5 g ; § 5 = t DVS- DEUTSCHER VERBAND FOR SCHWEISSEN UND \VERWANDTE VERFAHREN E.V. Contents: Purpose and range of application Evaluation groups Requirements for welding joins Deiails in engineering data Testing and evaluation Acceptance Other standards and guidelines appying ‘ppendhx:clagram Purpose and range of application ‘This guideline registers and deseribes faults in thermoplastic welding joints with the aim of making possitle a generally valid fevaluation with consideration being given to graded quaity requirements The description of the faults ie based on the terminology regulated in DIN 32502, if specific faults are to be excluded or kept within limits shen | Welding joints are produced this can be emphasised by Classification ito one ofthe evaluation groups The application ofthe guideline and the measures necessary for is fuliment ean, for example, be laid down by legal regulations oF by generally recognised ruies of engineering or be regulated fon the basis of delivery agreements. 11 Welding processes Faults in the following welding processes are dealt with: ‘Abbreviation Table No, Heated tool butt welding HS. 1 Heated tool socket welding HD Elect fusion welding HM Hot gas fan welding We Hot gas drawing welding WZ Hol gas extrusion welding WE aecorgT tis pepe, 12 Matrits The guidelines applies to welding joints on components. and systems, for example apparatus and pipelines, made from the plastics listed below. ‘Abbreviation Material description PEHD High density polyethylene (rigid PE) PPB Polypropylene block copolymer PP Polypropylene homopolymer PPR Polypropylene random copolymer Pvc CChorinated polyvinyl chioride PVC-HI High-impact polyvinyl chioide PvCU Unplastcised polyvinyl chloride (gid PVC) PVDF Polyinylidene fluoride ‘The appleation of the guideline for welding other thermoplastic plastics must be agreed separately between the customer and the manufacturer Imperfections in thermoplastic welded joints; features, descriptions, evaluation Directive DVS 2202-1 (December 1989) 2 Evaluation groups Specie requirements are laid down forthe carying capacity of a component particulary regarding the quality ofthe welding joints. The following classification is used as a basis, so that the converter knows the extent of the measures requited for quay contrat with regard to welding: Evaluation group Feequirement level 1 High requirements for salety andior carrying capacity u Medium requirements or safely andor carying capacity a Low requirements for salety andior carrying capacity ‘The requirements to be laid down for the welding joints on a component should in each case be restricted to those which are practicable with reterence to the local situalion or necessary ‘appropriate tothe application 22 Citerie or establishment In the eslablshment of the evaluation groups the following factor, amang others, should be taken into account: ~ type ot stress (for example static, dynamic) ~ material (for example viscous, brite) ~ operating conations (for example stationary, changing) ~ production (lor example workshop, constrained postion) ~ potential danger {for example gases, water-endangering fuids) ‘construction site, welding in 3 Requirements for welding joints 31 Quality features fr carrying out of wed (Tables 1105) The requirements for keeping a welded joint within @ particular {quali grade are classiid by the evaluation groups. In the majority of cases it concems requirements forthe carrying ‘ut with specie features and deseriaing thom with reference to the intemal and external state ofthe joint. By using Tables 1 to 5 It Is possible to lay down spect requirements forthe quality of welding Using the individual features, i.e. through the type and extent of the faults, an indivigual evaluation of welding jinis can be Undertaken as betore (lor example as part of the acceptance procedure forthe component). ‘This platen hasbeen caw up by a oup of experienced speci wong an honey capac and is condo i recormended, The ser sou 10 dnd hoe lv poping he puaiston ae geomet Hom ay tay wraps ptr cna whe vos nar sl ah The Cnuecher Varah Sewarechnk DVS, Technical Committee, Working Group “Plastics, Welding and Bonding’ ‘Oxers to: VS verlag Grb, FO. Box 1019.65, 40010 Dossedot, Getmany, Phone 49(0)211/159%-0, Teen: « 49(0)2119581-150Pago 2 to DVS 2202-1 412 Requirements for characteristics ‘This covers all addtional data such as: = delormation resistance (lor example welding factor) ~ plasticity {lor example bending angle to cracking) ~ resistance against chemical attack (lor example resistance factor 33 Requirements or after-treatment In certain cases, it can be necessary to process the completed welding joints. This can take place, among ther cases, inthe event of = dynamic stress (lor example note-ree transitions) ~ to smooth weld suraces (lor exampie lining) = 10 improve flow behaviour {lor example