‘Reprinting and copying. even in te form ot exorps, ony wit the consentof he pibher Januar 2019 HAN WELOING Technical Code DVS - German Welding Society Dvs 2207-4 Transtation of the ‘Garman issue (uly 2078) Technical Code DVS 2207-4 Welding thermoplastic materials Extrusion welding of pipes, piping parts, fittings and panels Procedures, requirements Technical Comittee in DVS Working Group W 4 “Joining Plastics” “This pubicaton hasbeen drawn up by 2 group of experianced specials woking in an honeary capaciy and is conside- ration ae an impernt source ofinfeation reconmended, Th ue shoud shay check fo what exten te contants a ‘Sppicable to hs parca cace and whether th version on hand ila. No isily can be accpta by the OVS ~ Deu Scher Verband fur Schwein und verwanci Vrfien eV. and those paricpatng in tie drawing up of te document.‘Content: 40. 40. 102. 403. 404. 405. 108. n 12, 43, 431 ‘Scope General requirements Materials. General process description Continuous welding process. Discontinuous welding process Machine variants Machine variant | Machine variant I Machine variant I ‘Structural design, weld seam shapes and weld seam structure Requirements Requirements for the welding machines and equipment Requirements forthe welding shoes Requirements for pre-heating Requirements for the materials and their weldabilty Requirements forthe qualty ofthe welded joints Commissioning the welding machinery and setting the welding parameters. ‘Weld preparation Equipment Measures to protect a ‘Welding Preparing the joint surfaces Tacking ‘Welding procedure: Mechanical post-processing of the welds “Thermal post-treatment of welds ‘Welding protocol Checking the welded joints. ‘Safety guidelines References Reguiations2207-4 Januar 2019 4. Scope “This Guideline applies to the hot-gas extrusion welding (WE) (hereinafter referred to as extrusion wel- ding) of pipes and panels in the construction of containers, apparatus and pipelines, the manufacture of self-supporting collecting pans and the sealing of concrete structures with thermoplastics. It descri- bes the different processes, highlights the limits ofthe processes and sets out requirements pertaining ‘to quality assurance. Hot-gas extrusion welding is commonly carried out on components with material thicknesses of bet- ‘ween approx. 6 and 50 mm, however thinner and thicker components can be hot-gas extruded (thicker ‘components can be produced with multi-layered welding as necessary). ‘Special instructions for the extrusion welding of ning membranes in earthworks and hydraulic engi- neering are contained in Guidelines DVS 2225-1 and DVS 2225-4. Information on the extrusion wel. ding of cased pipes can be found in Guideline DVS 2207-5. 2. — General requirements Hot-gas extrusion welding is mainly a manual welding process that cals fr extensive knowledge con- ceming the materials to be welded and handing ofthe machines and equipment, swell as high levels, of skis in the execution. Furthermore, the quality ofthe welded joins also depends on the suitably of the materials used, the Quality of the welding equipment and adherence to the welding guidelines. “The seams can be tested using non-destructive and destructive methods. “The welding work must be supervised. The extent and type of the supervision are to be agreed bet- ‘ween the partes to the contract. tis advisable to document the process data in welding protocols (see ‘example in Appendix 2). All welders must be trained and possess a valid Qualification Certificate. Guideline DVS 2212-1 is, extrusion welding in accordance with guideline DVS 2212-1, subgroups Il-1.1 to When welding materials that are not yet listed in Guideline DVS 2212-1 (for example PVC-U, PVC- C, PVDF, EICTFE, etc.), the requirements apply analogously. The certificate of qualification must be provided in the form of a proof of sutabiity, tailored to the application in question and based on the specifications of Guideline DVS 2212-1 3. Materials ‘This Guideline applies to the materials named in Supplements 1 to Guideline DVS 2207-4. “The Guideline may be applied analogously to other materials and material modifications (e.9. elect- cally conductive materials). Additional instructions from the manufacturer of the semi-finished products ‘must be observed. 4, General process description Extrusion welding is a manual or partially mechanized welding process. Work involves a welding filer made of wire or granules, which is melted and plasticised ina plasticising system (extruder). Awelding shoe shaped to correspond to the weld geometry presses the welding filer into the weld joint of the base material which is usually plasticised by hot air. Examples of other heat sources/carriers are light beams or inert gases. The compound output ofthe machines and equipment determines the maximum ‘weld dimension and affects the welding speed, The required joining pressure is generated by the es-Januar 2019 2207-4 ‘caping compound and the counterforee provided by the welder. ‘The folowing procedures are difterentiated + continuous welding process + discontinuous welding process 4.1. Continuous welding process ‘The plasticised welding filer emerging from the device or the machine, which is operated manually fr by machine, is continuously pressed via a welding shoe into the welding joint, which is also plasti- ised (Figs. 1, 3,4). During manual welding, the feed rate results from the volume of the escaping compound flow and the ‘seam cross section tobe filed. When welding with a feed system, the welding speed must be matched tothe compound output ‘The welding zone is preheated by means of a hot air blower mounted on the weiding head. Granulate hopper — Drive Extuder screw Hotigas device Pre-heating of Welding shoe cH) J, nina gov —! Direction of welding —e Figur 4. Schematic cogran for contnucus wang wih machine varia 42. Discontinuous welding process For welding purposes, the plastcised filer is removed in sections from the extruder using @ suitable Quiver, inserted into the welding joint, which has been plasticised wih a hot-gas device, and pressed in, shaped and smoothed with a pressing tool (Fig. 2) ‘This process is predominantly used where limited space or certain design details prevent continuous welding,2207-4 Januar 2019 Camprssen st Figure. Schematic diagram fr dscontnuous welting with machin vain I 5. Machine variants ‘The machines/devices consist of the + Plastcizing system (extruder) for plastiising the applied filer material + Presheating system for heating the joint surfaces (usually hot air) + Welding head for holding the