DVS 2205 Welding

Summary Theory
Introduction Plastic Fabrication
Basic Welding Principles
Pendulum Welding and Draw Welding
Hot Air Extrusion Welding
Arrangement of Welding Constructions
Test of Welding Connections
Page 2
24.03.2005
Summary Theory
Page 3
24.03.2005
Summary Theory
Page 9
24.03.2005

Materials in Plastic Fabrication
Scope (C)
Behaviour in
fire
Chemical
resistance
Remarks
HDPE
-50 C to +90 C
yellow flame, blue core,

paraffin-like smell
resistant to acids, leaches and

alcohols
sanitation tubes, tank construction,

ski coatings, toys
PP
0 C to 110 C
yellow flame, blue core,

paraffin-like smell
very good when in contact with

weak acids, leaches and solvents
benches, ventilating tubes, tank

construction
PVDF
-60 C to +150 C
self-extinguishing, flame
resistant, sharp smell
Outstanding when in contact with

halogens and hydrocarbons
chemical facilities, clean room

applications (pay attention to the
safety regulations!!)
PVC-U
up to 65 C
extinguishes when
removing from the flame
high chemical resistance
chemical plant construction
PVC-C
up to 130 C
inflammable
high chemical resistance at high

temperature
chemical plant construction at

increased temperature
PVC-P
up to 65 C
flammable depending on
portion of softener
chemical resistance depends on

portion of softener
hoses, gaskets, coatings
resistant to weak acids and

leaches and aliphatics
takes in a lot of humidity >

blowholes
smells of HCl
PMMA
(Acryl)
up to 85 C
crackling burning, smoking

and smells of fruits
is often clued
Page 10
24.03.2005

Materials in Plastic Fabrication
Basically, only identical thermoplastics can be welded together

(exceptions are e.g. PVC-P/PVC-U).
Not all thermoplastics are weldable, structure and molecular mass

determine the practical feasibility.
Not weldable are e.g.:
- high molecular PE-HD (molecular mass > 1000000)
- PMMA (in cast form)
- PTFE
In case of uncertainty please contact the manufacturer of
the material or STAR Process Heat Systems.
Page 11
24.03.2005

Welding Procedure
With Leister
Pendulum Welding (PW)
Draw Welding (DW)
Hot Air Extrusion Welding (EW)

Other Welding Procedures
Heating element butt welding
Heating element groove welding
Heating element bend welding
Heating element socket welding
Heating element helix welding

Page 12
24.03.2005

Choice of Welding Procedure
Pendulum Welding
(PW)
Draw Welding
(DW)
for confined spaces
DW is faster than PW
for short seams and

repair work
PVC-U cannot be welded

with DW (wire tears)
for wall thickness of up to

5-10mm

10mm
Page 13
Hot Air Extrusion

Welding
(EW)
better seam quality than with

PW/DW
more economic than
DW/PW as much faster
40mm
24.03.2005
Summary Theory
Page 14
24.03.2005
Pendulum Welding (PW)

F (1.5 2 kg)
extension
compression
The welder has to pay attention to the following:

even heating up of basic and additional material
vertical guidance of the additional bar
sufficient welding force
Page 15
24.03.2005
Draw Welding (DW)
F (0.5 3.5 kg)
draw nozzle
Advantages over pendulum welding:
higher welding speed
bigger cross sections of the welding addition possible

(profile welding rod)
Page 16
24.03.2005
Draw Welding (DW)
WELDING PEN R
Page 17
TRIAC PID
24.03.2005
Hot Air Welding

Welding Parameters (according to DVS 2207 part 3)
Material
Welding
procedures
Welding force F
(N) 3mm
Welding force F
(N) 4mm
Hot air temp.

(C)
Airflow
l / min
PE-HD
PW
DW
6 10
10 16
15 20
25 35
300 320
40 50
PP
PW
DW
6 10
10 16
15 20
25 35
305 315
40 50
PVC-U
PW
DW
59
8 12
8 12
15 25
330 350
40 50
PVC-C
PW
DW
10 15
15 20
15 20
20 25
340 360
40 50
PVC-P
PW
DW
15 20
48
18 25
7 12
300 370
40 50
PMMA
PW
DW
12 16
12 16
12 16
20 30
320 370
40 60
PVDF
PW
DW
10 15
12 17
15 20
25 35
365 385
45 55
PW = Pendulum Welding
DW = Draw Welding
Page 18
The hot air temperature is measured in the hot air

