after the chip-producing machining (e. g. free tool so that they have parallel faces in the clamped condition.
because of contact with the welder's hands), the welding areas The permissible gap width under the alignment pressure is 0.5 mm.
must be treated with a cleaning agent if an additional chip-pro-
The misalignment must be checked at the same time as the gap
ducing machining operation is not possible for process-related
width. The misalignment of the joining faces in relation to each
reasons.
other must not exceed the permissible dimension of 0.1 x wall
thickness on the outside of the pipe. A larger misalignment
results in a reduction in quality which restricts the load-bearing
4 Heated tool butt welding
capacity of the joint. In this case, an evaluation may be carried
out according to the DVS 2202-1 technical code taking account
4.1 Heated tool butt welding of pipes, piping parts and of the requirements on the joint.
fittings
The machined welding areas must not be either soiled or touched
4.1.1 Process description by the welder's hands since another chip-producing machining
operation would otherwise be necessary. An additional clean-
In the case of heated tool butt welding, the joining faces of the ing operation is not required and does not give rise to any
parts to be welded are aligned at the heated tool under pressure improvement in quality. Any chips which have fallen into the
(alignment), are subsequently heated up to the welding tempera- pipe must be removed.
ture at a reduced pressure (heating-up) and, when the heated
tool has been removed (changeover), are joined together under
4.1.3 Execution of the welding
pressure (joining). Fig. 1 shows the principle of the process.
In the case of heated tool butt welding, the faces to be joined are
Preparation heated up to the welding temperature using a heated tool and,
when the heated tool has been removed, are joined together
under pressure. The heated tool temperature is 230 ± 10°C. The
step-by-step sequence of the welding operation is illustrated on
Fig. 2.
Pipe Pipe
Heated tool
Pressure
Heating-up
Joining pressure
Alignment pressure

Heating-up pressure
Finished joint
Time
Changeover time

Heating-up time Cooling 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.

R&D INTAKE MANIFOLDS


The joining faces (i. e. the surface of the pipe and the inside of
Changeover
the fitting) overlap, are heated up to the welding temperature by
After the heating-up, the joining faces must be detached from the electrical energy with the aid of resistance wires positioned in the
heated tool which must be taken out without damaging or soiling fitting (heater spiral) and are welded in this way (see Fig. 4).
the heated joining faces. The joining faces must then be moved
together quickly until they almost touch. The changeover time Chip-producing machining
Joining face
should be kept as short as possible (see Table 1, Column 4)
since the plastified faces would otherwise cool down. This would
exert a detrimental influence on the weld quality.
Joining
The faces to be welded should come into contact at a speed of Fitting Insert
nearly zero. The required joining pressure is applied, if at all depth Pipe
possible, with a linear rise. The joining pressure build-up time
necessary for this purpose is shown in Table 1, Column 5. The
joining pressure is 0.25 ± 0.05 N/mm2.
A mechanical load on the joint is permissible, at the earliest, after
the end of the cooling process. For this purpose, the full joining Joining plane
pressure must be maintained during the cooling time at the
ambient temperature (see Table 1, Column 5). Figure 4. Sleeve welding with an incorporated heating element (principle).
An uniform double bead must exist after the joining. The bead
formation provides orientation with regard to the uniformity of the 5.2 Welding device
welds with each other. Different bead formations may be caused
by the various types of flow behaviour of the joined materials. It is only allowed to use welding devices which are adapted to the
K must always be > 0 (see Fig. 3). A rough uneven surface of the parts to be welded. Preference should be given to automatic
bead is permissible. welding devices – if at all possible, with recording. The welding
device must supply the welding parameters required for the fitting
Pipe wall surface Bead notch to be welded in each case, e. g. welding time, amperage and
on the outside voltage. The device must be switched off automatically as soon
as the necessary heat quantity has been supplied to the welding
zone.
Dimension
5.3 Preparation for the welding
For the manufacture of flawless welded joints, decisive signifi-
cance is attached to clean surfaces and to stress-free installation.
For axial pipe joints, the pipe ends must, if necessary, be cut off
Figure 3. Bead formation in the case of heated tool butt welding at a right angle with a suitable tool. In the case of conical collaps-
(principle using the example of a pipe). ing of the cut edge of the pipe, the unmachined pipe must exhibit
the nominal diameter d at the planned insert depth, at least in the
For a short version of the processing instructions, see the appen- area of the heater spiral (Fig. 5). If necessary, the pipe end must
dix. be shortened correspondingly immediately before the welding.