welding shoe and the preheating eystem (alternative to the quiver in the discontinuous process) ++ Welding shoe for introducing the extrudate into the welding joint and for forming the surface (ater- natively the compression tool for discontinuous welding) 5A. Machine variant | Machine- or device type in which all device components form a unit. The welding filer is usualy sup- plied to the device as round wire or, in the case of larger devices, as granules, Figure 1 52. Machine variant Il The extruder and welding head are structurally separate in this type of machine. For continuous wet- ding, both parts of the machine are connected to each other via @ heated hose for the welding filer, Figure 3). For discontinuous welding, the extrudate is taken directly ftom the extruder via interehange- able compound nozzles, Figure 2. ‘The machines of ths type have a high output, but are mainly used in stationary operations because of their size. The welding filler is usually delivered to the device in granulate form.Januar 2019 2207-4 Figura 3 Schematic diagram fr continuous welding wth machine variant I 5.3. Machine variant I ‘The machines/deviees consist ofthe welding wire feed, the plasticising unit and the pre-heating sys- tem. The welding filer wire is transferred tothe heating chamber via the wire feed. The plasticised wel- ding filer is introduced to the joining zone by the wire feed via the welding shoe, Figure 4. The devices are usually smaller and more manageable than machine varians | and Il, but also have a lower output Wie feed rte {Hot gas unit A? Plasicisaton uit Figure 4. Schematc diagram for continuous waking wih machin vara 6. Structural design, weld seam shapes and weld seam structure ‘The design of the components is subject to Guidelines DVS 2205 et seq., while the design ofthe welds 's subject to Guideline DVS 2205-3 and the supplements ofthe respective guidelines. In particular, the following points must be observed: + Crossing welds must be arranged so that they are offset. The clearance should be approximately three times the fnal pass width, but at least 50 mm. +The clearance between parallel welds should be approximately three times the final pass width,2207-4 Januar 2019 but at least 50 mm. + Inthe case of butt welds, connecting ends of differing thicknesses must be levelled out in the ma- terial thickness (Guideline DVS 2208). + Inorder to reduce the weld volume and in the interest of a more even distribution ofthe residual Weld stresses, the welds should be welded on both sides or with a sealing run if possible (double butt weld, double filet weld, double-bevelled butt weld). + Ifthe epot ie only accessible from one side, the weld gear shape gelected should guarantee that the cross-section of the thinner joining part in each case can be fully connected (for example using bevelled butt weld in the case of @ Tint) +The residual material at the root of butt weld and bevelled butt weld seams should not exceed 1 ‘mm to ensure penetration +The compound iniroduced into the weld joints should be minimized because of the shrinkage stresses occurring as the seams cool down. Its therefore advisable to change the weld prepara- tion angle according tothe joining part thickness. Figure 7 shows this in schematic and graphical terms. + The welds are generally produced ina single layer. For large workpiece thicknesses (> 30 mm for butt welds, bevelled but welds and filet welds), shrinkage stresses and the formation of vacuoles can be minimized through mutt-layer welding, +The root gap should not exceed 2 mm. If, for constructional or structural reasons, the root gap \width cannot be maintained, appropriate measures must be taken (e.9. by providing a backing). ‘The most important weld shapes with thei weld seam shape and execution are shown in Figures 5! ‘and 6. Other weld shapes and angles may be required for materials other than those listed in Appendix 1 DIN EN 22553 applies to the designation, depiction in drawings and symbolie depiction of the: weld seams, Buenas 2) nde via wetedsnlogne nutans Figure 5. Welding groove preparation and weld seams inthe case of but ji. 7 Tate case of hin worpiaces, 22 5mm, the weld coverage, contrary to Guideline DVS 2202 Supplment 5, can bevptoose‘Seniennummer: DVSmedia-RBFE /-E=1US-SAFAP-ABCIG-YZTSY Januar 2019 2207-4 Figure @ Weng rove reparion and weld seams inthe case of its, Figur 7. Recommends wel preparation anges for PE-HD and PP or but wes and beveled bust wl, depending on weld depth (ther seam weld preparation may be needed cher mai) 7. Requirements 7A. Requirements for the welding machines and equipment ‘The welding equipment must be CE-compliant, operational and suitable for the weldng assignment. This also apples to accessories such as nozzles, welding shoes, thermoelectric sensors, etc ‘These must be regularly checked to establish their condition and reliability (e.g. through manufacturer ‘monitering). (Output volume and pre-heating must be adapted to the welding assignment. ‘Special requirements for the welding machines and equipment are detailed in Supplement 2 to this Guideline 7.2. Requirements for the welding shoes ‘The joining pressure required for weliing purposes is applied tothe joining surfaces withthe welding show via the filer material At the same time, the welding shoe shapes and smooths the weld seam surface. “The welding shoes must therefore correspond to the welding task, must be adapted in design tems to the respective wed shape and thickness and, n particular, must meet the requirements for weld seam. execution according to Section 10.3. [As a rule, the welding shoes are made of polyietraftuorcethylene (PTFE). This material is suficienty temperature-resisant for the materials mentioned in Supplement 1, has smooth, ant-adhesive sur- faces and can be easily machined. For welding highly fuorinated plastics, such as PFA, however, the \eiding shoes must be made of more thermally durable materials (see Supplement 3 of this Guideline)2207-4 Januar 2019 “The pressure zones and sliding surfaces ofthe welding shoes (Fig. 8) should not be less than the mini- ‘mum lengths shown in Fig. 9, a8 well as in Table 1. This ensures that the joining pressure is applied for ‘a minimum time, so thatthe required bond can be generated inthe entire joining area (in particular the root of the weld and the weld flanks). For design reasons or in the case of filet welds, welding shoes with shorter compression lengths may bbe used ifthe prescribed weld geometry and the weld quality requirements are met Welding shoes as shown in Figure 10 are often used for small welds and when welding corners. The achievable quaity of the connection must be proven if necessary. ‘The "tab" formed at the front prevents the compound from running and is a prerequisite for the ge- eration ofthe required joining pressure, as well as supporting the forward movement of the welding ‘machine. It must correspond to the weld joint shape, but must not touch the weld joint surfaces during welding “The gap / undercut Ab between the tab and the weld edges should correspond to the weld coverage as described in Section 10.3 and must be at least 3 mm and a maximum of 6 mm. The distance between ‘the tab of the welding shoe and the weld edges of approx. 