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Welding of Thermoplastics Heated Tool Butt Welding Directive DVS 2207-25
Welding of Thermoplastics Heated Tool Butt Welding Directive DVS 2207-25
Welding of Thermoplastics Heated Tool Butt Welding Directive DVS 2207-25
2000
Letzte Änderung: 05.02.2002
File-Name: C:\DVS Merkblätter\2207\2207-25\e2207-25.fm
4 Welding processes
2 Terminology
The welded joints made from extruded PVC-U sections covered
Matching Section 4 and Fig. 1 by these directives, are produced by means of heated tool butt
Matching time Fig. 1 welding. Welding machines, as per Section 5 of these directives,
Heating cycle Fig. 1 are to be used for this. The connecting surfaces of the sections to
Heating time Fig. 1 be welded are matched on the heated tool under pressure
Heating pressure Fig. 1 and Section 5.5.1 (matching) until their entire surfaces are in contact. This has
Working pressure Section 5.2. been achieved if a clearly visible bead has formed over the entire
Adjustment plates Section 5.2. periphery of the section.
Jointing Section 4 and Fig 1
Components to be jointed Section 7 Matching is completed by a stop or by control of the working table
Jointing path Section 4 and Fig 1 movement, and passes directly into the heating process. Here
Jointing time Section 4 and Fig 1 the connecting surfaces are heated to the welding temperature
Jointing pressure Section 4 and Fig 1 and a sufficiently deep molten layer is formed. The heating
Heated tool butt welding (HS) Sections 4 and 8 process is controlled on a time basis, and the pressure in the joint
Bead limitation Section 5.3. surface corresponding to Fig, 1 must be reduced to the heating
pressure, PAW. When the warning-up time is over, the sections
Burn-off Section 7
are released by the heated tool and the heated tool is removed
Gap width Section 5.3.
from the welding plane (repositioning).
Clamping pressure Section 5.2.
Repositioning Section 4 and Fig 1 Directly after this, the two welding surfaces of the section are
Repositioning time Section 4, Fig. 1 and joined under the jointing pressure (jointing). The jointing path is
Section 5.5.2. limited by a stop or by control of the working table movement.
1) The internationally used term PVC-U, standing for 'unplasticised polyvinyl chloride' corresponds to the term 'rigid PVC' formerly in use.
2) Training courses on machining plastic casement sections are provided by the Plastics Processing Institute at the Aachen University of Technology (tel.:
+49 241/80 38 12), and in the associated course workshops, and by the South German Plastics Centre in Würzburg (tel.: +94 931/4104-0).
This publication was prepared by a group of experienced specialists working together in an honorary capacity, and it is recommended that it should be respected as
an important source of knowledge. The user must at all times check the extent to which the contents apply to his or her special case and whether the version available
to him or her is still current. Any liability on the part of the German Welding Society and of those participating in the preparation of this document is excluded.
DVS, Technical Committee, Working Group W 4 "Plastics, Welding and Adhesive Bonding"
and Plastic Casement Section Quality Group of Plastics Products Quality Association
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
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Page 2 to DVS 2207-25
The jointing time should be selected in such a way that the joint b) It must. be possible to set. the clamping pressure, matching
weld is sufficiently cooled. The jointing pressure should be pressure and jointing pressure separately and externally, and
selected in such a way that the stop is not reached until the the settings must be repeatable and easily read off
second half of the jointing time (0.3 to 0.7 N/mm²) and the fusion
c) The control and display elements must be clearly indicated3)
viscosity of the material and the jointing surface of the section
should be taken into account. When the stop has been reached, d) Rapid clamping devices must be stable, adjustable and
the jointing pressure in the jointing area is reduced. The jointing replaceable
pressure then decreases further as a result of the cooling e) The clamping elements must open sufficiently widely for the
process. Fig. 1 gives a schematic outline of the individual stages workpiece to be removed without difficulty
in the process.
f) Clamping devices should be designed in such a way that
injury to the operators is avoided
g) The sequence of operations for the welding process must be
extensively mechanised, in order to guarantee good
reproduceability
h) It must not be possible to bring the heated tool into the
operating position unless the clamping table is in the initial
position
i) The welding slides must be guided without any play but so
that they move easily, in order to obtain good reproduceability
j) Unintentional activation of the operating process must be
prevented by a safety device
k) An interruption in the power supply must not trigger any
uncontrolled phenomena of movement
l) The exhaust air from the pneumatic valves must not be
directed onto the heated tool.
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maintained, the strength and viscosity of the welds meet the Table 2. Permissible angular deflection on V-form heated tools.
requirements, and the pre-set dimensions of the window are
maintained. Fig. 1 gives schematic diagrams for the pressure- Length of a side mm permissible deflection mm
time progression and the path-time progression. It must be l a
possible to calibrate the control and adjustment equipment, and it d 100 0.3
must be tested at regular intervals and readjusted if necessary. > 100 ... 150 0.4
> 150 ... 200 0.6
5.5.1 Pressure control > 200 0.8
The matching pressure, heating pressure and jointing pressure
must be separately adjustable. The heating pressure must be The useful area here is taken as being the part of the heated tool
close to 0 (see Fig. 1). Pressure gauges of accuracy class d 1.6, in which the temperature and the amount of heat delivered can
as per DIN 16 005 and 16 063 must be provided for the matching be adjusted over the required range. The manufacturer must
pressure and jointing pressure, and the graduation of scale used display the dimensions of the useful area on the heated tool in
must be 0.2 bar. The minimum and maximum machine pressure permanent form.
which can be set, together with the effective piston surface of the
5.6.2 Surface finish
main cylinder, must be stated in the machine documents. The
pressure in the welding surface can be calculated from these The surface finish of heated tools in the useful area must be such
data and from the cross-section of the profile. as to avoid any plastic material residues remaining behind. It
must be possible to clean heated tools without damaging them.