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-

R&D INTAKE MANIFOLDS


tion of the welding. If necessary, the welding device as well as
the pipe and the fitting must be protected from (for example)
direct solar radiation.
Still permissible Wrong
5.4 Execution of the welding
The correct insert depth must be checked on the basis of the
mark. If necessary, suitable measures or jigs must be used in
order to prevent any changes in the positions of the components
to be welded.
Cables serve to connect the welding device with the fitting to be
Cold zone

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.

Table 2. Test procedures for welded joints.

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

Minimum bending path according to


DVS 2203-1, Supplement 3, Figs. 8 and 9
Internal pressure creep Test parameters according to ISO 22621; not meaningful for long-time welding factor > 0.5
test
Torsion shear test Not applicable DVS 2203-6, Supplement 1
Also as a site test for pipe wall thicknesses ≥ 4 mm
Radial peeling test Not applicable DVS 2203-6, Supplement 1
Site test for pipe wall thicknesses ≥ 4 mm
Compression test Not applicable DIN EN 12814-4, Section 8
Also suitable as a site test
Peeling decohesion Not applicable DIN EN 12814-4, Section 7
test

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

Appendix: Processing instructions (short versions)

Re. 4.1 Re. 5

R&D INTAKE MANIFOLDS


Heated tool butt welding of pipes, piping parts and fittings Sleeve welding with an incorporated heating element

Processing instructions (short version) Processing instructions (short version)


1. Create permissible working conditions, e. g. welding tent. 1. Create permissible working conditions, e. g. welding tent.
2. Connect the welding device to the mains or to the alternating 2. Connect the welding device to the mains or to the alternating
current generator and check its function. current generator and check its function.
3. Align and clamp the parts to be welded, e. g. with dollies. 3. Deburr the outside of the pipe cut off at a right angle. In the
case of excessively pronounced collapsing of the pipe end,
4. Close the pipe ends against draughts. shorten the pipe. See Fig. 5.
5. Clean the joining faces beyond the welding area with a clean- 4. Guarantee the roundness of the pipes using round pressing
ing agent according to Sections 3.2.1 and 3.2.3 with unused, clamps, permissible out-of-roundness: ≤ 1.5%, max. 3 mm.
absorbent, non-fraying and non-dyed paper. Machine the
joining faces, in the case of pipes using a plane (for exam- 5. Clean the joining faces beyond the welding area with a clean-
ple). ing agent according to Sections 3.2.1 and 3.2.3 with unused,
absorbent, non-fraying and non-dyed paper. Machine the
6. Take out the plane in the case of a pipe welding machine. pipe surface in the welding area, if at all possible with a
rotating peeling device and wall thickness removal of approx.
7. Remove the chips from the welding area without touching the
0.2 mm. Remove the chips without touching the pipe surface.
joining faces.
6. Clean the machined pipe surface (in so far as it is contami-
8. Check the plane parallelism by moving the joining faces
nated subsequently) and, if necessary, also the inside of the
together (max. gap width according to Table 1).
fitting according to the information from the manufacturer
9. Check the misalignment (max. 0.1 x wall thickness). with a cleaning agent according to Sections 3.2.1 and 3.2.3
with unused, absorbent, non-fraying and non-dyed paper and
10. Check the heated tool temperature (230 ± 10°C). ensure extraction.
11. Clean the heated tool with a cleaning agent according to 7. Push the pipes into the fitting and check the insert depth on
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fraying the basis of a previously applied mark. Fasten the saddle
and non-dyed paper and ensure extraction. fitting to the pipe. Pay attention to low-stress assembly.
12. Determine the movement pressure or the movement force Prevent any change in the position of the pipe, if necessary
before every welding operation and make a note of it on the with a holding jig.
welding record sheet. 8. Connect the cables to the fitting in a weight-relieved form.
13. Determine the setting values for the alignment, heating-up 9. Input the welding data (e. g. using a bar code reading pen),
and joining pressures. check the displays on the device and start the welding
14. Stipulate the guide values according to Table 1. process.

