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Welding
4 Electrofusion welding 14
4.1 Basic conditions 14
4.2 Weld seam preparation 14
4.3 Welding process 14
5 Friction welding 15
5.1 Process 15
5.2 Weld seam preparation 15
5.3 Welding process 15
6 Extrusion welding 17
6.1 Weld seam preparation 17
6.2 Temperature 17
6.3 Influence of moisture 18
6.4 Equipment 19
6.5 Rework on the weld seam 20
6.6 Avoidance of void formation in the welded seam 21
6.7 Types of seam 21
6.8 Variables enabling flawless weld seams 22
8 Welded joints 26
8.1 Structural strength of welded joints 26
8.2 Position of weld seams 27
The term plastic welding means the permanent joining of Only plastics of the same kind, e. g. PP and PP, and within
thermoplastics by applying heat and pressure, with or without these types only ones with the same or a similar (adjacent)
the use of a filler. The processes erroneously described as molecular weight and the same density, can be welded to
cold welding or solution welding are no longer included in this one another, whereby colour does not have to be taken into
term because here the surface is dissolved and adhesively account.
bonded with solvents.
Welding station equipment includes not only a hot-gas welding Optimal values only arise if the base material and rod are
unit with nozzles (high-speed welding nozzles in diameters 3, equally ductile. At intervals the units have to be checked for
4 and 5 mm, fan welding nozzles, tack nozzles, profiled rod temperature and air flow and readjusted if necessary.
nozzles), thermometer, air flow meter, oil and water separa-
tors. Thermometers or temperature measuring stations with a Before the welding rod is applied, the starting point is pre-
needle-shaped tip have proved to be ideal because they can heated briefly until the surface is plasticised down to a depth
be pushed into the nozzle in order to measure the tempera- of approx. 0.5 mm. Before every new welding pass the weld
ture. Accurate measurement of temperature takes place seam and the oxide layers appearing more and more quickly
without contact 5 mm inside the nozzle (see Table 10). It is at high temperatures are scraped out by machining with
one of the preconditions for weld seams with a high weld suitable tools.
factor (see Section 7.2).
To avoid distortion it is important for each weld seam to cool
down in the air before a new layer is applied. If relatively
2.2 Weld seam preparation thick sheets have to be welded with DV seam preparation, the
sheet must be turned over after each welding layer so that
The most important types of seam are the DV-(X) seam, the the seams are always arranged in sequence opposite to one
V seam and, for sheets to be welded at right angles, the fillet. another. When welding, it is important to ensure that there is
Sheets must have been properly straightened and have a a heated zone of equal width on both sides of the seam, the
chamfer of 30°– 35°. This can be performed with a plane, width being approx. 5 – 8 mm. To ensure a good connection of
straightener, milling cutter, knife, saw or card scraper. sheets to one another it is also important to obtain a double
bead, whereby both sides fuse in their ductile zones. The
The seam used most frequently is the DV seam, in which the molecular chains flow into one another and a double bead is
welding is performed from both sides alternately, in order to created.
reduce distortion. For relatively thin sheets and structures
where it is only possible to perform welding from one side it
is advisable to make a V-seam. Cleaning of surfaces to be a)
welded on sheet and rod by machining is essential.
b)
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V-seam
2 1x4
3 3x3 Correct welding rod guidance
4 1 x 3 and 2 x 4 Welding direction
5 6x3
DV-seam (X-seam)
4 2 (1 x 4)
5 2 (3 x 3)
6 2 (3 x 3) Incorrect welding rod guidance
8 2 (1 x 3 and 2 x 4) Unacceptable stretching
Welding direction
10 2 (6 x 3)
Welding filler
Welding nozzle
Contact pressure Oscillating
motion
Base material Preheating
Working direction
PP PFA
Weldability is confirmed within the melt index group with MFR Hot-gas temperature: 450 – 480 °C
(190/5) 0.4 – 1.0 g/10 min. You can read this statement in Hot-gas flow: 50 – 60 l/min.
DVS 2207 Part 11.
For the other fluoroplastics it can be assumed that the weld
PVC will be of high quality if the melt indices of the materials used
Even though it is not possible to derive a weldability statement are close to one another (see also DVS 2207-3, Supplement
for rigid PVC using the melt index, the moulding compound 3). In case of doubt, tests will be necessary.
name defined by DIN EN ISO 11833-1 is again used as a basis.
High weld seam quality is achieved for those materials that
meet the following specifications / classifications:
Pressure
Adaptation pressure
Joining pressure
Build-up time
Fold welding
PE 220 140 ~30
PP 230 150 ~45
PVDF 240 160 ~45
Bending
PVC 220 170 ~30
Finished
joint
The weld seam area must not be allowed to cool down and the
use of coolants is not permitted.
