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How to Inspect HDPE Butt Fusion Welds

High-density polyethylene (HPDE) pipe welding is different from traditional welding, and butt welding of HDPE is even more so. It requires specialised equipment like an HDPE welding machine, which comes in different types, such as hydraulic, manual, and automatic.

Butt welding presents challenges like decreased structural strength and other flaws, making it necessary to inspect welds to ensure optimum quality. There are various ways to do this, including non-destructive testing (NDT) technologies like ultrasound. 

That said, HDPE material has some attributes that can make ultrasonic scans challenging. So, it is crucial to have a reliable inspection strategy that includes several testing techniques to find flaws in welds without compromising the strength of the results.

What flaws can occur during butt fusion welding?

Flaws can occur while using an HDPE welding machine due to inaccurate temperature, lack of weld force or pressure, improper surface cleaning, existing external inclusions in the material, insufficient cooling times, and other factors. These incidents could cause problems like cold fusion or a partial bond, cracks, and porosity, requiring proper and thorough identification.

Ways to inspect weld quality

HDPE has attenuative properties that require inspection with minimal frequencies, unlike when inspecting carbon steel. With this in mind, it’s advisable to use inspection methods using pulse-echo, tandem PAUT, and TOFD (time of flight diffraction). Combining PAUT with TOFD delivers volumetric inspection capabilities with optimum flaw detection sensitivity. It achieves the following:

Focus on weld joints and heat-affected zones to identify flaws

Find any inclusions, voids, pores, or slags

Gauge the fusion weld bond strength

Reduce the effect of thickness irregularities or variation

Inspect for durability and quality

Appropriate inspection and testing methods can ensure high-quality welds created by the HDPE welding machine. They support the accuracy of inspecting HDPE butt fusion welds to enable fast and informed decision-making.

More stringent inspection requirements and standards are necessary as HDPE fittings and pipes continue to be widely utilised in many industries. PAUT inspection allows accuracy and speed in identifying flaws on butt fusion welds so that you can make the most of the material and its superb properties. Ensuring weld quality and strength with minimal interruption also helps increase productivity and cost-effectiveness.

About the author:

This article is written by team Riyang Marketing Dept. Riyang Welding, founded in 2010, a leading China-based manufacturer specializing in thermoplastic welding machines known for their excellent engineering, ease to use, and ability to survive in the toughest conditions.

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Electrofusion Welding Machine – World Class Fully Automatic Welding Machine

Welding requires precision equipment to ensure strong and reliable welds. One of the technologies you can consider using is the electrofusion machine, specifically for fixing two plastic pipes together with fittings. It is fully automatic as it is controlled by a computer and capable of working on HDPE, PP, and PVDF pipes.

An electrofusion welder can connect parts from 10 to 32 bars. However, it’s crucial for this type of machine to conform to international standards, particularly ISO 12176-1. The best equipment is lightweight and easy to set up and use. Most machinery can work in ambient temperatures of 120 Amps at -15 to 60 degrees Celsius.

World-class welding

Electrofusion welders connect polyethylene fittings and pipes to fulfil their intended purpose. The pipes become functional with additional parts connecting them.

The process of electrofusion welding involves placing the pipes in the fittings and connecting them to the machine. Each electrofusion machine requires a barcode system where the transferred heat is based on that information from the piece. This way, HDPE pipes and electrofusion parts are fused. It is possible to combine 20mm to 1600mm pipes. After welding, the machine can produce a resource report.

Applications

Electrofusion welding machines are practical in every application where HDPE pipes are necessary or utilised, such as plumbing, subway water supplies, hydraulics, potable water, engineering, and construction. They offer ease of use and savings in transportation with their lightweight structure. They are practical for repairing pipes, too.

Advantages

Modern welding machines are more flexible to suit most work areas. They are easier to move and operate, making them beneficial to operators and contractors. Welds accomplished by an electrofusion machine are durable and won’t require subsequent control. Therefore, you can be sure it does not harm the integrity and structure of the pipe. Technological advances have made it possible to complete welds faster with minimal downtime.

You can get a world-class, fully automatic electrocution machine from a reputable manufacturer and supplier. Equipment comes in different types and sizes for specific pipes and materials. Some companies offer custom solutions to suit your requirements and guarantee the most competitive prices and the best services.

About the author:

This article is written by team Riyang Marketing Dept. Riyang Welding, founded in 2010, a leading China-based manufacturer specializing in thermoplastic welding machines known for their excellent engineering, ease to use, and ability to survive in the toughest conditions.

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How Long Does It Take to Fuse HDPE Pipe?