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

of piping parts Underground

Building owner Executing company Welding machine:

Weather: Protective measures:

Title of the order Name of the welder Code no. Make: 1 = sunny 1 = none

Type: 2 = dry 2 = screen

No. of the order Name and company of welding supervisor Machine no.: 3 = rain or snowfall 3 = tent

Year of construction: 4 = wind 4 = heating

In the case of multiple designations, sequence of the numbers as above

(e.g. 34 = rain and wind)

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

Signature of the welder: Date and signature of the welding supervisor:

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.
Page 7 to DVS 2207-16
Record sheet for the sleeve welding of piping parts Overground Material Sheet of

with an incorporated heating element Underground

Building owner Executing company Welding machine:

Weather: Protective measures:


Page 8 to DVS 2207-16

Title of the order Name of the welder Code no. Make: 1 = sunny 1 = none

Type: 2 = dry 2 = screen

No. of the order Name and company of welding supervisor Machine no.: 3 = rain or snowfall 3 = tent

Year of construction: 4 = wind 4 = heating

In the case of multiple designations, sequence of the numbers as above

(e.g. 34 = rain and wind)

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

Signature of the welder: Date and signature of the welding supervisor:


R&D INTAKE MANIFOLDS

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

DVS – DEUTSCHER VERBAND Welding of Thermoplastics Directive D


Heated Tool Butt Welding DVS 2207-25
FÜR SCHWEISSEN UND V
VERWANDTE VERFAHREN E.V. Welding of Casements sections made from PVC-U (October 1989) S 
R&D INTAKE MANIFOLDS
Contents: 3 General requirements

1 Range of application The sections to be joined together are to be conditioned of at


2 Terminology least 24 hours until the temperature reaches at last 15 °C over
3 General requirements the entire section.
4 Welding processes
5 Welding machines During this time, the sections should be stored in such a way that
no impermissible deformation takes place.
6 Preparing the machine
7 Preparing the components to be jointed The sections must be dry and their surfaces must be clean. In
8 Producing welded joints connection with this, it is advisable to open the packaging at the
9 After-treatment of welded joints front faces or, if necessary, to remove it completely. Any moisture
10 Testing welded joints which may be adhering to the sections must be removed by
11 Other standards and directives applying means of suitable measures (for example using an air jet).
12 Clarifications
The connecting surfaces of the sections to be welded must not
13 Appendix: Operating symbols for welding machines
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher

be damaged and must be free from impurities (for example dirt,


14 Appendix: Guidelines on safety at work and accident pre-
grease, swarf) and moisture (condensation of water vapour due
vention
to variations in temperature).
The working area, and the welding area in particular, should be
1 Range of application protected against the effects of draughts, moisture and
impurities. Before the welding operation commences, the set-up
These directives apply to the production of joints on extruded should be checked to make sure that it coincides with the pre-set
sections, made from unplasticised polyvinyl. chloride (PVC-U1)), welding parameters. If necessary, some test pieces should be
for the manufacture of windows, doors, frames and other welded and the results checked. Test corners welded may not
structural elements, by heated tool butt welding, for example undershoot the minimum breaking loads laid down in the section
casement sections made from PVC-U (predominantly PVC HI) in manufacturer's system description (see Section 10, 'Testing
accordance with RAL-RG 716/1. Welded Joints').
The directives also apply to extruded sections made from PVC-U Welding operations should be carried out by specialist personnel
with coated surfaces, where the coating may consist of other who are familiar with the work and have adequate experience2).
thermoplastic plastics.