At pipe diameters
J ≥ 63 mm PE-HD and PP Warming
J ≥ 50 mm PVDF
an appropriate welding jig must be used.
After that, in the case of all welds an insertion depth mark has
to be applied to the pipe ends.
Welding process
The welding tools are heated to 260 ± 10°C. A temperature
check is performed with a fast-indicating surface temperature
measuring instrument or with an infrared thermometer. For
warming up, the fitting is first pushed on up to the stop and
then the pipe is pushed in up to the mark. The parts to be
welded have to be heated according to the times specified in
Tables 27 to 29.
When the warming time has elapsed, the fitting and pipe are
removed from the heated tool with a jerk and pushed together
up to the mark and up to the stop, respectively, without
twisting or tilting. The parts joined must be fixed in position
and cooled down according to the specifications in Tables 27
to 29.
Lead to the
4.2 Weld seam preparation
welding unit
5.1 Process
The connecting surfaces of the parts to be welded must be Figure 14: Welding the seam
devoid of soiling. Cleaning agents that have a dissolving or
swelling effect on the plastic must not be used.
5.3 Welding process
For the success of a welding process the geometric configura-
tion of the connecting surfaces is important. In the case of a The workpieces to be welded are clamped into a jig (see
butt joint between parts up to a diameter of about 40 mm the Figure 15); then one of the workpieces is rotated against the
connecting surfaces must be turned (butt seam) whilst in the other one, which is usually stationary. When the welding
case of parts with a diameter above 40 mm one or both temperature has been reached – the correct time is evident
connecting surfaces have to be shaped slightly convex by from the fact that plasticised material oozes out all round the
machining (fillet) (see Figure 14). perimeter – the fixture of the stationary workpiece is released
and consequently the rotary motion of the two workpieces
Thin-walled parts (pipes) must be supported near the con- against one another is terminated as quickly as possible. The
necting surfaces in a suitable manner. joining pressure is maintained until adequate cooling has
taken place.
Centre point,
rotatable
Drive
Jig, locked
Jig, unlocked
Figure 15: Principle of friction welding; left: prepared for welding; right: welding completed
Preparation zones
6.2 Temperature
Table 4: Temperature
SIMONA® materials Material names Temperature of extrudate Air temperature measured in Air flow
according to DVS measured at the nozzle outlet the hot air nozzle (cold air intake)
(TM) (TL)
°C °C l/min
PE-HD PE-HD 210 – 230 250 – 300 ≥ 300
PE 100 PE-HD 210 – 230 250 – 300 ≥ 300
PE FOAM 210 – 230 250 – 300 ≥ 300
PP-H AlphaPlus®/PP-H/PP-C/PP-R PP-H/PP-B/PP-R 210 – 240 250 – 300 ≥ 300
PP FOAM 210 – 240 250 – 300 ≥ 300
PVC-CAW PVC-U 170 – 180 300 – 360 ≥ 300
CPVC PVC-C 195 – 205 300 – 360 ≥ 300
PVDF PVDF 240 – 260 280 – 350 ≥ 300
ECTFE ECTFE 270 – 300 340 – 380 ≥ 300
➀
Approximation is possible by means of linear interpolation
6.4 Equipment
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J Plasticization depth is 0.5 – 1.0 mm.
J The extruded compound is brought into form with a weld-
ing shoe and pressed into place.
J Compared to hot-gas welding, shorter working times and
higher levels of strength are achieved whilst seam quality
is high and inherent stresses are low.
Figure 19: Welding shoe
Design of welding shoes
The extruded welding filler is brought into form with a welding
shoe, e. g. made of PTFE, and pressed into place. The follow-
ing factors depend on the shape of this welding shoe:
J Shot capacity
J Injection speed
J Material flow
J Seam seal / type
V-seam Fillet seam
J Uniform pressure
Figure 20: Design of a welding shoe
Welding shoes must be adapted to the particular type of
seam. General rules: The wider the weld seam, the longer the
shoe should be (see also DVS 2207-4). 6.5 Rework on the weld seam
The only materials that can be used for the welding shoe are Weld seams should always be made so that no subsequent
plastics with high thermal resistance, and PTFE has proved machining is necessary. Extrusion weld seams should have a
successful. Apart from the required high thermal resistance uniform smooth surface and flawless welded edge zones.
this plastic has good slip properties and is anti-adhesive.
To avoid notches in the seam root a root sealing run or seam
securement can be hot-gas welded.
Voids develop only after the welding process proper. They can
be reduced by altering the level of moisture, the cooling rate
and welding shoe geometry, and, to a minimal extent, by
varying the welding parameters.