internal pipe beads) ~ for technical inspecton reasons It's advisable to test andlor evaluate the weld both before and after mechanical manipulation, 4 Details in engineering da Requirements for welding joints are to be defined in the ocumentation which is binding for manufacture (tor example werking eanin, weling agra, wih relerence © the OVS guideline As a rue itis sulicient to identy a weld in accordance with following example: wav where WZ = abbreviation forthe welding process = welding symbol and dimensions |S evaluation group code ‘Should all the welding joints on a component come under the ‘same evaluation group then i can be entered in a space provided for his purpose onthe drawing, Example: All welding joints a per evaluation group I-DVS 2202, Pad’ ‘Addtional requirements for the carrying out or characteristics of ‘welding joints and for mechanical manipulation are also to be Noted in the engineering data, 5 Testing and evaluation 51. Testing Visual inspection, measurements and, where necessary, suitable non-destructive or destructive testing procedures are to be used to veri thatthe requirements for tne Individual welding groups have been adhere to ‘Tipeudedin OVS notebook e81V Tests must be carried out on the welding joints o the component. ‘Specific characteristics can also be verted on test pieces which ate manufactured under comparable conaltons. ‘The nature and extent of the tests together with thelr timing are to be agreed between the customer and the manulactuer. The test reulls are tobe dacumanted in suitable orm 52 Evaluation The test result forms the basis for the classification of welding Joints into one ofthe three evaluation groups, in accordance with Tables 1 10 5, The test reports should be used to determine points were’ the. result’ does. nol comtespond with te Fequirements, Should the component of individual welding joints ot correspond to the evaluation group spectied (Section 2-1.) then itor they may be touched up. 152.1 Touching up faulty welding joins In 0 far as the inspector considers It possible, fauly welding Joints may be expert touched up, as long as technical rules are adhered to. The purpose of touching up operations is finally to ‘biain the welded joint quality laid down by the requirements. It hecessaty, the results shall be determined by addtional test procedure ‘Should two or more types of faults arise simultaneously on welding joints, ths can increase the etfect of an individual fault Tests should then be carried out to ascertain whether the welded joint stil meets the requirements laid down or whether resticions have to be imposed as regards safety and qualiy standards because "ofthe accumulation of fauls. Under certain ‘roumstances, the component ots welding joints should be re- Classified Ino anather evaluation group. 6 Acceptance It tests on the component confirm that it meets the requirements laid down in he technical documentation the component shal be considered as being accepted. A separate acceptance document Isto be drawn up. ‘Should the requirements not be met and should touching up not be possible then the manufacturer has to produce a special Socument on the usabiliy of the component. The customer and the manufacturer are to reach agreement in good time on the nature, exten! and evaluation of his document 7. Other standards applying DIN 1810") Welding plastics; Processes, Part 3 DIN 32 502") Faults in welding joints on plats ~ Classtcation, designation, clartications {Aso the guidelines and specifications of volume 68iIV of the DVS notebook, together with any publications of the OVS 22.. series which have been published in the meantime (all nthe most recent versions)Teble 1. Deseription of evaluation groups for heated tol but welds. ‘No. | Feature External state of joint Description Evaluation groups Page 3 to DVS 2202-1 7 | Cracks | ‘Cracks running lengthwise or oss wise to weld ‘They may be located = inwela = in base material = in heat affected zone Not permissible ‘Not permissible Not pernissible Welding flash notches 4 xe WNoiches and futes ‘Continuous o local notches lengthwise to weld wih notch rat in base material, caused by, for example = insufficient joint pressure = warming-up time too short = cooling te too short | Notches in edge of base materia, lengthwise or Cross-mise to weld, caused by, for example, = clamping tools = incorrect ranspot = fault in edge preparation Not permissible Locally permissible iWending Nat and assois but max. 05 mm Not permissible Localy permissible iWending Nat and ass01s but max. 1 me Not permissible Permissiie ‘ending lat and as <0.158 but max. 2 ma ‘Mismatch of joint faces “int faces are displaces relative to one another or thickness variations are not adjusted Permissibiet es0ts but max. 2s Permissibo es0.5s but max. 4 mm Permissiie es02s ut max. § ma For example machine faut = layout faut