HDPE pipe welding is a process that fuses an HDPE conduit to a fitting or another piece of conduit. The time it takes to complete the process depends on the methodology and equipment. Joins may be created using several different processes, such as butt fusion, electrofusion, saddle fusion, and socket fusion. An HDPE fusion machine simplifies the process without impacting the integrity and properties of the high-density polyethylene pipe. It may also ensure faster fusion to increase productivity.

Butt welding

Butt or fusion welding relies on a heated plate on the HDPE pipes’ squared ends. The heating plate is removed after a particular period, and the pieces are combined and cooled under pressure. Here is an overview of the maximum heater plate removal times according to different pipe wall thicknesses:

0.20” to 0.36” – 8 seconds

>0.3” to 0.55” – 10 seconds

>0.55” to 1.18” – 15 seconds

>1.18” to 2.5” – 20 seconds

>2.5” to 4.5” – 25 seconds

An HDPE fusion machine can join one or two pipes to a fitting.

Socket fusion welding

Socket fusion welding uses custom heating plates instead of standard flat plates. The specially shaped plates cover most of the pipe’s surface area to reduce the time to heat and fuse the pipe. The process typically refers to joining a pipe to a fitting instead of one pipe to another, but it is usually preferred for pipes less than 4”. 

Depending on the pipe size, the heating times could take anywhere from seven to thirty seconds, and cooling times can range from 30 to 60 seconds.

Saddle fusion

Saddle or sidewall fusion is like socket fusion but for joining a perpendicular fitting to a pipe’s surface. The fitting and pipe can go under pressure. The heating and cooling times are as follows:

1 to ¼” IPS – Not exceeding 15 seconds when hot topping (heating), and 5 to 30 minutes (minimum cooling time)

2” IPS – Same as above, but with a minimum of 10 to 30 minutes for cooling

3” IPS or more – 1/16” melt pattern at the fitting base, with 10 to 30 minutes to cool.

Invest in the right machinery

Be sure to get a high-quality HDPE fusion machine that can speed up the process of fusing HDPE pipes and fittings. It will save you time while preventing costly errors.

About the author:

This article is written by team Riyang Marketing Dept. Riyang Welding, founded in 2010, a leading China-based manufacturer specializing in thermoplastic welding machines known for their excellent engineering, ease to use, and ability to survive in the toughest conditions.

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How Effective is a Plastic Sheet Welding Machine?

Plastic welding machines come in different types and configurations to meet different requirements. Some are ideal for specific applications, such as manufacturing water tanks and pipes, and others may be suitable for welding a wide range of thermoplastic sheets made of PVDF, PVC, HDPE, and PP. They can butt weld and bend sheets according to your project specifications, and they can handle different thicknesses from 3mm to 30mm and 1.5m to 6m wide.

A plastic sheet welding machine can save you time by continuously applying pressure during heating and cooling to create an effective molecular bond between parts. It also ensures strong plastic welded joints.

Understanding plastic welding

A plastic sheet welding machine is a device that uses heat to weld two pieces of plastic together. The process is similar to soldering, but the temperatures are much higher. Welding is often used to join pieces of plastic too large to be joined by adhesive or mechanical means such as snap-fit connections.

Plastic welding techniques vary according to the heating processes used. For instance, ultrasonic welding applies mechanical vibrations with high frequency and low amplitude to combine two plastic polymers. The vibrations create frictional heat to melt plastic polymers and a robust molecular bond, resulting in high-quality and stronger plastic welded joints.

You can also find a plastic sheet welding machine that uses the hot plate method, which heats a plate to melt the joining surfaces of thermoplastics. The two halves are brought together after melting and left for a specified period to create a permanent molecular and hermetic bond.

Hot plate welding must be performed with extreme control and precision, and a specially designed welding machine can help with that. It is ideal for any thermoplastic, especially semi-crystalline and soft thermoplastic materials like PE and PP. The machine can join large plastics and shorten cycle times, depending on how fast it reaches the material’s melting point.

More benefits of plastic welding machines

A plastic sheet welding machine can reduce costs, risks, and complications associated with traditional welding methods. Advanced machinery has a control system with the Siemens PLC button operation. The low cycle time and reduced need for consumables make it cost-effective for joining thermoplastics. Moreover, it works with any joint shape, including irregular shapes and curves. Plastic sheet welding machines are also versatile for any part dimension or size.

About the author:

This article is written by team Riyang Marketing Dept. Riyang Welding, founded in 2010, a leading China-based manufacturer specializing in thermoplastic welding machines known for their excellent engineering, ease to use, and ability to survive in the toughest conditions.