stream, approx. 5mm in the middle of the nozzle.
24.03.2005
Hot Air Welding

Welding Seam Preparation
Welding area and welding rod:
dry, clean, free of oil and grease
free of splints
free of notches
free of oxidation
(joining area has to be scraped off right before the welding process)
Air pressure:
The use of air pressure requires the installation of pressure

reducer with oil and water separator.
Page 19
24.03.2005
Hot Air Welding

Welding Seam Shapes (DVS data sheet 2207 part 3, 2205 part 3 and 5)
X-Seam (double-V-seam)
V-Seam
X-seam for thickness of 5mm and more
Angle Joints
Page 20
Fillet weld
24.03.2005
Hot Air Welding

Evaluation of the Welding Seams
Correctly welded seams:

slight flattening of the welding rod
no notches between the welding layers
flat seam raise
in particular for PVC:
- foamy to smooth bead
- no discolouring (e.g. brownish colour)
in particular for PE, PP, PVDF:
- smooth double bead on both sides
- dull surface in the area of the welding zone
Page 21
24.03.2005
Hot Air Welding

Flawed welding seams:
no building of bead or welding rod

hardly flattened
>> temperature too low or
>> speed too fast or
>> welding force too small
notches between the welding layers

>> distance between the layers too big
Page 22
24.03.2005
Hot Air Welding

Flawed welding seams:
in particular for PVC:

brownish discolouring of the
welding bead
>> temperature too high or
speed too slow
in particular for PE, PP, PVDF:

shiny welding zone
>> temperature too high or
speed too slow
Page 23
24.03.2005
Hot Air Welding

Tools
External air supply with air
pressure or Robust
Built in air
supply
External air supply with

blower or pressure air
DIODE
TRIAC
Blower:
WELDING PEN
MINOR
Blower:
HOT JET S
ROBUST
Page 24
24.03.2005
Summary Theory
Page 25
24.03.2005
Extrusion Welding
Influences During Extrusion Welding
Plastic temperature control survey

- to be measured with insertion thermometer approx. 5mm in welding shoe
Hot air temperature for preheating control survey

- with probe 5mm in the middle of the nozzle
Measurement of mass flow rate of the Extruder at the output in kg/h

- to be evaluated by weighing the out-flowing plastic
Adjustment of temperature differences between components

- avoid higher temperature differences between the components > strain!
> steel tube of 10m length > rise in temperature 10C > expansion = 1.2mm
> PE tube of 10m length > rise in temperature 10C > expansion = 34.0mm
Page 26
24.03.2005
Extrusion Welding
Temperature of the plasticized zone on the basic material

- Difficult to be measured during the welding process. Check possible by insertion. The
minimum melting depth should be approx. 0.5mm (check by insertion!)
Welding speed depends on the output capacity of the extruder and the
seam volume
- The welding speed must be constant.
- The welding speed and hot air temperature must be harmonised with each other so that
the required minimum melting depth of 0.5mm is guaranteed.
Welding force (welding pressure)

- Depends on shape and length of the welding shoe. Welding force cannot be measured,
and depends on the welders experience.
Page 27
24.03.2005
Extrusion Welding
Preparation of Welding Seam
Welding surface has to be scraped off with a

scraper right before the welding process
Page 28
24.03.2005
Extrusion Welding
Welding Parameters (DVS 2207-4 supplementary sheet 1)
PE-HD4)
PP
Temperature of
mass1) C
Temperature of hot air2)

C
Airflow3) l/min
210...230
210...240
210...300
210...300
> 300
> 300
1) measured with insertion thermometer at the extruded product output of the welding machine
2) measured 5mm in the middle of the nozzle opening
3) drawn-in cold air volume at ambient pressure
4) PE 63, PE 80, PE 100
Page 29
24.03.2005
Extrusion Welding
Environmental Influences
Impact
Counter Measure
high humidity
(building of condensate)
bad welding connection
pre-heat welding zone

dry welding surface
humid welding
addition (wire,
granulate)
building of vacuoles or blowholes
pre-dry welding addition

(3 4 h at approx. 100C)
low temperatures
(<5C)
- not sufficient pre-heating

- building of condensate on
material
erect protection tent and heat it
too fast cooling of the

welding seam
- vacuoles in the welding seam
Too fast cooling is avoided by

covering the seam. Big seam cross
sections are in general to be
covered.
draught
uneven or too fast
cooling
- not sufficient pre-heating