Figure 23: Butt joint weld with DV-seam – weld seam without gap
Table 6: Examples of the dimensional design of a welding nozzle and the cross-section of the air outlet aperture for welding operations up to 40 mm
(DIN EN 13705, 2004)
xV-profile xX-profile x x x x
x
x profile
x x x x x
xx
x
x
Weld seam T-profile Angle profile Overlap
x
x
x
18.00 23.0023.00
23.00 23.00 32.0032.00
32.00 32.00 48.0048.00
48.00 48.00
18.0018.00
18.00
Figures: © www.leister.com
7.2 Weld factor (tensile test) Figure 24: Illustration of mechanical testing
(DVS 2205-1 BB 6)
the joint and hence the quality of the weld seam as executed. h
50
The creep of a welded joint can only be determined to a limit-
Ls α
ed extent by the results of a bending test. Lt
Table 8: Dimensions of the test specimens and the experimental setup (DVS 2203-5)
Test specimen Experimental setup
Thickness h Width b Minimum length Lt Effective span L S Bending die
Nominal dimension Pipe Sheet thickness d
mm mm mm mm mm mm
3<s≤5 20 150 80 4
5 < s ≤ 10 0.1 x d ➀ 20 200 90 8
10 < s ≤ 15 Min.: 6 20 200 100 12.5
15 < s ≤ 20 Max.: 30 30 250 120 16
20 < s ≤ 30 30 300 160 25
➀
Nominal diameter
50 25
Test specimen thickness [mm]
HS
30 HS 15
20 10
WE, WF
WZ
10 5
WE, SIMONA®
WZ
PVC-CAW,
SIMONA® PVC-MZ-COLOR,
0 PE-HD, PE 100 0
PVC-GLAS
0 6 12 18 24 30 0 6 12 18 24 30
Bending distance [mm] Bending distance [mm]
30 30
25 25
Test specimen thickness [mm]
20 20
HS
15 15 WE , WF
WZ
WE, WF
WZ
10 10 HS
5 5
Figure 26: Dependence of minimum bending distances for SIMONA® Semi-Finished Products on test specimen thickness
0% 100 %
Figure 29 shows connections that are being exposed to a
tensile load. Tensile stresses and shear stresses development
in the seam zone. A machined V-seam provides high structural
strength because the flow of force is not hindered and the
notch effect is minimised. In the case of simple butt strap
joints there are not only thrust forces and tensile forces but
also bending moments in the weld seam. Structural strength
is very low because the flow of force is considerably hindered.
By contrast, a double butt strap joint enables a favourable
deflection of forces. The type of connection has a high level of Figure 29: Flat welded joints
structural strength. The same applies to cross connections.
The following design examples must be seen in context and in Accumulations of weld seams should be avoided. Intersecting
addition to DVS 2205 Sheet 3. seams are not allowed.
Corner joint
1, 2 = sequence of welds
Frame corner
Unfavourable
Favourable
Correct
2201 –2 07/1985 Testing semi-finished products made of thermoplastics – Suitability for welding – Test methods – Requirements
2202 08/2016 Evaluation of plastic joints connecting to pipework components and sheets – Characteristics, description, evaluation
2203 Testing of welded joints in sheets and pipes made of thermoplastics
–1 01/2003 Test methods – Requirements
–2 08/2010 Tensile test
–3 04/2011 Tensile impact test
–4 12/2021 Tensile creep test
–5 08/1999 Technological bending test
2204 –1 01/2011 Gluing of thermoplastics
2205 Calculation of tanks and equipment made of thermoplastics
–1 12/2021 Specifications
–2 12/2021 Vertical, circular, pressureless tanks
–3 04/1975 Welded joints
–4 01/2020 Flange assemblies
–5 07/1987 Rectangular tanks, design details
–5 Supplement 10/1984 Rectangular tanks, design details
2206 Non-destructive testing of tanks, equipment and pipelines made of thermoplastics
–1 09/2011 Dimensional and visual inspection
–2 09/2015 Leak test
–4 09/2011 Testing at high electrical voltage
–5 09/2011 Angle measurement on electrofusion (HM) welded joints and heated-tool socket (HD) welded joints
2207 Welding of thermoplastics
–1 08/2015 Heated-tool welding of pipes, pipework components and sheets made of PE-HD
–3 12/2019 Hot-gas welding and hot-gas fan welding of pipes, pipework components and sheets – Methods, requirements