1 to 3 mm prevents melted base material ‘rom being removed. When using pressure tools are used for discontinuous welding, the above provisions apply accordingly. tote ta te gv wang noe Fan weg toe Figur 8 20 eprecenaons of ferent welding shoe version. ‘ ae | ay Figure 8. Weldng shoe cross secion. Page 9Januar 2019 2207-4 Figure 10, Welding shoes for small welds and ins. “Teble 4. Referance values for welding shoe dimensions ‘Welling deph for butt wells ‘Compression nah | ‘com irom). 2S 5 35020 s 320050 = 7.3. Requirements for pre-heating Preheating must engure that the joining eurfaces and the areas af the eeam overlap (Ab Fig. 9) are sufficiently plasticised, even ifthe geometry of the weld seam changes (see Section 10.3). The welding ‘shoes and the preheating (nozzle geometry, air volume and hot-gas temperature) must be coordinated (see Supplement 2 ofthis Guideline). 7.4. Requirements for the materials and thelr weldability: ‘The semi-finished product and filer materials must be-auitable for extrusion welding. Round weiding filler (knowin as round wire) is mainly used, while granulate is also used in large-volume extruders. For Welded joints that are to comply with the requirements pursuant to Guideline DVS 2203-1 Supplements 1,2 and 3, the use ofa filler material thatis of equivalent type to the base material, or is atleast similar, isa prerequisite. For sern-crystalline materials such as PE, PP and PVDF, the melt flow rate is used as a characteristic value for weldabilty. If the melt flow rate values (MFR values) of the items to be welded together lie within the permitted melt index ranges set out in Guidelines DVS 2207-1, -11 and -15, one can gene- rally assume weldabilly.Iftwo semi-finished products in different MFR groups from these ranges are to bbe welded to one another, it is necessary to select a filler material where the MFR value lies between the values for the combination of semi-fnished products. For PE-HD, PP and PVDF, the instructions inthe "Seope" section of Guidelines DVS 2207-1, 2207-11 and 2207-15 must be observed. If the melt flow rate lies outside the ranges permitted in the above guidelines, the weiding documentation in ac- cordance with Guideline DVS 2203-4 must be provided following a tensile creep test. ‘The following applies to PVC: Only semi-finished products of the same moulding compound fype can bbe welded together. ‘The semi-fnished produets and filler materials must be labelled appropriately and so that they cannot bbe confused (on the packaging in the case of filer materials). Only semi-finished products with defined quality requirements should be welded (for example test cer- tifcate based on DIN EN 10204). ‘The filer materials. must comply with the requirements pursuant to Guideline DVS 2211 and DIN EN Page 10‘Seriennumimer: DVSmedia-ABFE7-EE 103: SAFAF-AGC36-92159 2207-4 Januar 2019 12043. ‘The base material and filler materia's must be in perfect processing condition, clean and dry. I there are any doubts as to whether the semi-finished produet andlor the filer material are ofthe same type, for example through lack of labelling, or if changes in the material are feared due to + incorrect storage, + low joining part temperatures, = contamination, = ageing, ‘operating influences (media, temperatures), \weldabilty must be determined by means of tests carried out on trial welds. The type and scope of the teats must be agreed. The Guidelines DVS 2203-1 and 2201-2 provide information on this point. 75. Requirements for the quality of the welded joints With correct execution of the welds in accordance with this guideline, the minimum requirements con- cerning quality of welds (weld strength reduction factors, angle of bend) set out in Guideline DVS 2203-1 Supplements 1, 2 and 3 are certain to be attained. With regard to the application in question, any statutory requirements (German Water Resources Act, Pressure Equipment Directive, etc.) and the required dimensions, the client and manufacturer should agree on the corresponding requirements for the component and the necessary minimum quality of the welded joints, and specify these points. ‘The Guideline DVS 2202 Supplement 5 contains information and criteria for this purpose. Proof of the required quality may be provided as part ofa suitabilly test for test welds based on Guide- line DVS 2242-1. This applies in particular to materials for which no requirements have been defined in the relevant Guidelines (for example PVC- C, PVDF, EICTFE, etc.. 8. Commissioning the welding machinery and setting the welding parameters. ‘Commissioning takes place in accordance with the operating instructions of the machine manufacturer. Before the extrusion dive is switched on, residual extrudate must be metted inside the extruder, at the outlet opening, and possibly in the transport hose. In order to avoid using thermally impaired filer material, the reheated meit should be completely extru- ded before welding begins. This also applies when work is disrupted for longer periods. The maximum. {dwell imes depend on the respective material (approx. § min. for PE and PP). For thermally sensitive ‘materials, such as PVC and PVDF, the extruder compound discharge should not be interrupted if we! ding is disrupted, \When changing materials, itis necessary to ensured that all the materials replaced by cleaning or fully extruding the welding extruder. necessary the nozzles must be changed. For machine variant I itis, also always necessary to change the hose. In practice itis advisable not to use the same extruder for different materials. ‘The filer material must be dry. if necessary, it must be dried before use (e.9. several hours in an ex- hhaust air oven at temperatures of approx. 