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Selection Guide for Fusion Machine for HDPE Pipes

A fusion machine for HDPE pipes is also responsible for fusing the fittings with the pipes. It prepares and joins thermoplastic polymer materials like high-density polyethylene, PVDF, polypropylene, and ECTFE by heating the ends of fittings and pipes. Then, it forces them together to create pressure-tight homogeneous joints, creating a robust and reliable continuous pipe system.

Choosing the right fusion machine is critical for creating a continuous pipe system. Your choice can depend on your welding technique, such as butt fusion, electrofusion, and socket fusion. Here’s a brief overview of each:

Butt fusion welding 

This welding process welds thermoplastic pipes end-to-end. It’s also used in fabricating custom pipe fittings from piping material. Butt fusion welding uses a heated plate inserted between two pipe ends, and the pipes are pressed against the plate for the heat to soak and soften the material. Then, the heated plate is removed, and the pipe ends are pressed together and held until they cool down.

Socket fusion welding 

A socket fusion machine for HDPE pipe assembles piping systems with injection moulded fittings. This time, the metal socket is mounted on the hot plate and heats the outer diameter of the pipe. A metal spigot on the hot plate’s opposite side heats the interior of the fitting.

Electrofusion welding 

This process joins thermoplastic pipes and fittings with a built-in electric heating element. Power is applied to the heating element, so the heat melts the interior of the fitting and the pipe wall’s exterior while they are held together.

A fusion welder is typically adjustable to accommodate different pipe diameters. There’s a limit to what an individual fusion welding machine can handle, so check the size of the pipes you’re manufacturing to pick the right product. Ensure the fusion machine for HDPE pipe has locks and guides to secure the pipes and fittings in place and additional components to maintain and apply sufficient force on the pieces during heating and cooling.

Options

Reputable manufacturers of fusion machines for HDPE pipes offer high-quality butt fusion machines with a small footprint. Despite their size, they are guaranteed durable, robust, and stable performance for refined workmanship. Choose a fusion machine for HDPE pipes with a warranty of at least two years.

About the author:

This article is written by team Riyang Marketing Dept. Riyang Welding, founded in 2010, a leading China-based manufacturer specializing in thermoplastic welding machines known for their excellent engineering, ease to use, and ability to survive in the toughest conditions.

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How to Use HDPE Welder Correctly

HDPE stands for high-density polyethylene, usually referring to a heavy-duty pipe used in physically demanding environments, such as to transport natural gas or water. HDPE welding means fusing an HDPE conduit with another conduit or a fitting. The joins are accomplished using different processes, including butt fusion, saddle fusion, electrofusion, and socket fusion. You’ll need an appropriate HDPE welder to ensure the best results.

HDPE pipes are expensive and conduct critical actions, so they must be welded together to get the utmost value out of their length. However, you need to ensure correct usage, not just for optimum outcomes but also for your safety. Here’s a guide for using an HDPE welder correctly.

Pre-welding safety

Before you start welding pipes, remember you’ll be using potentially dangerous equipment and that you must know how to operate it correctly and safely. Moreover, remember that just because the equipment is not in use doesn’t mean it’s not hazardous.

Don’t stick your fingers between the pipes when sliding.

Lock the shaver in place before use so it doesn’t spring loose.

Don’t touch the shaver when it’s in use, or you risk serious injury, including losing your fingers.

Touch the hot plate only by the handle to prevent burns.

Maintain a clean working environment and ensure long power cords are out of the way.

Prepare everything

Lay out all the materials and pieces of equipment, including the HDPE welder, and ensure their visibility at all times. These include the hot plate, electricity source, pipe shaver, and time-keeping device.

How to fuse

1. Place a pipe in the welder and ensure it’s fastened down tightly. One turn after the pipe is clamped tight.

2. Place another pipe of similar diameter into the other side of the HDPE welder and keep it fastened.

3. Place the HDPE pipe fitting into the other side of the welder. Fasten it to prevent it from sliding.

4. Slide the pipes and pipe fitting together where they must attach. Make the necessary adjustments before welding.

5. Slide the pipes back apart when they appear flushed together. Attach the pipe shaver to the welder while ensuring each arm of the shaver is fitted neatly onto the bars of the welder.

After shaving the pipes, slide them flush together to verify that the shaver did its job.

About the author:

This article is written by team Riyang Marketing Dept. Riyang Welding, founded in 2010, a leading China-based manufacturer specializing in thermoplastic welding machines known for their excellent engineering, ease to use, and ability to survive in the toughest conditions.