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)

R&D INTAKE MANIFOLDS


viscosity of the material and the jointing surface of the section
should be taken into account. When the stop has been reached, d) Rapid clamping devices must be stable, adjustable and
the jointing pressure in the jointing area is reduced. The jointing replaceable
pressure then decreases further as a result of the cooling e) The clamping elements must open sufficiently widely for the
process. Fig. 1 gives a schematic outline of the individual stages workpiece to be removed without difficulty
in the process.
f) Clamping devices should be designed in such a way that
injury to the operators is avoided
g) The sequence of operations for the welding process must be
extensively mechanised, in order to guarantee good
reproduceability
h) It must not be possible to bring the heated tool into the
operating position unless the clamping table is in the initial
position
i) The welding slides must be guided without any play but so
that they move easily, in order to obtain good reproduceability
j) Unintentional activation of the operating process must be
prevented by a safety device
k) An interruption in the power supply must not trigger any
uncontrolled phenomena of movement
l) The exhaust air from the pneumatic valves must not be
directed onto the heated tool.

5.2 Removal of workpiece and clamping device


High standards are set for the surface quality of the components
to be welded. The seats and clamping devices must therefore be
designed in such a way that they
– fix the sections securely
– transmit the forces required for welding without damaging or
deforming the section surface
– avoid any impermissible mismatch in the weld.
The sections should be supported in the vicinity of the jointing
Figure 1. Sequence of operations for heated tool butt welding of zone, in such a way that deflection and deformation during
sections with jointing path limitation – path-time and pressure- warning-up and jointing are avoided. Depending on the type of
time diagrams (schematic). section in question, 'adjustment plates' are to be provided to
support the sections, so that the working pressures or clamping
sAG Matching path tF Jointing time pressures required for welding can be accepted by the sections
sF Jointing path tS Welding time (total) without any deformation. The clamping elements must exercise a
sS Welding path (overlength) PAG Matching pressure uniform pressure on the clamping surface, in order to clamp the
tAG Matching time PAW Warming-up pressure
section securely and without deformation.
tAW Warming-up time PF Jointing pressure
tU Repositioning time
5.3 Bead limitation
Should the thickness of the bead be limited by a heated device,
its temperature in the jointing area must be controllable to within
5 Welding machines
± 5 °C. (The usual temperatures for bead limitation lie in the
range between 45 and 50 °C.). The range of the limitation
Section welding machines are intended exclusively for stationary influences the strength of the welded joint. Reducing the gap
workshop operation. They must meet the safety regulations width reduces the strength.
applicable. They are used for welding sections, for example
window and door profiles, to frames, T-connections, double 5.4 Heated tool design
junctions or various angles can also be welded, depending on the
construction and equipment of the welding machines. The mounting brackets and guidance of the heated tool must be
designed in such a way that it can be matched to the joint
The welding machine must be set up in a dry area on a level surfaces or can be centred, and can easily be moved. The
load-bearing base support. It must also be in a place free from release and removal of the heated tool from the joint surfaces
draughts. after the heating process must take place as quickly as possible,
so that the permissible repositioning time of max. 2 s is not
5.1 Structure of machine and safety in use. exceeded. Special measures are usually adopted to make it
easier to release the heated tool from the plasticised joint
To meet the requirements for design and construction, the surfaces (for example PTFE covering).
following points should be. taken Into account in the structure of
the machine: 5.5 Control and adjustment for pressure. time and path
a) The structure must be stable and the table construction The control and adjustment of the welding machine must be
torsion-proof designed in such a way that the welding parameters are

3) See Appendix, Section 13: Operating Symbols for Welding Machines.

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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