–4 12/2019 Extrusion welding of pipes, pipework components and sheets – Methods, requirements
–6 09/2003 Contactless heated-tool butt welding of pipes, pipework components and sheets – Methods, machines, parameters
–11 05/2020 Electrofusion welding of pipes, pipework components and sheets made of PP
–12 12/2006 Electrofusion welding of pipes, pipework components and sheets made of PVC-U
–14 04/2009 Heated-tool fold welding of sheets made of PP and PE
–15 12/2005 Electrofusion welding of pipes, pipework components and sheets made of PVDF
2208 –1 09/2019 Welding of thermoplastics – Machines and equipment for the heated-tool welding of pipes, pipework components and
sheets
2210 –1 04/1997 Industrial piping made of thermoplastics – Design and execution – Above-ground pipe systems
2211 05/2021 Welding of thermoplastics – Welding fillers – Marking, requirements, tests
2212 –1 12/2015 Testing of plastic welders – Test groups I and II
DVS Information sheets can be obtained from: DVS Media GmbH, Aachener Str. 172, 40233 Düsseldorf, Germany
DIN Standards can be obtained from: Beuth Verlag GmbH, Am DIN-Platz, Burggrafenstraße 6, 10787 Berlin, Germany
VDI Guidelines can be obtained from: Beuth Verlag GmbH, Am DIN-Platz, Burggrafenstraße 6, 10787 Berlin, Germany
KRV Guidelines can be obtained from: Kunststoffrohrverband e.V., Gütegemeinschaft Kunststoffrohre e.V., Dyroffstr. 2, 53113 Bonn, Germany
9.5 References
References:
J Above standards and guidelines
J Hoechst brochure: „Umformen, Bearbeiten, Fügen“
J Hadick: Schweißen von Kunststoffen
J Taschenbuch DVS-Merkblätter und -Richtlinien, Fügen von Kunststoffen, Band 68/IV, 16. Auflage, 2016
J Figures 1, 2, 4, 5, 17, 18, 19 and figures in table 6:
J Leister Technologies AG
Galileo-Strasse 10
6056 Kägiswil
Switzerland
www.leister.com
Table 10: Recommended figures for hot-gas string bead welding of SIMONA® Sheets and Pipes
SIMONA® Materials Material names Air Temperature➀ Speed➁ Welding force
according to DVS
cm/min N
with high-speed welding nozzle Ø with welding rod Ø
l/min °C 3 - 4 mm 3 mm 4 mm
PE
PE-HD, PE 100, PE-EL PE-HD 45 – 60 300 – 340 25 – 35 15 – 20 25 – 35
PE FOAM 40 – 60 320 – 340 < 50 – –
PE 500 PE 500 40 – 60 270 – 300 < 25 – –
PP
PP-H AlphaPlus®, PP-H, PP-H/PP-B 45 – 60 300 – 340 25 – 35 15 – 20 25 – 35
PP-C, PP-EL
PP FOAM 50 – 60 300 – 340 < 50 – –
PPs 50 – 60 300 – 320 < 50 – –
PVC
PVC-MZ-COLOR PVC-U 45 – 55 350 – 370 < 50 15 – 20 25 – 35
PVC-GLAS PVC-U 45 – 55 350 – 370 < 60 15 – 20 25 – 35
PVC-CAW PVC-U 45 – 60 350 – 370 25 – 35 15 – 20 25 – 35
CPVC PVC-C 45 – 60 370 – 390 18 – 22 20 – 25 30 – 35
COPLAST-AS 45 – 50 340 – 360 < 100 15 – 20 25 – 35
SIMOPOR 45 – 50 340 – 360 < 100 15 – 20 25 – 35
PETG
SIMOLUX PET-G 45 – 50 300 – 320 < 50 15 – 20 25 – 35
Fluoroplastics
PVDF PVDF 45 – 60 365 – 385 20 – 25 20 – 25 30 – 35
ECTFE ECTFE 50 – 60 380 – 420 22 – 25 10 – 15 15 – 25
ETFE ETFE 50 – 60 420 – 460 – – –
FEP FEP 50 – 60 400 – 460 7–9 10 – 15 15 – 25
PFA PFA 50 – 60 420 – 480 6–8 10 – 15 15 – 25
➀
Measured 5 mm inside the nozzle, at the centre of the nozzle outlet aperture.
➁
Depending on welding filler diameter, welding temperature and weld joint geometry.
Table 11: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PE-HD / PE 100 / PE-EL
Sheet thickness Temperature➀ Adaptation➁ Warming Change-over Joining
p ≈ 0.15 MPa p ≈ 0.01 MPa p ≈ 0.15 MPa
Bead height Time Max. time➂ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
3 220 0.5 30 <3 3.0 6.0
4 220 0.5 40 <3 4.0 6.0
5 215 1.0 50 <3 5.0 7.0
Table 12: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PE 500
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p ≈ 0.15 – 0.30 MPa p ≈ 0.01 MPa p ≈ 10.00 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
3 210 0.5 60 <3 < 10 4.5
4 210 0.5 80 <3 < 10 6
5 210 1.0 100 <3 < 10 7.5
There is no guideline concerning the welding of high-molecular weight materials. However, good results are achieved with the figures indicated above.