60 - 80°C). The instructions from the filer manufacturer must be followed. While the machine is running, the required compound temperature is checked directly at the outlet in the middle of the line using the penetration probe of a fast-acting thermometer. Page 11Januar 2019 2207-4 ‘The hot air temperature is measured in the hot air nozzle between the nozzle exit level and a depth of S mm depth with a fine probe of approx. 1 mm in diameter (see the information in Guideline DVS 2207-4 Supplement 2). In the case of devices with an extemal air supply, the specified air volume must be checked; devices with their own air supply must be checked to make sure they are working propery ‘The compound and hot-gas temperature must be checked directly before welding begins. Repeated checks are recommended for longer welding assignments or following interruptions to the work. {All measurements must be carried out with calibrated measuring equipment that has been checked at reguiar intervals (in accordance with Guideline DVS 2207-4 Supplement 2) and must be documented (Appendix 2). 9. Weld preparation ‘The welding grooves ofthe joint parts are prepared in line with Section 6. It must be ensured that the joint surfaces are sufficiently accessible with the welding head of the ma- chine or device. Qut-of-position welding should be avoided or minimised, due to the necessary counter force that the welding operator must apply. Steps must be taken to ensure that, during welding, the welding operator is not impeded by the necessary adjustment of the connecting cables and hoses, and of the filer material. When welding in confined spaces, an angled welding head may be attached to the welding machine ifnecessary. 9.1. Equipment For correct execution ofthe welded joints, the following minimum equipment is necessary: Hot-gas extrusion welding device, in accordance with the welding assignment and this Guideline Welding head and welding shoes appropriate for the welding assignment Flow meter for welding gas ‘Thermometer in accordance with Guideline DVS 2207-4 Supplement 2 Suitable measuring equipment for checking misalignment, diameter, thickness Suitable tool rest Scraper, drawing blade Personal protective equipment Dust protection for welding wire Adequate lighting Measures to protect against weather conditions (see Section 9.2) ‘Special cleaning agent (non-swelling, non-dissolving and free from grease), lint-free cloths + Welding parameters in line with Guideline DVS 2207-4 Supplement 1 and/or information from the ‘semi-finished product manufacturers + Welding protocol inline with Appendix 2. 9.2. Measures to protect against environmental influences ‘The ambient conditions may have a significant effect on the welding operation and therefore the quality of the joint. For this reason, the following points must be observed + The welding area must be protected from adverse weather conditions, such as moisture, conden- sation, wind, draughts and temperatures below 5 °C. + Provided that suitable measures have been implemented (for example preheating, tenting, hea- ting) to ensure that a semi-finished product temperature suitable for welding can be maintained, then welding may be carried out regardless of the ambient temperature - assuming this does not Page 122207-4 Januar 2019 impair the welder’ ability to cary out the work. If necessary, trial welds should be produced and tested under the prevailing conditions as additional evidence. + In the case of joining parts at ctferent temperatures, for example due to one-sided exposure to sunlight, different storage conditions, etc. the temperatures must be balanced prior to welding 10. Welding 10.1. Preparing the joint surfaces, ‘The joint surfaces must not be damaged, oxidised or contaminated. They and the surrounding weld overiap areas must therefore be machined with suitable tools directly prior to welding. Machining tools such as scrapers, draw blades, miling cutters and saws are suitable. Grinding tools, are only permitted if contamination caused byy the introduction of abrasives and overheating of the surface can be ruled out. Particularly in the ease of joining parts that are exposed to UV or the influence of media for a relatively long period of time, the damaged layer may ise so deep that a check of the residual wall thickness is, necessary, with consideration of the structural requirements, is necessary after completion of the weld When the joint surfaces need to be cleaned, special, non-greasy cleaning agents must be used * 10.2. Tacking Tacking is used to ffx the joining parts in their intended position with regard to one another, in order to exclude the possibility ofthe joining parts shifting position during welding. Tacking is usually achieved by partial or continuous hot-gas string-bead welding of a root pass with welding filer wire. 10.3. Welding procedure Before the welding process begins, the welding lug must be warmed up (e.9. by means of a deflection plate), as when welding with a cold welding shoe, a rough and uneven weld surface is created. This also applies to pressure tools during discontinuous welding, ‘The start ofthe weld is preheated with hot air and melted. Already discharged welding filer is removed from the welding shoe opening immediately before the welding shoe is placed on the welding joint. After the joint has been filed, the compound pressure builds up due to the back pressure generated by the welder. The tab on the welding lug deflects the pressure and causes the welding shoe to move forwars, ‘The compound output of the extruder and the size of the seam eross-section determine the welding speed. ‘The hat-gas output must be adjusted to the welding speed so that the base material is plasticised bey- ond the seam width to a depth of between 0.5 and 1 mm. ‘The weld width results from the material thickness and the weld preparation angle. ‘The plasticising zone must be wider than the weld (Weld width + at least 2 mm), The casing uid, or fui usec to impregnate ccthe dampened 3 the factory, must consi of 2100 % eraporabie sohvert, €g of 89 pars efanol wth adagre of pry of $8.8 ard ane pat MEK (methyl ey! ketone, denaturing). Mate tested according to DVGW VE 60S conforms this specfeation, The use of whit spnt Can result ina degradaton in quay (due tots watar contre. The paper used for deaning must be clean, previously unusea absorber. sree and must nt be red Page 13Januar 2019 2207-4 ‘The weld overtap Ab should be = 0.2 x oining part thickness, but at least 3 mm and at most 6 mm Reinforcement As should be 2 0.2 x joining part thickness and < 0.4 x joining part thickness, but no more than 6 mm. Reintersemert ae Ds Recto walt ~ Pieaiation one ning planes Figure 41, Example