5.5.1 Pressure control


R&D INTAKE MANIFOLDS
must be tested at regular intervals and readjusted if necessary. > 100 ... 150
> 150 ... 200
> 200
0.4
0.6
0.8
The matching pressure, heating pressure and jointing pressure
must be separately adjustable. The heating pressure must be The useful area here is taken as being the part of the heated tool
close to 0 (see Fig. 1). Pressure gauges of accuracy class ≤ 1.6, in which the temperature and the amount of heat delivered can
as per DIN 16 005 and 16 063 must be provided for the matching be adjusted over the required range. The manufacturer must
pressure and jointing pressure, and the graduation of scale used display the dimensions of the useful area on the heated tool in
must be 0.2 bar. The minimum and maximum machine pressure permanent form.
which can be set, together with the effective piston surface of the
5.6.2 Surface finish
main cylinder, must be stated in the machine documents. The
pressure in the welding surface can be calculated from these The surface finish of heated tools in the useful area must be such
data and from the cross-section of the profile. as to avoid any plastic material residues remaining behind. It
must be possible to clean heated tools without damaging them.
5.5.2 Time-control
Coatings or coverings, for example PTFE, are recommended to
The heating time and jointing time must be separately adjustable make it easier to keep the surface clean and to reduce the
in stages. The repeatability of the heating and jointing time must adhesion when the components being jointed are removed.
be within an accuracy of ± 0.5 s. The repositioning time is Coverings must remain in contact with the heated tool at the
specified by the equipment. It must not exceed 2 s and must be welding temperature.
repeatable within ≤ 0,2 s.
PTFE spray acts as a parting agent and must not be used
since it is removed from the heated tool along with the
5.5.3 Path control
jointed components and transferred into the weld!
Path control must ensure that the pre-set dimensions of the Heated tools newly covered or newly coated with PTFE must be
window are maintained. In conjunction with the placing stop, the heated for at least 0.5 hours to a temperature of 280 °C, when
matching path and the jointing path must display a repeatability first put into operation.
of ≤ 0.1 mm.
The roughness depth value, Rt, (the roughness class as per DIN/
5.6 Heated tool ISO 1302 is given in brackets) is as follows, depending on the
version of heated tool used:
– Heated tool with indirect heat release through a heat conductor
(DVS 2208, Part 1) – – With PTFE covering or coating, Rt ≤ 16 µm (17). Usual coating
depths are 30 to 50 µm, and PTFE/fibreglass tissues in
The heat is transmitted from embedded electrical heaters to the thicknesses of 100 to 300 µm.
surface of the heated tool through a material which is a good
conductor and resistant to corrosion. Cast heated tools must be The covering or coating material must withstand a temperature
free of shrinkholes. stress of 300 °C for an hour without any significant change in its
anti-adhesive properties or its adhesive strength. In continuous
5.6.1 Design use the temperature should not exceed 270 °C.

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 data in Table 2 apply to the permissible angular deflections


on V-form heated tools (Fig. 2).

Figure 3. Example for the position of the useful area.

The entire welding surface must lie within the useful area.

5.6.4 Minimum heated tool power


The minimum heated tool power is dependent on the conditions
of use and the type of model. The electrical power, based on the
Figure 2. Representation of angular deflection on V-form heated tools. heater area (aH, bH,), must be at least 2 W/cm².

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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