Table 13: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PE FOAM
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p ≈ 0.30 MPa p ≈ 0.01 MPa p ≈ 0.30 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
6 215 1.0 60 <3 5.5 8.5
8 215 1.5 80 <3 6.5 11.0
10 215 1.5 100 <3 7.0 12.5
12 210 2.0 120 <3 8.0 16.0
15 210 2.0 150 <3 8.5 19.5
20 205 2.0 200 <3 10.5 25.0
➀
Bead height on the heated tool at the end of adaptation time (adaptation at 0.30 MPa)
➁
Change-over time must be kept as short as possible or else the plasticised surfaces will become cold.
Table 14: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PP-H AlphaPlus®/ PP-H /PP-C / PP-EL / PPs
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p ≈ 0.10 MPa p ≤ 0.01 MPa p ≈ 0.10 ± 0.01 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
3 200 – 220 0.5 105 <3 5 6
4 200 – 220 0.5 130 <3 5 6
5 200 – 220 0.5 145 <3 5–6 6 – 12
Table 15: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PP FOAM
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p ≈ 0.20 MPa p ≈ 0.01 MPa p ≈ 0.20 ± 0.01 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
6 215 0.5 160 <3 5–6 6 – 12
8 215 1.0 190 <3 6–8 12 – 20
10 215 1.0 215 <3 6–8 12 – 20
12 210 1.0 245 <3 8 – 11 20 – 30
15 210 1.0 280 <3 8 – 11 20 – 30
20 205 1.5 340 <3 11 – 14 30 – 40
➀
Bead height on the heated tool at the end of adaptation time (adaptation at 0.20 MPa)
➁
Change-over time must be kept as short as possible or else the plasticised surfaces will become cold.
Table 16: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PVC-CAW / PVC-MZ-COLOR / PVC-GLAS
at an outside temperature of 20°C and with moderate air movement
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p = 0.50 MPa p ≈ 0.01 MPa p ≈ 0.50 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
1.9 222 – 238 0.5 28.5 ≤ 2 2 4
3 222 – 238 0.5 45 ≤ 2 3 6
4 222 – 238 0.5 60 ≤ 2 3 8
Table 17: Recommended figures for heated-tool butt welding of sheets made of SIMONA® CPVC
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p = 0.50 ± 0.01 MPa p = 0.01 MPa p = 0.50 ± 0.01 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
2 see Fig. 34 0.5 28 ≤ 2 4 4
3 see Fig. 34 0.5 42 ≤ 2 4 6
4 see Fig. 34 0.5 56 ≤ 2 4 8
240
235
Heated tool temperature (°C)
Upper limit
230
225
Lower limit
220
215
210
0 5 10 15 20 25 30
Wall thickness (mm)
Table 18: Recommended figures for heated-tool butt welding of sheets made of SIMOLUX
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p ≈ 0.10 ± 0.01 MPa p ≈ 0.01 MPa p ≈ 0.10 ± 0.01 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
2 210 0.5 30 <2 4 3
3 210 0.5 40 <2 4 4.5
SIMOLUX sheets do not normally have to be predried.
➀
Bead height on the heated tool at the end of adaptation time (adaptation at p = 0.10 ± 0.01 MPa)
➁
Change-over time must be kept as short as possible or else the plasticised surfaces will become cold.
Table 19: Recommended figures for heated-tool butt welding of sheets made of SIMONA® ECTFE
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p ≈ 0.30 MPa p ≤ 0.01 MPa p ≈ 0.15 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
2.3 260 – 270 > 0.5 35 <3 3 ~5
3 260 – 270 > 0.5 45 <3 4 ~6
4 260 – 270 > 0.5 60 <3 5 ~8
Important! The heated tools of the familiar butt welding machines have a temperature limit of 250°C. Please contact the manufacturers of the machines.
Table 20: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PFA
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p ≈ 0.10 ± 0.01 MPa p ≈ 0.01 MPa p ≈ 0.10 ± 0.01 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
2.8 500 0.5 245 <2 4 6
➀
Bead height on the heated tool at the end of adaptation time (adaptation at 0.10 MPa)
➁
Change-over time must be kept as short as possible or else the plasticised surfaces will become cold.
Table 21: Recommended figures for heated-tool butt welding of sheets made of SIMONA® PVDF
Sheet thickness Temperature Adaptation➀ Warming Change-over Joining
p = 0.10 MPa p ≤ 0.01 MPa p = 0.10 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
mm °C mm s s s min
3 245 0.5 70 <3 3.5 5.5
4 245 0.5 80 <3 4.0 7.0
5 245 0.5 90 <3 4.5 8.0
Contactless heated-tool butt welding of PVDF is subject to DVS Guideline 2207-6: Welding of thermoplastics – Contactless heated-tool butt welding of pipes,
pipework components and sheets – Processes, machines, parameters.