ofa sngle-V but wald with indication ofthe meling zones andthe seam ove. ‘The melting depth is checked immediately in front ofthe welding lug. This can be checked with a nar- row, blunt too! ‘The welder must take care that the melted base material at the eeam edges is not removed by the lug on the welding shoe. Before applying new material and at weld ends on round seams, the already welded seam ends are-to bbe removed at an angle. If multi-layer welds are required, the cooled weld edges and surfaces of the already welded layers must bbe machined. ‘To avoid excessively fast cooling of the weld surface and the resulting formation of voids, itis recom- mended, itis advisable to cover the extrusion weld immediately after welding, especially in large- volume welds. Design-related changes in the seam geometry in the weld (e.g. in segment arches and branches) require particularly careful manipulation of the welding shoe. If necessary the welding shoe must be changed, Inthe case of partially and fully automated systems and equipment for extrusion welding, the welding parameters for compound output, preheating and welding speed must be coordinated and adjusted accordingly. We recommend that test welds should be produced During ciscontinuous welding, the welding filer is taken from the extruder with the quiver and inserted section-by-section into the plasticised weld joint. The joining pressure is applied in several steps ac- ross all seam cross-section areas (middle and edge areas) with the compression tool, while the weld surface is formed at the same time. 10.4. Mechanical post-processing of the welds ‘The choice of the right welding shoe design and machine guidance during welding can avoid the need to rework the welds (see also Guideline DVS 2202-1, Table 5) Page 14Seriennummer: DVSmedia-ABFE7-EE103-SAFAF-A6C36-92159 2207-4 Januar 2019, ‘Any material pressed out to the side from under the welding shoe bearing surfaces must always be: removed (Fig. 12) Any resulting fat notches must not be any deeper than a maximum of 10% of the ‘material thickness. Excessive weld beads and excessive weld roots are to be removed without creating any notches. “The weld may only be dressed after it has cooled sufficienty, The weld should be allowed to cool to ‘approx. 30 °C lukewarm) before a load is applied. Figure 12. Weld seam wih surplus beads before and after mechanical processing, 105. Thermal post-treatment of welds Inherent welding stresses can be reduced through tempering. The tempering conditions depend on the ‘material and the component. The instructions from the manufacturers must be folowed. 10.6. Welding protocol ‘The completed welding protocol documents the welding conditions and welding parameters, among other things. Itforms the basis for assessment of the weld quality by the welding supervisor (Guideline DVS-2213) see sample protocol in Appendix 2 44. Checking the welded joints Adistinction is made between non-destructive and destructive test methods, These methods are listed in Table 2 "Possible test procedures" for the main weld shapes. “The visual inepection according to Guideline DVS 2202 Supplement 5 focuses particularly on the weld shape, surfaces and edge areas that are free trom grooves, optimal weld filing, complete fusion on the: root side and offset ofthe joining parts. The general dimensional and visual inspections of components are specified in Guideline DVS 2206-1, BBy testing with ultrasound (see Guideline DVS 2206-3), defects inside the welds can be determined in a non-destructive manner. However, these alone do not provide sufficient information on the quality of ‘the welded joint. n addition, the possible uses ofthese test methods are limited with regard to the weld geometry and the thickness ofthe weld. “The type and scope of the tests must be defined on an individual basis. Material specific tests can be found in the Guideline DVS 2201-1 “Tabla 2. Common test methods for extrusion welds, ppiabilly and requirements ‘Non-dostrucive tasting Visualnspecton of the undamaged seam [Wiss inspecion ofthe seam surface and seam geomaty. (enema ndings) Ealuston nine vith Guieane DVS 2202 Suppimert 9 based onthe qualiy level be detrmined in he indvidual Case, pursusr wo Guideine OVS 2202, Secton 3. Teak es wih vacuum ‘Using suitable vacuum cups and fearing ig. The 12s condone must be defined for aac india case, Ul test presure0.4 9-0. Sbzr, tes! period approx. 10sec. Page 15‘Senennummer: DVSmedia-ABFE/-EE1US-SAFAF-ABCSE-Y21S9 Januar 2019 22074 Teale tes oh aecrical gp volage ‘Execution feat and aqupment requrementsin ine wih Guideline DVS 2206-4. The typeof text equpment (wah or \whou reciprocal pole) and te test votoge must be detfied foreach incividsal case Further detal-can be found in DIN EN {4879-4 and DINEN 134004. Uiraronie xing ‘Execution and application lmiations mine wth Guvaine vs 2206-2 Destructive tests Visual inspection ofthe seam Goss secion Visual inspection ofthe seam cross-section afr cing (etemalfrdings) open the sear. Evaluation is ne with Guideline DVS 2202, SUpplemant 6, bazed on the quaity lave determined nthe indvidval case, pursuant to Guideline DVS 2202, Section 3. Teale eat ‘Execion in accordance with Gudeina DVS 2202-2, min ‘mum requiemeris in accordance with Guideline DVS 2208. 4 Supplement 4 (Creep rigtire tonsie text ‘Execution in accordance with Gudeina OVS 22024, mine ‘mum requirements in accordance wih Guideline DVS 2203 {Supplement 2. Technoiagical bend ist “Execution in accordance win Guideline DVS 2202-5, mine ‘mum recuemerts in cordance wih Guideline OVS 2203 1 Supplement 3 12, Safety guidelines When overheated beyond the thermoplastic state (decomposition range), some materials develop ‘dangerous products of decomposition and fumes that are hazardous to health (for example PVC, PVC- ‘C, PVDF), while others, such as E/CTFE, FEP and PFA, develop these during welding, ‘When these materials are welded, strict safety requtations must therefore be observed. information ‘on this ean be found in Guideline DVS 2207-3 Supplement 3 and the respective semi-finished product manufacturers. Based on the safety data pane's to be provided by the manufacturer in accordance with Article 14 of the German Hazardous Substances Directive, the company must produce operating instructions that hhighlight all the potential risks and the necessary protective measures. Other specific protective mea- ‘sures need to be taken as necessary on a case-by-case basi In areas at risk of explosion, the applicable safety regulations must be observed with regard to welding ‘work and any necessary measures must be coordinated with the responsible safety officer; see also the German Ordinance on Industrial Health and Safety (BetrSich¥), 13. References 43.4. Regul DIN 19103 Welding of Plastics, Processes DIN EN ISO 2553 Welded, brazed and soldered joints ~ Symbolic representation on drawings: DINEN 10204 Metallic products - Types of test certificates Guideline “Joining of plastics - Acronyms and abbreviations - Welding processes Dvs 2200-1 Supplement 4 Guideline Testing of semi-finished products made of thermoplastics — Weldebilty - Test Dvs 2201-2 methods ~ Requirements Page 162207-4 Januar 2019 Guideline Imperfections in thermoplastic welding joints — Features, descriptions, evalua- Dvs 2202-4 tion, Guideline Testing of welded joints of thermoplastic sheets and pipes — Requirements in Dvs 2203-1 the tensile test— Short-term tensile weld strength reduction factor ‘Supplement 4 Guideline Testing of welded joints of thermoplastic sheets and pipes — Requirements in Dvs 2203-1 tensile creep test — Tensile creep test weld strength reduction factor ‘Supplement 2 Guideline ‘Testing of welded joints of thermoplastic sheets and pipes — Requirements in Dvs 2203-1 technological bend test — Bending angle/bending path ‘Supplement 3 Guideline ‘Testing of welded joints of thermoplastic sheets and pipes - Tensile test DVS 2203-2 Guideline ‘Testing of welded joints of thermoplastic sheets and pipes; Creep rupture Dvs 2203-4 tensile test Guideline ‘Testing of welded joints of thermoplastic sheets and pipes; Technological bend DVS 2203-5 test Guideline Calculation of thermoplastic tanks and apparatus, welded joints Dvs 2205.3 ‘Guideline Non-destructive testing of tanks, apparatus and piping made of thermoplastics Dvs 2206-1 = Dimensional checking and visual inspection ‘Guideline Non-destructive testing of tanks, apparatus and piping made of thermoplastics Ds 2206-3 = Testing using ultrasound Guideline Non-destructive testing of tanks, apparatus and piping made of thermoplastics Dvs 2206-4 = Testing with efectrical high voltage Guideline Welding of thermoplastics - Heated tool welding of pipes, pipe components and Dvs 2207-1 sheets made of PE-HD Guideline ‘Welding of thermoplastics — Hot-gas string-bead welding and hot-gas welding DVS 2207-3 with the torch separate from the filer rod of pipes, pipes, pipe components and ‘Supplement 1 _ sheets - Welding parameters. Guideline ‘Welding of thermoplastics — Hot-gas atring-bead welding and hot-gas welding DVS 2207-3 with the torch separate from the filer rod of pipes, pipes, pipe components and ‘Supplement2 sheets, requirements for welding equipment Guideline Welding of thermoplastics — Extrusion welding of pipes, pipes, pipe compo- Dvs 2207-4 ents and sheets — Welding parameters ‘Supplement 1 Guideline Welding of thermoplastics - Extrusion welding of pipes, pipes, pipe compo- Dvs 2207-4 nents and sheets, Requirements for the welding machines and welding equip- ‘Supplement2 ment Page 17Januar 2019 Guideline Dvs 2207.5 Guideline Dys 2207-11 Guicetine Dys 2007-46 Guicetine Dvs2z104 Guideline Dvs22104 ‘Supplement 2 Guideline Dys2211 Guicetine Dys 22124 Guicetine Dvs 2213, Guideline Dvs 2226-4 2207-4 \Vielding of thermoplastics - Welding of PE casing pipes — Pipes and pipe components \Vielding of thermoplastics - Heated tool welding of pipes, pipes, pipe compo. nenis end sheets made of PP. \Vielding of thermoplastics - Heated tool welding of pipes, pipes, pipe compo. rents end sheets made of PVDF Industrial pipelines made of thermoplastics - Planning and execution - Above- ground pipe systems Industrial piping made ol thermoplastics ~Planning and execution — Above- «ground pipe systems - Recommendations forthe internal pressure and leak teats Filer materials for thermoplastics Scope, designation, cequiterneis, tests (Quaiifcation testing of pasics welders; Guaification test groups andl ‘Speciatstfor plastics welding and testing Wielding o ning membranes made of polyetrylene (PE) for the sealing of landfill and contaminated sees DDIN standards can be obtained from Beuth Veriag, Berin, OVS leafets and Guidelines can be ottained from DVS Media GmbH, Disseldrt. Page 182207-4 Januar 2019 Appendix 4. Quick guide to welding, 4. Putting together the welding equipment (Section 9) + Valid welder's certificate +The hot gas extrusion welding equipment appropriate to the welding task with operating instruc- tions Possibly a hot-gas welding device for tacking the joining parts Welding shoes in line with the weld shape Flow meter for welding gas ‘Thermometer with sensors to measure the hot-gas and extrudate and the temperature of the semi-finished product Suitable measuring equipment for checking misalignmenticiameterithickness Tool rest Scraper, drawing blade Personal protective equipment Dust protection for welding wire Cleaning agent ‘Supplement 1: Materials and welding parameters Appendix 2: Welding protocol ‘Special welding procedure specification: 2. Check working conditions and arrange measures (Section 9) Accessibility ‘Adequate lighting Protective tent Heating ‘Adequate ventilation J fume extraction + Special protective equipment 3. Checking weldability (Section 7) + Check the manufacturers information regarding the semi-finished products and filer materials to ensure @ match + Check the condition and cleanness ofthe items to be joined and clean if necessary + Where necessary, check the weldabilty of the items to be joined by surface welding in accordance with Guideline DVS 2201-2 or by trial welds. 4, Preparing the weld seams and joint surfaces (Section 6, 10) + Check, define and establish the weld geometry and weld shape + Remove oxide layer on the joint surfaces 5, Tacking the joining parts (section 10) + Partial or continuous root pass with hot-gas welding device 6. Commission and prepare the weld extruder (Section 8) + Check supply ines (current, air) for anything that could obstruct the welding operation Page 19‘Senennummer: DVSmedia-ABFE7-EETWS-SAFAF-ABUSE-Y21EU Januar 2019 2207-4 + Connect and start the extruder in tine with operating instructions + Select, adjust and mount the welding ehoe and hat-gas nozzle according to seam geometry and seam shape + Extrude re-heated welding filer from the cylinder + Set and check parameters (Appendix 1) + Pre-heat the welding shoe 7. Welding (Section 10) ‘Check for sufficient plasticisation of the base material (for example by piercing with a blunt too!) Check speed of travel and monitor evenness CCheok the weld extruder continuously and make the necessary corrections Ifnecessary