- vacuoles in the welding seam
protect welding area
Page 30
24.03.2005
Extrusion Welding
Welding Mistakes
Building of blowholes and vacuoles:

temperature of mass too high
rest humidity in the welding addition
humidity too high
welding beads or wet hands
welding shoe too cold
vacuoles with V-seam (material PP)

Page 31
24.03.2005
Extrusion Welding
Welding Mistakes
Rough surfaces of the welding seam:

welding shoe too short
welding shoe too cold (always pre-heat welding shoe!)
welding shoe sliding surface too rough
bad
Page 32
good
24.03.2005
Extrusion Welding
Welding Seam Shapes (according to DVS guidelines 2207 part 4 and 2209 Part 1)
V-Seam:
z = seam covering
b = max. 30mm
h = (0.1 to 0.4) x s
penetrated welding seam root
Rework output bead and webs if

possible!
Page 33
24.03.2005
Extrusion Welding
Welding Seam Shapes (according to DVS guidelines 2207 part 4 and 2209 part 1)
Fillet weld:
= 0.7 x s
a max = a + 0.4 x a
Page 34
24.03.2005
Extrusion Welding
X-Seam:
mechanically fixed or tacked
rework seam root if necessary
Page 35
24.03.2005
Extrusion Welding
Overlap seam:
Page 36
24.03.2005
Extrusion Welding
Design of Welding Shoes (DVS guidelines 2207 part 4)
Material of welding shoe: PTFE
Measures of Length
- LA = pressure length
- LN = length of shoe nose
seam thickness a
Lengths
of V-seams
(mm)
(mm)
nose
up to
to
to
The nose prevents an overflow of the melting mass and makes

the required pressure build-up possible.
Page 37
24.03.2005
Extrusion Welding
WELDMAX
Scope
Plastic Fabrication
Civil Engineering
Output
0.8 kg/h
Weight
3.8 kg
Size lxwxh mm
443 x 94 x 255 mm
Separately, steplessly regulated

temperature > air / plastic
Ideal for confined spaces
Smallest hand extruder of its size
Low noise
Complies with DVS and CE conformity
Page 38
24.03.2005
Extrusion Welding
WELDMAX
heating chamber
digital display
- set air temperature
- set plastic temperature
- set plastic output
adjustable handle
welding rod feeder:

- twist-free
- d4 mm
hot air blower
Page 39
24.03.2005
Extrusion Welding
WELDPLAST S4
Scope
Plastic Fabrication
Civil Engineering
Output
PE (I3) 1.6 2.3 kg/h

PE (I 2.4 4.0 kg/h
PP (I3) 1.3 2.0 kg/h
PP (I 2.1 3.3 kg/h
Weight
8.7 kg
Size lxwxh mm
560 x 110 x 300 mm

Brushless and maintenance-free blower

motor
Menu with functioning program to regulate

welding process
Low noise
Page 40
24.03.2005
Extrusion Welding
WELDPLAST S4
Worm
180
digital display:
- set air temperature
- set plastic temperature
- set plastic output
- service display
- language choice (D, E, F, Esp)
- program
welding rod feeder:
- double-sided
- twist-free
- 3 and 4 mm
hot air blower
- brushless motor
simple change to different welding directions

Page 41
24.03.2005
Extrusion Welding
WELDPLAST S6
Scope
Plastic Fabrication
Civil Engineering (G6)
Output
3.5 - 6 kg/h
Weight
11.5 kg
Size lxwxh mm
680 x 110 x 310 mm

Menu with functioning program to regulate
welding process
Brushless and maintenance-free blower
motor
Low noise
Page 43
24.03.2005
Extrusion Welding
FUSION 3
Scope
Plastic Fabrication
Civil Engineering
360
two positions L/R
Output
PE (I3) 1.6 2.3 kg/h

PE (I 2.0 3.5 kg/h
PP (I3) 1.3 2.0 kg/h
PP (I 1.5 2.7 kg/h
Weight
7.2 kg
Size lxwxh mm
670 x 90 x 180 mm
Compact and handy

potentiometer
output control
potentiometer
air temperature
Page 44
Very simple handling