Table 23: Recommended figures for heated-tool butt welding of pipes made of SIMONA® PE 80 / PE 100 / PE 100 RC
Wall thickness Adaptation➀ Warming Change-over Joining
p = 0.15 MPa p = 0.01 MPa p = 0.15 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
(minimum figure➂)
mm mm s s s min
to 4.5 0.5 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
➀
Bead height on the heated tool at the end of adaptation time (adaptation at 0.15 MPa)
➁
Change-over time must be kept as short as possible or else the plasticised surfaces will become cold.
➂
Depending on ambient temperature (e.g. in the workshop) different cooling times may apply (see DVS Guideline).
Table 24: Cooling times of pipes and pipework components made of SIMONA® PE 80 / PE 100 / PE 100 RC depending on ambient temperature
or under special conditions
Pipe wall thickness Cooling times in relation to ambient temperature Cooling times under special conditions➀
(minimum figures)
mm min min
bis 15 °C 15 °C – 25 °C 25 °C – 40 °C
bis 4,5 4 5 6,5 3,5
4,5 – 7 4–6 5 – 7,5 6,5 – 9,5 3,5 – 5
7 – 12 6 – 9,5 7,5 – 12 9,5 – 15,5 5–8
12 – 19 9,5 – 14 12 – 18 15,5 – 24 8 – 12
19 – 26 14 – 19 18 – 24 24 – 32 12 – 16
26 – 37 19 – 27 24 – 34 32 – 45 16 – 23
37 – 50 27 – 36 34 – 46 45 – 61 23 – 31
50 – 70 36 – 50 46 – 64 61 – 85 31 – 43
70 – 90 50 – 64 64 – 82 85 – 109 43 – 55
90 – 110 64 – 78 82 – 100 109 – 133 55 – 67
110 – 130 78 – 92 100 – 118 133 – 157 67 – 79
➀
Cooling times apply under the following conditions:
■ the joint is made in a workshop and
■ r emoval from the welding machine and temporary storage up to the end of cooling time as per table only subject the joint to minimal strain
Table 25: Recommended figures for heated-tool butt welding of pipes and sheets made of SIMONA® PP-H AlphaPlus® / PP-H / PP-C / PP-R
up to 40°C and with moderate air movement
Wall thickness Adaptation➀ Warming Change-over Joining
p = 0.10 MPa p ≤ 0.01 MPa p = 0.10 ± 0.01 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at
build-up joining pressure
(minimum figure➂)
mm mm s s s min
to 4.5 0.5 to 53 5 6 6
4.5 – 7 0.5 53 – 81 5–6 6–7 6.5 – 9.5
7 – 12 1.0 81 – 135 6–7 7 – 11 9.5 – 15.5
➀
Bead height on the heated tool at the end of adaptation time (adaptation at 0.10 MPa)
➁
Change-over time must be kept as short as possible or else the plasticised surfaces will become cold.
➂
Cooling times apply under the following conditions:
■ the joint is made in a workshop and
■ removal from the welding machine and temporary storage up to the end of cooling time as per table only subject the joint to minimal strain
Table 26: Cooling times of pipes and pipework components made of SIMONA® PP-H AlphaPlus® / PP-H / PP-C / PP-R depending on ambient
temperature or under special conditions
Pipe wall thickness Cooling times in relation to ambient temperature Cooling times under special conditions➀
(minimum figures)
mm min min
to 15 °C 15 °C – 25 °C 25 °C – 40 °C
bis 4.5 4 5 6.5 3.5
4.5 – 7 4–6 5 – 7.5 6.5 – 9.5 3.5 – 5
7 – 12 6 – 9.5 7.5 – 12 9.5 – 15.5 5–8
12 – 19 9.5 – 14 12 – 18 15.5 – 24 8 – 12
19 – 26 14 – 19 18 – 24 24 – 32 12 – 16
26 – 37 19 – 27 24 – 34 32 – 45 16 – 23
37 – 50 27 – 36 34 – 46 45 – 61 23 – 31
50 – 70 36 – 50 46 – 64 61 – 85 31 – 43
➀
Cooling times apply under the following conditions:
■ the joint is made in a workshop and
■ removal from the welding machine and temporary storage up to the end of cooling time as per table only subject the joint to minimal strain
Table 27: R
ecommended figures for heated-tool butt welding of pipes and sheets made of SIMONA® PVDF at an outside temperature of
approx. 20°C and with moderate air movement
Wall thickness Adaptation➀ Warming Change-over Joining
p = 0.10 MPa p ≤ 0.01 MPa p = 0.10 MPa
Bead height Time Max. time➁ Time to full pressure Cooling time at joining
build-up pressure
(minimum figure➂)
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
➀
Bead height on the heated tool at the end of adaptation time (adaptation at 0.10 MPa)
➁
Change-over time must be kept as short as possible or else the plasticised surfaces will become cold.