R&D INTAKE MANIFOLDS


3.
5.6.6 Temperature precision
6.3 Commissioning the welding machine
The temperature precision should correspond to the welding
temperature differences listed in Table 3. These welding Good welded joints can not be obtained unless the welding
temperature differences correspond to the temperature machine has reached a constant operating condition. It takes
variations: about 0.5 hours to achieve this because of the heating of the
heated tool and the clamping devices. The welding machine must
a) over. the useful area therefore be switched on at least 0.5 hours before production
b) through the standard interval starts.
c) on the two sides.
Table 3 shows the resulting maximum permissible total 6.4 Functional testing
temperature differences in the effective area. The effective area Before production starts, and after any long interruptions, a
is the surface within the periphery of the profile section. functional test is to be carried out. At least one welded joint is to
be produced for this. Apart from the maintaining of the welding
Table 3. Maximum permissible temperature differences. parameters, special attention is to be paid to satisfactory
useful area area of temperature differences °C clamping of the section and the regular formation of the bead.
cm² a b c total
7 Preparation of components for jointing
≤ 150 4 2 2 6
> 150 ... 250 5 3 3 8 The profile sections which are intended to weld should be
> 250 ... 400 7 3 3 10 checked with regard to their geometric form and usability before
> 400 9 3 3 12 being cut to size. In the case of main profiles special attention
should be paid to mismatch and to the flatness of the surfaces
These values are to be maintained after a build-up time of app. which are visible after jointing.
30 min., at room temperature, in an environment protected from
draughts, in the working position, within the useful area and at a The burn-off – the difference between the component cut to size
reference temperature of 250 °C. for jointing in the unwelded condition and the finished size in the
welded condition – is to be taken into account when cutting to
5.6.7 Temperature control size takes place. It comes about in connection with the formation
of a bead of plasticised material during matching, heating and
The temperature control must guarantee the characteristic
jointing. (The burn-off was also previously known as the
temperature values required under Sections 5.6.5 and 5.6.6.
'consumption'.)
From the initial contact of the jointed surfaces to repositioning,
the temperature must not fall by more than 4 °C. The heated tool The cutting equipment used (preferably circular saws) must be
temperature must return to the nominal value during the jointing manufactured in such a way that the jointing surfaces do not
time of the welded component. deviate from the nominal values by more than 0.5 mm.
An additional check on the heated tool surface temperature is Deviation includes
required. Suitable equipment for this consists of (for example) – angular deflection
rapid-indicating contacting electrical surface temperature gauges – flatness
with appropriate mass-impregnated and drained probes or – roughness of jointing surface.
contactless radiation meters 4).
The cutting tools must be manufactured in such a way that the
jointing surfaces can be produced without difficulty and without
6 Preparation of machine impermissible heating, Swarf which impedes the jointing process
should be removed (for example by suction or blow-off).
6.1 Visual assessment of function capability of welding machine
The jointing surfaces must be kept free from damage and
The functional capability of the welding machine is to be impurities (for example dust, grease, hand sweat, protective foil,
evaluated before commissioning. The welding machine and the etc.). Moreover, the components cut to size for jointing are to be
leads must be in a condition allowing for a satisfactory sequence stored in a constant climate.
of operations. The machine's service units must be inspected
and maintained at the intervals laid down by the machine
manufacturer. 8 Production of welded joints
The condition of the heated tool surface is of special importance. – Place the jointing components to be welded, cut askew (on the
In the welding area, the surface coating of the heated tool must median) to size, into the machine.
be clean, free from faults and free of damage (for example,
pimples, cracks, etc,). No residues must be present. A stretched – Press the sections against the stops and the adjustment plates
PTFE/fibreglass tissue must be in uniform contact with the unless this part of the work has been taken over by the
heated tool at the welding temperature. machine.
When a new PTFE/fibreglass tissue has been fitted, the heated – Hold the jointing components in this position and release the
tool should be operated for 0,5 hours at 280 °C, in order to clamping devices.
harden the surface. The first three welded joints produced using – Activate the welding process.
this new PTFE/ fibreglass tissue are of inferior strength and
should therefore not be used. – The welding of the jointing components is carried out by the
welding machine automatically in accordance with the welding
6.2 Setting welding parameters parameters to which the welding machine is set.
The welding parameters laid down for the section to be welded – – The welding process is completed when the clamping device
working pressures, temperatures, times and bead limitations – opens.

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:

R&D INTAKE MANIFOLDS


possible must be put on the joint.
F soll = 2 ⋅ W ⋅ σ-
--------------------
--a- – ------
e-
9 After-treatment of welded joints 2 2
The welding bead should be taken off as soon as possible, once F ⋅ h-
σ = ----------
enough cooling has taken place, so as to avoid any impairment of 2W
the weld strength and appearance. Accelerated cooling, for l
example using compressed air, is not permissible and can lead to W = ---
e
stress cracking.
a e
Welding beads should be removed manually or mechanically h = --- – -------
2 2
using suitable means. The process can have a significant
influence on the strength of the welded joint.
Some examples of factors which can reduce the strength are:
– notches in inside corner
– grooves in the visible surfaces
– streaking of surfaces.
Using polishing and cleansing agents which dissolve PVC is not
permissible, as can lead to stress cracks and discolouration.
Consult the profile manufacturer's instructions for the after-
treatment of welded joints Involving co-extruded surfaces, coated
surfaces, or surfaces laminated with foil.

10 Testing welded joints

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).

Figure 4. Test rig with movable supporting (a = 400 mm).

In a suitable test rig, as in Fig. 4, which has movable supporting


chassis which can rotate around the transverse axis, the corners
are deformed in a pressure test, with a testing speed of (50 ± 5)
mm/min at room temperature (18 to 28 °C) without jolting, until Figure 6. Example of a minimum failure curve Fsoll as a function of the
they break, and the maximum forces arising are measured. section modulus with e = 40 mm and σ = 35 N/mm2.