Unique price/performance ratio
Protection of drive with overload and
temperature protection
24.03.2005
Extrusion Welding
Welding Shoe Assortment
Access. FUSION
Blank complete
Welding shoe complete, blank 50x30x38mm
Welding shoe complete, blank 70x50x47.5mm
Welding shoe blank complete 99x99x99mm
V-Seam
Welding shoe complete, V5 & X10
Welding shoe complete, V20 & X35/40
Welding shoe complete, V25
Welding shoe complete, V30
K-Seam
Welding shoe complete, K-seam 5mm
Welding shoe complete, K15
Overlap
Welding shoe complete, overlap 25mm
board thickness
mm
WELDMAX
FUISON 3
WELDPLAST 4/6
x
x
-
x
x
x*
x*
x
x
x
x
x
x
x
x*
x*
x
x
x
x
x
x
x
x*
x*
x
x
x
x
x
x
x*
x*
x
x
x
x
x
x
x
x
x
x
x
5 mm / 12 mm
6 mm / 10 mm
8 mm / 16 mm
10 mm / 20 mm
12 mm / 25 mm
15 mm / 30 mm
20 mm / 40 mm
25 mm
30 mm
x
x
x
x
5 mm
6 mm
8 mm
10 mm
15 mm
20 mm
25 mm
30 mm
x
x
x
x
x
* pay attention to the maximum welding speed
Page 45
24.03.2005
Extrusion Welding
... with Leister
WELDPLAST S4
welding tanks for waste
water treatment plants made
of PE
up to board thickness of
20mm
Page 46
24.03.2005
Extrusion Welding
... with Leister
FUSION 3
repair of shuttering panels
made of PP
two-shift operation
Page 47
24.03.2005
Summary Theory
Page 48
24.03.2005
Angle Joint
unfavourable
Frame Corners
favourable
unfavourable
favourable
Put welding connections to the outside of the main exposure zone.
Page 49
24.03.2005
Changes in Cross Section
Frame Corners
wrong
right
wrong
Avoid abrupt changes in cross section.
Page 50
right
Cross joints are not allowed in carrying

parts.
24.03.2005
Summary Theory
Page 51
24.03.2005

Test Method in Plastic Fabrication
Destroying Test Methods:
tensile test DVS 2203-2
impact-tensile test DVS 2203-3
long-time tensile test DVS 2203-4
technological bending test DVS 2203-5
Page 52
24.03.2005

Test Method in Plastic Fabrication
Non-Destructive Test (Visual Check)
Welding Procedure
Appearance of Seam
Pendulum Welding and

Draw Welding
building of bead
notches
seam covering
penetrate welding of roots
offset
extension and compression
mistake in seam cross section
Extrusion Welding
seam covering
notches and seam surface

mistake in seam cross section
min. melting depth of 0.5mm (check it during the

welding process by insertion)
Page 53
24.03.2005

DVS 2205 Welding

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Summary Theory

Introduction Plastic Fabrication

Basic Welding Principles

Pendulum Welding and Draw Welding

Hot Air Extrusion Welding

Arrangement of Welding Constructions

Test of Welding Connections

Introduction Plastic Fabrication

Basic Welding Principles

Pendulum Welding and Draw Welding

Hot Air Extrusion Welding

Arrangement of Welding Constructions

Test of Welding Connections

Introduction Plastic Fabrication

Basic Welding Principles

Pendulum Welding and Draw Welding

Hot Air Extrusion Welding

Arrangement of Welding Constructions

Test of Welding Connections

Basic Welding Principles

yellow flame, blue core,

resistant to acids, leaches and

sanitation tubes, tank construction,

yellow flame, blue core,

very good when in contact with

benches, ventilating tubes, tank

Outstanding when in contact with

chemical facilities, clean room

high chemical resistance

chemical plant construction

high chemical resistance at high

chemical plant construction at

chemical resistance depends on

hoses, gaskets, coatings

resistant to weak acids and

takes in a lot of humidity >

crackling burning, smoking

Basic Welding Principles

Basically, only identical thermoplastics can be welded together

Not all thermoplastics are weldable, structure and molecular mass

Basic Welding Principles

Pendulum Welding (PW)

Draw Welding (DW)

Hot Air Extrusion Welding (EW)

Heating element butt welding

Heating element groove welding

Heating element bend welding

Heating element socket welding

Heating element helix welding

Basic Welding Principles

for confined spaces

for short seams and

PVC-U cannot be welded

for wall thickness of up to

for wall thickness of up to

Hot Air Extrusion

better seam quality than with

Introduction Plastic Fabrication

Basic Welding Principles

Pendulum Welding and Draw Welding

Hot Air Extrusion Welding

Arrangement of Welding Constructions

Test of Welding Connections

Pendulum Welding (PW)