cover the surface of the weld to prevent it from cooling down too quickly Bevel seam ends before new starts + Protect filer material from contamination 8. Post-processing of the weld seam (Section 10) + Allow welded parts to cool sufficiently before unciamping them and subjecting them to loads + Mechanical dressing of escaped weld seam material and weld reinforcements 8. Drawing up a welding protocol (Section 10) + Complete welding protocol (Appendix 2) and carry out visual inspection in line with Guideline DVS 2202-1 rage 20Januar 2019 2207-4 ‘Appendix 2. Welding protocol for extrusion welding. vwoamene | gtouresen | Covspos) |” 99 | sour wegen] Set | come | USS | sll oa ‘rmx | tee | Sette! | see | ean enaoen | sedate] 9 | uscrte| “eer | meme ho Seal sadid pue sjoued jo Buypjam uojsnnxg Page 21‘Reprinting and-eepying, evenin the xm of excerpts, ony wih the consentof fe pubsher Januar 2019 Technical Code DVS - German Welding Saciaty Dvs 2207-4 ‘Supplement 1 Transtation ofthe (Garman issue (ay 2018) Technical Code DVS 2207-4 Supplement 1 Welding thermoplastic materials Extrusion welding of pipes, piping parts, fittings and panels Welding parameters Technical Comittee in DVS Working Group W 4 “Joining Plastics” “This pubicaon has been draum up by 2 group of experienced specastsworkingin an honerany capacty andi conside- ‘aon 2s an ieporiant courceofnfrmstion is reconmended. The ser should slays check to what extent the Cones a2 ‘appicabe to hs particular case and whether te version on hand sil vai No labbty canbe accepted bythe OVS ~ Deut- ‘Sther Verband ir Schweden und verwandie Verfaiven ©, andhose panicpatng the crauing up of the document (Orders so: DVS Masia Grit, P.O. ex 10 1965, 40090 Dlssekiort, Germany, Phone: #49(0) 21115810, Tear: +49 (0) 214/199%- 180Januar 2019 DVS 2207-4 Supplement 1 ‘This supplement to Guideline DVS 2207-4 contains parameter reference values for hot.gas extrusion welding. They apply to manual welding with the machines and equipment specified in Guideline DVS 2207-4 Supplement 1 and the materials ised in Table 1 ‘When welding is carried out with welding machines, other parameters may also be required (see sec- tion 10.3), “The welding speed depends directly on the compound output, the weld cross-section and the prehea- ting temperature. Experience indicates it should be between 200 and 350 mmimin, lt must be ensured that the parts to be joined are plastcised to a depth of between 0.5 mm and 1 mm. atthe joint and across the width of the weld (gee Section 10.3). “Tao 1. Welding parameter reference values. ‘compound otgas otges Materials | Avrevietion temporature® | temperature > volume ro. rel rc Poyetiyiene Pee 210.230 Zo..00 150.400 Polypropylene | PPHLPPE PPR 210.240 250..300 10.400 Type 23 Poininyicnonae | PVCU 180.200 30,360 760.400 passed | Poininyicherde | PVEHI 170.180 280.20 780.400 igh impact resistance Poininyichonde | VES 16.25 0.350 760.400 chonnated Polpinyiaene foods [PVDF 250250 220,250 150.400 ‘measured with a thermometerinsened athe extruder cute of he welding machine Measured atthe cere of he nz oie, 8m ino the noe 3 Caldantake volume tambien pressure, depending on the cut volume “BE 6, PE a0, PE 100 Page 2‘Reprinting and epying, even inthe form of excerpts, oy Win the consent he pubs her Januar 2019 gaya WELOING Technical Code DVS. German Welding Society Dvs 2207-4 ‘Supplement 2 Transtation of the German issue (duly 2018) Technical Code DVS 2207-4 Supplement 2 Welding thermoplastic materials Extrusion welding of pipes, piping parts, fittings and panels Requirements for the welding machines and welding equipment Technical Comittee in DVS ‘Working Group W 4 "Joining Plastics” “This pubcatin has been drawn up by 3 group of experienced specialists werkng in an honorary capacty ands conside- raion as an important source of iflrmaton is recommended. The user shou lvays check to what extent the comets are “Sposa os particular case and whether ne version on Mand ssl vad. No ably can be accepted bythe DVS ~ Dese- ‘Scher Verband fur Schwaiten und vrwandie Verfahren eV, and those partipating inthe drawing up ofthe document.Januar 2019 Content: 1 Scope 2 Requirements 24. General requirements 22. Marking and documentation 23. Safety requirements, 24. Plasticizing system 25. — Pre-heating system 26. Welding shoes. 27. Accessories for discontinuous welding 3. References 3.1. Regulations 32. Bibliography DVS 2207-4 Supplement 2DVS 2207-4 Supplement 2 Januar 2019 Scope ‘This supplement to Guideline DVS 2207-4 describes the general, qualitative and safety-relevant requi- ements for machines and equipment for extrusion welding of thermoplastic materials. It applies to machine variants |, II and Ill specified in Guideline DVS 2207-4 and seeks to ensure that the seam quality required in the guideline is achieved during the proper handling and use of the equip- ment and machines. Requirements 24. General requirements ‘The machines and equipment must ensure that + reliable operation is quaranteed within the correct temperature range of -10 to +60°C, + storage within a temperature range of -20°C to +80°C does not cause any damage, + the mechanical loads incurred during proper transport and operation do not cause any faults or damage, + suficient protection against corrosion from externally-acting humidity and against the intended filer material or its components is present on the internal surfaces and in the screw, + the machines and equipment tools are ergonomically designed in accordance with their purpose: ‘and handling and can be used easily and safely, + allparis and functional components can be easily accessed in accordance with their intended use ‘as well as for cleaning and maintenance purposes, + the necessary joining pressure can be applied at the appropriate welding positions by means of ‘corresponding clamping devices and handles. + supply hoses and cables are flexible and cause no great exertion for the welder, neither do they kink or twist during correct use, + the preheating of cooled extrudates at the output ofthe compound nazzle is assured by suitable means, e.g. a bypass nozzle for the hot-gas, + they can be securely stowed away after the welding operation has been completed or during stop- pages. “The equipment must comply with the applicable European directives (see also section 3). ‘The manufacturer or his authorised representative established in the Community is responsible for issuing the EC Declaration of Conformity and CE mark. The market surveillance authorities must on request be presented with all relevant measuring and testing documentation that verifies. conformity with the directives. 