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11 Standards and directives also applying


Start
DIN 1910, Welding; welding plastics, processes
Part 3

R&D INTAKE MANIFOLDS


DIN 7728, Plastics; Code letters and abbreviations for
Release, normal position
Part 1 polymers and their special properties
DIN 16 005 Excess pressure gauges with flexible error detector
for general use, requirements and testing Setting up
DIN 16 063 Excess pressure gauges with bourdon tube,
housing diameters 40, 50 and 63 mm, precision
class 1.6, 2.5 and 4.0 – dimensions and Indicating Clamping off
ranges
DIN 16 830, Draft Casement sections made from polyvinyl
Part 1 chloride of high impact strength (PVC-HI) – Test Clamping, clamping pressure
process
DIN 16 830, Draft Casement sections made from polyvinyl
Part 2 chloride of high impact strength (PVC-HI) – Brake
Requirements
DIN 32 502 Faults in welded joints made from plastics;
classification, terms, clarifications Matching pressure
DVS 2206 Testing of structural elements and structures made
from thermoplastic plastics
Heating-up time
DVS 2208, Machines and equipment for welding thermoplastic
Part 1 plastics – Heated tool welding
RAL-RG Plastic windows, quality assessment. (Quality and Jointing pressure
716/1 test regulations for plastic windows)
VDE 0100 Regulations for the erection of power plants with
rated voltages of up to 1,000 Volts Jointing time
VDE 0105, Regulations for the operation of power plants –
Part 1 General regulations
Check machine settings (weld strength risk)
VDE 0250 Regulations for insulated power lines
VDE 0551 Regulations for safety transformers
VDE 0612 Regulations for power distribution on building sites Temperature monitoring on
for rated voltages of up to 380 Volts AC and
currents of up to 630 A
VDE 0720 Regulations for electrical heating units for domestic Heated tool
use and similar purposes (apply by analogy)

Heated tool cleaning


12 Clarifications

These directives were drawn up by the GWEA/PCSQG Joint


Working Party. This consists of members of GWEA Working 14 Appendix: Guidelines on safety at work and accident
Party W4, representatives of the Plastic Casement Section prevention
Quality Group, and representatives of manufacturers of welding
machines for casement sections. The directives are intended to The 'Law on Technical Means of Operation' (Equipment Safety
allow window producers to optimise welded joints in window Law) of 24th June, 1968 lays down that technical. means of
manufacture and to keep them constant, and thus to ensure operation may be brought into use only if they correspond to the
welded joints of uniform quality. generally recognised rules of the art, as well as to the guidelines
on safety at work and accident prevention.
The results of long years of practical experience from the
manufacturers of profile sections and welding machines have Consequently, the generally accepted rules of the art, for
gone into these directives, together with the most recent example the relevant VDE guidelines, together with the
developments in machine technology. Special attention has been guidelines on safety at work and accident prevention, are to be
paid to the results of the research projects 'Welding PVC respected during the construction of plastic welding machines.
casement sections' and 'Welding corner joints on PVC casement
sections' of the South German Plastics Centre in Würzburg. 14.1 Electrical equipment
The following guidelines, in particular, apply as regards to the
construction and operation of welding equipment:
13 Appendix: Operating symbols for welding machines
VDE 0100 Regulations for the erection of power plants with
rated voltages of up to 1,000 V
On VDE 0105 Regulations for the operation of power plants –
Part 1 General regulations
VDE 0250 Regulations for insulated power lines
Off
VDE 0551 Regulations for safety transformers
VDE 0612 Regulations for power distribution on building rites
for rated voltages of up to 380 V AC and for
Placing, preparation currents, of up to 630 A

459
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VDE 0720 Regulations for electrical heating units for domestic


use and similar purposes (apply by analogy)

14.2 Constructions and handling

R&D INTAKE MANIFOLDS


General guidelines on safety at work and accident prevention
should be respected in the manufacture, handling and
maintenance of welding machines. Particular attention should be
paid to the chapter on 'Welding Machines and Welding
Equipment' in the guidelines of the Chemical Industry
Professional Trade Association on machines for processing and
converting plastics.

460

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