High Purity Systems

1. High Purity Systems Welding and Inspection Seminar Presented by: Roger Govaert Asahi/America Inc.

2. Welding Techniques • Socket Fusion • Butt Fusion • IR Fusion • HPF (Electrofusion), BCF & SIB

3. Socket Fusion Heater Material Align/Prepare Material Insert and Heat Join and Cool Inserts Coupling

4. Socket FusionLimitations • Can not be Visually Inspected from Outside • Excessive internal Cracks and Crevices • Repeatability is limited • Limited Size Ranges

5. Butt Fusion Theory Cool Down Time Initial Melt Pressure PRESSURE Ramp Up Pressure Change Over Heat Soak Time & Pressure TIME

6. Plane Material Align Material Apply Heat Join Material Butt Fusion Process

7. Butt & IR Fusion ASTM D 2657 “(B)ring the melted ends together immediately with sufficient force to form a uniform flash (bead)… This is the most critical part of the whole joining procedure. If the components are brought together with too much force, all molten material may be pushed out of the joint and cold material brought into contact forming a “cold” joint. If too little force is used, only the melt beads may be fused…”

8. Cross Sectional View Butt Fusion Result

9. Butt FusionLimitations • Material in Contact with Heating Element*Possible Source of Contamination • Smaller Crevice/Bead than Socket Fusion, but not small as possible

10. IR Fusion Theory Heat Soak (Pressure of Clamps on Heater, Not Material) Cool Down Time PRESSURE Ramp Up Pressure Change Over TIME

11. Plane Material Align Material Apply Heat Join Material IR Fusion Theory

12. Cross Sectional View IR Fusion Result

13. Material in Weld Zone Normal Weld Butt & IR Fusion Importance of Pressure Control No Material in Weld Zone Failure mode: COLD JOINT

14. Melt Flow IndexDefinition Melt Flow Index measures the rate of extrusion of molten resins, through a die of specified length and diameter, under prescribed conditions of temperature, load, and piston position in the barrel, as the timed measurement is being made. ASTM D 1238

15. Melt Flow IndexImportance to Welding and Weld Inspection • The melt flow index is measured to determine the flow behavior of thermoplastic materials. • Different indexes within thermoplastic families and groupings display different welding characteristics. • The higher the index, the larger the bead under constant parameters

16. Solef® HP PVDF ResinMelt Flow Indexes for Purad by Asahi/America • Pipes 1010/0001 • MFI = 4 - 7 g/10min • Fittings (2-1/2” - 12”) 1008/0001 • MFI = 22-27 g/10min • Fittings (1/2” - 2”) 1009/0001 • MFI = 12-16 g/10min

17. GF PVDF ResinMelt Flow Indexes for Sygef® • Pipes Kynar 740® • MFI = 2 - 2.5 g/10min • Fittings (1/2” - 9”) Solef® 1008/0001 • MFI = 22-27 g/10min

18. PolyPure®Resin Melt Flow Index • RA 130E random co-polymer natural polypropylene • Test Cond. 190/5, MFI = 0.5 g/10min • Test Cond. 230/2.16, MFI = 0.3 g/10min • Test Cond. 230/5, MFI = 1.25 g/10min

19. Alignment Environment Incorrect Parameters Improper Planing Improper Joining IR Weld Inspection Common Causes for Failure

20. IR Weld Inspection Alignment • Symptom: Joining Areas are offset by greater than 10% of wall thickness. • Cause: Misalignment, lack of alignment control or inspection

21. IR Weld Inspection Misalignment • Symptom: Angular Deviation • Cause: - Faulty Alignment- Improper Planing- Improper Clamping

22. IR Weld Inspection Environment, Heat or Parameters • Symptom: Inconsistent Bead Size or Excessive Weld Notch intruding into joining area • Cause: - Excessive Draft- Improper Heat- Wrong Weld Parameters

23. b1 b2 IR Weld Inspection Uniformity • Symptom: Non-uniform welding bead • Cause: Non-angular joining surfaces resulting in diversely built-up welding beads locally or all along the weld length, caused by improper planing or inconsistent heating • Acceptable variation of the beads = b1³ 0.5 x b2

24. IR Weld Inspection Uniformity • Symptom: Narrow, excessive welding bead. Excessive and sharp-edged welding bead locally or all along weld length or weld circumference. • Cause: Inadequate welding parameters.- Too much joining force or - Too quick joining- Wrong Weld Parameters

25. IR FusionPolyPure & PP Inspection / Bead Size Allowable bead size as measured on outside bead (recommendation - only)

26. IR Fusion UF2000 Semi-Automated Welders UF2000-1 1/2” - 2” UF2000-2 2 1/2” - 10”

27. IR Fusion UF2000 Semi-Automated Welders • Programmed Parameters • Computer Monitored Pressure • Semi-Automated Process • Integrated Printer • Reliable Welds

28. IR Fusion SP Automated Welders SP-110 1/2” - 4” SP-250 2 1/2” - 10”

29. IR Fusion SP Automated Welders • Automated Fusion Process • Touch Screen Operation • Controls and Monitors: • Welding Parameters • Heating • Joining Force and Time • Computer Memory • Engineered for PureBond®

30. IR Fusion SP Automated Welders Touch Screen Control

31. IR Fusion SP Automated Welders Weld Info Documentation

32. IR Fusion SP Automated Welders Magnetic Clamps

33. IR Fusion SP Automated Welders Quick & Easy Alignment Control

34. IR Fusion SP Automated Welders Quality, Uniform Welds

35. HPF Fusion Theory

36. Plane Material Insert Coupling Align Material Insert Balloon Scan Size Code Complete Weld HPF Fusion Process

37. HPF Fusion Result Without Balloon With Balloon

38. HPF Fusion Weld Time Comparison

39. HPF Fusion Labor Comparison Total Amount of Welds = 420

40. HPF Fusion Labor Comparison Cont.

41. IR Fusion Sample QA Log

42. HP SystemsThank You