➂
Cooling times apply under the following conditions:
■ the joint is made in a workshop and
■ removal from the welding machine and temporary storage up to the end of cooling time as per table only subject the joint to minimal strain
Table 28: Recommended figures for heated-tool socket welding of pipes and fittings made of SIMONA® PE-HD / PE 100 / PE 100 RC
at an outside temperature of 20°C and with moderate air movement
Pipe diameter Warming Change-over Cooling➀
d Time Max. time Min. time
SDR 11 SDR 17
Fixed Total
mm s s s s min
16 5 ➁ 4 6 2
20 5 ➁ 4 6 2
25 7 ➁ 4 10 2
32 8 ➁ 6 10 4
40 12 ➁ 6 20 4
50 18 ➁ 6 20 4
63 24 ➁ 8 30 6
75 30 18 8 30 6
90 40 26 8 40 6
110 50 36 10 50 8
125 60 46 10 60 8
Heated tool temperature is 260 ± 10°C.
➀
In manual welding the joined parts must be held tightly / fixed in accordance with the time indicated in the „Fixed“ column. The joint may be subjected to loading by
the other laying operations only when the cooling time has elapsed (see „Total“ column).
➁
Not to be recommended because wall thickness is inadequate.
Table 29: R
ecommended figures for heated-tool socket welding of pipes and fittings made of SIMONA® PP-H AlphaPlus® / PP-H / PP-R
at an outside temperature of 20°C and with moderate air movement
Pipe diameter Warming Change-over Cooling➀
d Time Max. time Min. time
SDR 11 SDR 17
Fixed Total
mm s s s s min
16 5 ➁ 4 6 2
20 5 ➁ 4 6 2
25 7 ➁ 4 10 2
32 8 ➁ 6 10 4
40 12 ➁ 6 20 4
50 18 ➁ 6 20 4
63 24 10 8 30 6
75 30 15 8 30 6
90 40 22 8 40 6
110 50 30 10 50 8
125 60 35 10 60 8
Heated tool temperature is 260 ± 10°C.
➀
manual welding the joined parts must be held tightly / fixed in accordance with the time indicated in the „Fixed“ column. The joint may be subjected to loading by
In
the other laying operations only when the cooling time has elapsed (see „Total“ column).
➁
Not to be recommended because wall thickness is inadequate.
Table 30: R
ecommended figures for heated-tool socket welding of pipes and sheets made of SIMONA® PVDF at an outside temperature of
20°C and with moderate air movement
Pipe diameter Pipe wall thickness Warming Change-over Cooling➀
d Time Max. time Min. time
Fixed Total
mm mm s s s min
16 1.5 4 4 6 2
20 1.9 6 4 6 2
25 1.9 8 4 6 2
32 2.4 10 4 12 4
40 2.4 12 4 12 4
50 3.0 18 4 12 4
63 3.0 20 6 18 6
75 3.0 22 6 18 6
90 3.0 25 6 18 6
110 3.0 30 6 24 8
Heated tool temperature is 260 ± 10°C.
➀
In manual welding the joined parts must be held tightly / fixed in accordance with the time indicated in the „Fixed“ column. The joint may be subjected to loading by
the other laying operations only when the cooling time has elapsed (see „Total“ column).
Nozzle(s):
Date Design detail Weld seam no. Joined part thickness Weld seam type Method Air flow
mm (symbol) WF/WZ l/min
Hot gas Welding speed Ambient Semi-finished product Weather Protective measures Visual
temperature2) temperature temperature (code no.) (code no.) assessment
°C cm/min °C °C
1)
Plastics welding specialist to DVS 2213
2)
Measured at the centre of the nozzle outlet aperture, 5 mm inside the nozzle Remarks, e. g. difficult conditions:
Weather
1 = sunny, 2 = dry, 3 = precipitation, 4 = wind
Protective measures
1 = none, 2 = umbrella, 3 = tent, 4 = heater
Owner: Contractor:
Welder: ID:
Material:
Seam no. Date Sheet thickness Measured heated tool temperature1) Set points2)
°C
Adaptation3) Warming3) Joining3)
mm Minimum Maximum
bar / kp bar / kp bar / kp
Warming time4) Change-over time4) Joining pressure Cooling time Ambient temperature
build-up time4) at joining pressure3)
s s s min °C
1)
From control interval, frequency as per 4.1.2 Remarks, e. g. difficult conditions:
2)
According to the welding machine manufacturer's specifications or from a
machine test plus movement pressure or force
3)
Delete what is inapplicable
4)
The measured values have to be entered
Owner: Contractor:
Welder: ID:
Material:
Seam no. Date Pipe size Measured heated tool Movement Joining Setpoints2)
Ødxs temperature1) pressure pressure
°C (machine table)
Adaptation Warming Joining
mm Minimum Maximum bar bar
bar bar bar
Warming time3) Joining pressure Change-over time3) Cooling time Ambient Weather Protective measures
build-up time3) at joining pressure3) temperature (code no.) (code no.)