22. Marking and documentation. ‘The following must be permanently affixed to all machines and equipment: Manufacturer's details and equipment type Power supply, power consumption and frequency details + ID number and + CE mark and protection class. Page 3‘Senennummer: DVSmedia-ABFE/-EE1US-SAFAF-ABCSE-Y2TSE Januar 2019 DVS 2207-4 Supplement 2 (Operating and maintenance manuals must be provided for all machines and equipment These must, ‘contain atthe very least Functional description with operating instructions Details ofthe application area (power range), ‘Maintenance plan with test cycle details and Service addresses. ‘A.compilation of possible operating errors including possible causes and solutions is recommended. 2.3. Safety requirements ‘The machines and equipment must not pose any risk of injury to the user. In particular: + surfaces that become hot must be kept as small as possible and, if technically possible, should be insulated, + Pars in proximity to the user must not exceed an operational temperature of + 40°C, even during periods of extended use, + no sharp edges are permitted on the machine, equipment or accessories. ‘The machines and equipment must comply with the applicable regulations and directives. 2.4, Plasticizing system ‘The following requirements must be satisfied + Even delivery ofthe filer materia to all the designated welding positions in accordance with the speed of the screw + Asuitable barrier must be present on the corresponding machinery or equipment to interrupt the supply of granulate. + Ifthe compound temperature and the hot-gas temperature (if integrated in the system) are higher or lower than the specified tolerance limits, then an automatic drive lock and an overtemperature protection device must be activated. + Compound output above 1.5 kg/h should be fully adjustable on the machine or device by means of the screw speed. Constant speeds are permissible for machines and equipment with which only discontinuous welding takes place. + Adrive lock must be activated for the time required to heat the welding filer that has cooled in the extruder and in the feed hose. + The interrupt switch (on or aff forthe plasticising system must be positioned so that it can be acti- vated by the welder at any time. This also applies to the compound temperature controler. + The extrudate must be fully homogeneously plasticised and temperature stable with a constant ‘compound output +The compound temperature at the compound output must be displayed + Temperature fluctuation of the compound must not exceed +/- 3 K (measured at the centre of the ‘mass) during continuous operation and with a constant control setting. + The deviation between the temperature set on the controller and the actual outlet temperature ‘must not exceed +/- 10 K. Page 4DVS 2207-4 Supplement 2 Januar 2019 ‘The following applies to machines and equipment used solely for discontinuous welding: + The compound nozzles must be easily interchangeable. + The nozzle diameter must correspond to the respective seam volume to be welded, 25. Precheating eystem ‘The preheating system must ensure that the weld edges, weld overiap and weld root are sulficiently lasticised. This can be achieved with different systems, for example using hot-gas or radiant heat Based on the practical application, only preheating by means of hot-gas wil be discussed below. + Inline with the material tobe welded, the hot-gas temperature is infinitely adjustable and is dis- Played. Temperature fluctuations with an unchanged controller setting must not exceed +/- 10 K. Welding gas temperature must be achieved after max. 10 minutes. + The volume flow must be kept constant during the welding process (for welding parameters see Guideline DVS 2207-4 Supplement 1). + The preheating system is permanent installed on the welding head or on the plasticising system. ‘The pre-heating system is operated independently of the plasticising system in the case of machi- nes and equipment with which only discontinuous welding takes place. + The hot-gas nozzle must ensure intensive and uniform preheating (plasticisation) of the base ma- terial over the entire weld width - with the lowest possible hot gas temperature. The distance from the hotgas nozzle to the base material must be adjusted accordingly. ‘Table 1 shows an example of nozzle geometry. The nozzle cross-sections shown in the table ensure reliable overiapping ofthe different weld seam geometries and weld widths [1]. The present basic geo- metry must be scaled up accordingly for larger weld joint widths. Itmust be easy to change the nozzle on machines and equipment with which only discontinuous wel- ding takes place. ‘Table +. xamles of welting nezae geometry an air outlet ress sections for weld seam wich upto 40mm, Teese er (air outlet) ‘Weld width x Neale (rm) 7 z z }-—ss 3 = } 16-20 fn z Lo 2.20 @ Eg a0 i = Maxima welding jit wih 2.6. Welding shoes ‘The welding shoes must comply with the specifications in DVS 2207-4, section 7.2 ‘The welding shoe must be securely fastened and should be easy to replace (not applicable for devices that are only used discontinuously for welding). Page 5Januar 2019 DVS 2207-4 Supplement 2 2.7. Accessories for discontinuous welding ‘The compression tools used in discontinuous welding must ensure that the extrudate is applied and compressed as uniformly as possible. The radius of the compression area with an arc length of 120 = 430 mm is approx. 100 mm. The width of the compression area corresponds to the weld width. The ‘edges of the compression area must be rounded. If necessary, special compression tools are required for special seam geometries. ‘The quiver consists of a PTFE tube with a handle that can be used to close the tube on ane side. The inner diameter of the tube corresponds to the filer material to be accommodated, 3. References 3.1. Regulations Prods Gesetz Uber die Bereitstellung von Produkten auf dem Markt (German Product Safety Law) Guideline Welding of thermoplastics — Extrusion welding of pipes, pipes, pipe compo- vs 2207-4 nents and sheets — Processes and requirements Guideline Welding of thermoplastics — Extrusion welding of pipes, pipes, pipe compo- vs 2207-4 nents and sheets — Welding parameters ‘Supplement 1 GUY 100-500 Machines of the chemical, rubber and plastic industry 32. Bibliography [1] Gehde, M.: Zum Extrusionsschweilten von Polypropylen. (Extrusion Welding of Polypropylene.) Doctoral Dissertation, University of Eriangen-Nuremberg, 1993. Page 6