Permisibie esimm Permissibo esemm Perissibie es4mm ‘Narrow, excessive welding ‘lash Excossive and sharp ‘edged welding fash ‘ver par oral of weld length ‘or weld gith due to wrong welding parameters, especi ally caused by = excessive joint pressure with polyoletns only Not permissible ‘Not permissible Not pernissbie ‘Welding flash incorectiy formed See note" ee ‘Welaing lash too wide or too narrow over par or all of ‘weld length, caused by, for example Mncorrect warming-up ime incorrect heated toot Temperature ~ incorrect joint pressure Valve range A see ciagram page 14 Valve range 8 508 ciagram page 14 Value range C see diagram page 14 ‘Non rifgrm welding Wash Seenoe bbe ‘Non angular joint plane, leading to variations in form ‘of welding fash over part o allof weld length, caused by, for example = edge preparation fauits = incoreet welding unit Permissibie by20.7: by Permissibie by 206 by Permiseibie by205-byaga 4 to DVS 2202-1 ‘Table 1. Fotsotzuns. No. | Feature Deseripion Evaluation groups 7 i oy Thermal damage | High-oless welding fash wih | Not permissible | Not permissible | Not permissible ‘yids or nodules, usually associated with faulty \elaing flash formaton and marked bead notches. intemal state ofjoint 10 | Lackot fusion No sion orincompiete | Notpermissbie [Notpermssibve | Not pemissibe fsion ono faces, ver part or the oe of weld ross socton caused by, or example contaminated elt aces ~ tise it faces Grenssve reversal tio = ft tome ttolow ~ heated oo temperature toon Holow space noi planes | Notparmissbie | Not permssbve | Not persue caused by fr exampe stele ein pressure = insutcen cooing time ores caused by inclusions | Isolated, numerously disper- | Smallisolated | Pores and rows of_| Pores and rows of of foreign mater sed or locally concentrated | pores permissible | pores permissible | pores permissible pores orinclusions caused | As s005-s 48 50.10°s As s0.15-s by, for example vapeur formation during welding = contaminated heated too! TY Deserion and evaluation as pe earent owed on polyolefins. Arenas may be necostary afer evsion of guideline DVS 7207, Part 7 and Part 2 gps only to wos which are produced using equipment as per OVS 2208, Pat. ‘Table2. Description of evaluation groups fr heated tool socket welds. No. | Feature Descripion Evaluation groups i External state of joint 1 12 | Faulty welding flash Variable welding fash Notpemissible | Not permissible | Not permissible formation, formation or no welding flash ‘See note” present on ane or bath sides (over pan or whole of weld Fength) due to = excessive Rested tool temperature ~ excessive eating times — impermissibe tolerances See note? Variable welding fash Notpemissible | Notpermissible | Not permissible formation orno welding lash present on ane or bath sides (over part or whole of weld length) due to = insufficient heating time insuffiient heated tool Temperature — impermissible tolerancesTable 2. Fortstzung. No. Feature Description Evaluation groups i Page 5 to DVS 2202-1 is rr ‘Variable welding fash formation or no welding flash present on one or both sides {over part or whole of weld engin) de to Unprocessed joint faces = contaminated joint faces = heated tool temperature too high Not permissible ‘Not permissible Not permissible ‘Angular daiecion (detect of form) +__J = Pipe welded int iting at ‘angle on one or both sices, ‘rth slighty fully grip ping, caused by, for example ertnachine fault = layout faut Permissibiet esimm Permissible t es2mm Permissible es4mm Lack of fusion due to selormation Deformation or oval ofpine fed or fiting with locally Insufficient welded pressure, caused by, lor example “insufctent radi of curva lure on eaiars ~ faulty storage of pipe and otting ~ unsuitable clamping sevice PPrissible deviation from average external pipe diameter 15% but max. 1.5 mm from average external pipe diameter 2% but max. 2 mm from average external pipe siameter 3% but max.2 me ‘rom average extemal pipe diameter Lack of fusion due to Incomplete insertion of pipe Insufficient weld length with {ully or only partialy fused Init faces, caused by, for example “insuiient warming-up time ~ pipe ends not alright angles = heated tool temperature too low ~ axial movement during ‘paling perios = reversal ime to tong Permissible ceases o sight Undershooting of nominal wels Tengih and notch- free, closed welding flash up to xs005-0 20.1: socket ‘depth Permissible upto xeot-d XS0.15- socket depth Permissible upto xe0td X502- socket depth Internal state of joint a3 Tack of fusion due insufficiently closed form Toca, extensive, axial or CSreular channel formation, caused by, for example “notches in pipe faces = giameter tolerances on pipe orfiting exceeded = faulty mechanical manipu: lation = Pipe not aligning in socket Not permissible Not permissible Notpernissble Lack of fusion due to Inuticient meting Local or extensive