s s s s °C
1)
From control interval, frequency as per 4.1.2 Remarks, e. g. difficult conditions:
2)
According to the welding machine manufacturer's specifications or
from a machine test plus movement pressure or force
3)
The measured values have to be entered
Weather
1 = sunny, 2 = dry, 3 = precipitation, 4 = wind
Protective measures
1 = none, 2 = umbrella, 3 = tent, 4 = heater
Year of manufacture / last machine inspection: Method variant acc. to DVS 2207-4:
Date Weld seam no. Joined part thickness Weld seam type Welding shoe no. Air flow Mass temperature2)
mm (symbol) l/min °C
Hot gas Welding speed Ambient temperature Semi-finished product Weather Protective measures
temperature3) temperature (code no.) (code no.)
°C cm/min °C °C
1)
Plastics welding specialist to DVS 2213
2)
Measured with an insertion thermometer at the extrudate outlet of the welding Remarks, e. g. difficult conditions:
machine / of the welding unit
3)
Measured at the centre of the nozzle outlet aperture, 5 mm inside the nozzle
Weather
1 = sunny, 2 = dry, 3 = precipitation, 4 = wind
Protective measures
1 = none, 2 = umbrella, 3 = tent, 4 = heater
Owner: Contractor:
Welder: ID:
Material:
1)
= manufacturer's abbreviation (e. g. Friatec = F, Plasson = PL,
A Weather
Georg Fischer = GF) 1 = sunny, 2 = dry, 3 = precipitation, 4 = wind
2)
B = fitting code (1 = socket, 2 = angle, 3 = tee, 4 = reducer, 5 = saddle,
6 = cap, 7 = transition fitting) Protective measures
3)
Entry as required depending on the system used 1 = none, 2 = umbrella, 3 = tent, 4 = heater
4)
The measured values have to be entered
Manufacturer Hot-gas string Hot-gas extrusion welding Hot-air blowers and Heated-tool butt welding
bead welding (WZ) (WE) heated tools of sheets
Forsthoff GmbH
Freiheitstr. 24
D-42719 Solingen
Phone +49 (0) 212 336052
X X
info@forsthoffwelding.com
www.forsthoffwelding.com
Haubold Technik
Wehrstraße 44
D-69509 Mörlenbach
Phone +49 (0) 6209 8819
email@haubold-technik.de
www.haubold-technik.de
HERZ GmbH
Kunststoff- und Wärmetechnologie
Biberweg 1
D-56566 Neuwied
X X X X
Phone +49 (0) 2622 88550
info@herz-gmbh.com
www.herz-gmbh.com
Ingenia GmbH
Hauptstraße 72
D-56858 Altlay
Phone +49 (0) 6543 50490
X
info@ingenia-gmbh.de
ingenia-gmbh.gmbh
Leister Technologies AG
Galileo-Strasse 10
CH-6056 Kägiswil
Phone +41 (0) 41 6627474
X X X
salessupport@leister.com
www.leister.com
X X X
X X X
X X X X X
X X X X
X X
MUNSCH Kunststoff-
Schweißtechnik GmbH
Im Staudchen
D-56235 Ransbach-Baumbach
Phone +49 (0) 2623 8980 X
info-kst@munsch.de
www.munsch-kunststoff-
schweisstechnik.de
RITMO SPA
Via Volta, 35/37 – Z.I. Selve
IT-35037 Bresseo di Teolo (PD)
Phone +39 (0) 49 9901888
X X
info@ritmo.it
www.ritmo.it
ROTHENBERGER Werkzeuge
GmbH
Industriestraße 7
D-65779 Kelkheim
Phone +49 (0) 6195 8001
info@rothenberger.com
www.rothenberger.com
VULKAN AG
Trischlistrasse 23
CH-9400 Rorschach
Phone +41 (0) 71 8447888
X X
info@vulkanag.ch
www.vulkanag.ch
As at March 2023. Please note that this equipment is also available from other manufacturers.
X X X X
X X X X
Upon publication of a new edition all previous editions shall Our applied technical advice is given according to our best
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All information furnished in this publication reflects our cur- ranty of specific characteristics or qualities and shall not estab-
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Upon publication of a new edition all previous editions shall become void. The authoritative version of this publication can be found on our website at www.simona.de. All information
furnished in this publication reflects our current scope of knowledge on the date of publication and is designed to provide details of our products and potential fields of application
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