Incomplete welding with separation in the joint plane, caused by, for example thermal damage = contaminated jin faces = wrong material paring = residues on heated too! ‘Not permissible ‘Not permissible Not permissibleaga 6 to DVS 2202-1 ‘Table 2. Fontsotzuns. No. | Feature Deseripion Evaluation groups 7 i oy ‘Compressed pipe cross | Pipe inserted too far in Not permissible | Nopermissible | Not permissible section 1mm Notches caused by inadequate weld fling on root, caused by, for example “bent up and Unwelded joint ‘aces ~ 100k opening too smal = wolding force too small, = root fling back due to shrinkage Not pemissibe Locally pamissibie in limited numbers itase0.18 but max. 1 mm PormissibieW asso1s bout max. mmPago 12 10 DVS 2202-1 ‘Table 5. Fortsotzuns. No. | Feature Tncompletely welded cross: section “th Deseripion | Caused by or example = inadequate edge Preparation 7 Not permissible Evaluation groups i 7 Not permissible oy ‘Locally permissibie inlined numbers itas<0.18 but max. mm 7 | Weld roti igh Descripion Caused by, for example = root opening too big = welding force too great Permissibe i ase0.158 ‘but max. 2mm Permissie 482028 but max.3 mm Permissibie # 520258, but max. 4 mm | Weiding fash too high Finch pass too high, caused by, for example ~ inadequately formed welding shoe = welding force to small ‘Continuously permissible Orssassoss but max. 6 mm ‘Continuously permissible 005ssass05s utmax. 9mm Continuously permissible Ozas<08s but max. 12 mm ‘Welding material overiow on ‘one or both sides, usualy ‘without suicent fusion to base material Not permissible Locally permissible in small numbers if Abe 5 mm Coninuously permissible it Ab='S mm ‘Wield underarching ZK 17 [Mismatch fit aces ‘Angle defections (elec of form) ‘Weld cross-section isnot ‘obiained, caused by, for example = shrinkage of welding filer = inadequately formed welding shoe welding speed too high 1 For example =aiflerent wall thickness ae ‘ot compensated equal wall thickness are csplaced | Length L of shorter side is decisive for permissible ‘ellection Not permissible Permissibe ey20ts 220.158 at max. 2 mm Permissible upto esi Not permissible Permissibe # eys0i5s ens02s atmax. 4 mm " Permissibie upto este Locally permissibie in imted numeers itas<0.18 but max. 1 mm Permissible W e028 2350258 bat max. 5 mm | Permissible upto eeu Not permissible Not permissible Not permissible ‘symmetrical weld cover Z2EERS Wavy weld suface ‘Welding shoe has been ‘uided outside weld centre Caused by, for example = welding force non: tnitoemly applied = vweiding speed non- Lnilormly applied Not permissible Locally peissibie Pormissibie tthe required weld Cross-sectionisnot undershat ‘Continuously permissible Locally permissibie in med numbers itas<0.18 but max. mm Coninuously permissiblePage 13 10 DVS 220244 Toole 5. Fortsetzung, 16 | Rough weld surface Fine open bubbles, steaks | Isolated spots | Limited areas ‘| Permissible ‘ornodules and the ike, for | permissible permissible example Snot in form mass = form mass temperature ‘eo low 17 | Start faut Tncorpletely welded cross” | Not permissible | Not permissible | Low reduction in section al slr of end of cross-section with weld ut sharp transitions Permissible Wat damage Discoloration, formation of | Notpermissie | Isolated spots | Limited areas, nodules, high-gloss welded permissibe. permissiie. surface and the tke External state of weld surface of filet welds 18 | Weld too high Exceeding of standard lt] Permissiblow | Permissible | Pormissibio# weld thickness of bsoa bs05a bs0sa y a=07's utmax:6mm | butmax. mm | but max. 12mm Weld cross-section under- | Required weld cross-section | Notpermissible | Permissible t__| Permissible shoot Is not obtained, caused by, minal dimension | nominal dimension for example slighty undershot | a under shot locally ~ shrinkage of welding filer locally beosa = inadequately formed bs0.15a wolding shoe ‘neompletely welded weld | Weld geometiy natto | Notpermissible | Permissible it | Permissible cross-section standard 250158 25038 Tternal state of V-welds, double V.welds and filet wolds 22 | Pores due to inclusions of | Isolated, numerously ‘Smallisolated | Pores and pore | Pores and pore foreign matter Aisporsed or locally porespermissibleit | rows pormissibleit | rows permissible it concentrated pores or 4850.05 "s A850.10°S a8 <0.15-8. 2} | inclusions, for examole due EZRA ree tn se welding (water, solvent) = diny heated tool No fusion, or incomplete | Not permissible | Not permissible | Locally permissible fusion on opposite poston, in ited numbers Fastening porns and weld sides, caused by, for example = dirty joint faces wolding force too small, = inadequate heatingPago 14 to DVS 2202-1 8 Appendix ' Anvondic Perms lsh wish on sted ol ut weld en pipes made rom PE and PP | "The anges > 15 mm wil be etabshed ater revision of OVS 2207 Pans and 2