5.5.2 Time-control
Coatings or coverings, for example PTFE, are recommended to
The heating time and jointing time must be separately adjustable make it easier to keep the surface clean and to reduce the
in stages. The repeatability of the heating and jointing time must adhesion when the components being jointed are removed.
be within an accuracy of r 0.5 s. The repositioning time is Coverings must remain in contact with the heated tool at the
specified by the equipment. It must not exceed 2 s and must be welding temperature.
repeatable within d 0,2 s.
PTFE spray acts as a parting agent and must not be used
since it is removed from the heated tool along with the
5.5.3 Path control
jointed components and transferred into the weld!
Path control must ensure that the pre-set dimensions of the Heated tools newly covered or newly coated with PTFE must be
window are maintained. In conjunction with the placing stop, the heated for at least 0.5 hours to a temperature of 280 °C, when
matching path and the jointing path must display a repeatability first put into operation.
of d 0.1 mm.
The roughness depth value, Rt, (the roughness class as per DIN/
5.6 Heated tool ISO 1302 is given in brackets) is as follows, depending on the
version of heated tool used:
– Heated tool with indirect heat release through a heat conductor
(DVS 2208, Part 1) – – With PTFE covering or coating, Rt d 16 Pm (17). Usual coating
depths are 30 to 50 Pm, and PTFE/fibreglass tissues in
The heat is transmitted from embedded electrical heaters to the thicknesses of 100 to 300 Pm.
surface of the heated tool through a material which is a good
conductor and resistant to corrosion. Cast heated tools must be The covering or coating material must withstand a temperature
free of shrinkholes. stress of 300 °C for an hour without any significant change in its
anti-adhesive properties or its adhesive strength. In continuous
5.6.1 Design use the temperature should not exceed 270 °C.
Heated tools must be suitable for the jointing surfaces in terms of 5.6.3 Useful area of heated tool
form and dimensions. If laminar heated tools are used on both
sides, they must be plane parallel within their useful areas. The external dimensions of a heated tool should exceed the
Permissible deviations from plane parallelism are given in Table length of the sides of the useful area by at least 5% all the way
1 and are based on room temperature. round. The useful area AN is then obtained from the external
dimensions of the heated tool, aH and bH, for example as in Fig.
3:
Table 1. Plane parallelism of laminar heated tools.
AN = aN x bN in cm², where aN = 0. 9 aH, bN = 0.9 bH
Useful area cm² Permissible deviation mm
Plane paralellism Heated tool thickness
d 250 d 0.2 r 0.1
> 250 ... 400 d 0.4 r 0.15
> 400 d 0.5 r 0.2
The entire welding surface must lie within the useful area.
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5.6.5 Minimum temperature range are to be set or checked. The heated tool temperature in the
The heated tool must be continuously adjustable over the useful area should be measured using a suitable gauge (see
required temperature range within the useful area, at least Section 5.6.7). The average standard interval should not deviate
between 200 °C and 300 °C. from the nominal value by more than the amounts listed in Table
3.
5.6.6 Temperature precision
6.3 Commissioning the welding machine
The temperature precision should correspond to the welding
temperature differences listed in Table 3. These welding Good welded joints can not be obtained unless the welding
temperature differences correspond to the temperature machine has reached a constant operating condition. It takes
variations: about 0.5 hours to achieve this because of the heating of the
heated tool and the clamping devices. The welding machine must
a) over. the useful area therefore be switched on at least 0.5 hours before production
b) through the standard interval starts.
c) on the two sides.
Table 3 shows the resulting maximum permissible total 6.4 Functional testing
temperature differences in the effective area. The effective area Before production starts, and after any long interruptions, a
is the surface within the periphery of the profile section. functional test is to be carried out. At least one welded joint is to
be produced for this. Apart from the maintaining of the welding
Table 3. Maximum permissible temperature differences. parameters, special attention is to be paid to satisfactory
useful area area of temperature differences °C clamping of the section and the regular formation of the bead.
cm² a b c total
7 Preparation of components for jointing
d 150 4 2 2 6
> 150 ... 250 5 3 3 8 The profile sections which are intended to weld should be
> 250 ... 400 7 3 3 10 checked with regard to their geometric form and usability before
> 400 9 3 3 12 being cut to size. In the case of main profiles special attention
should be paid to mismatch and to the flatness of the surfaces
These values are to be maintained after a build-up time of app. which are visible after jointing.
30 min., at room temperature, in an environment protected from
draughts, in the working position, within the useful area and at a The burn-off – the difference between the component cut to size
reference temperature of 250 °C. for jointing in the unwelded condition and the finished size in the
welded condition – is to be taken into account when cutting to
5.6.7 Temperature control size takes place. It comes about in connection with the formation
of a bead of plasticised material during matching, heating and
The temperature control must guarantee the characteristic
jointing. (The burn-off was also previously known as the
temperature values required under Sections 5.6.5 and 5.6.6.
'consumption'.)
From the initial contact of the jointed surfaces to repositioning,
the temperature must not fall by more than 4 °C. The heated tool The cutting equipment used (preferably circular saws) must be
temperature must return to the nominal value during the jointing manufactured in such a way that the jointing surfaces do not
time of the welded component. deviate from the nominal values by more than 0.5 mm.
An additional check on the heated tool surface temperature is Deviation includes
required. Suitable equipment for this consists of (for example) – angular deflection
rapid-indicating contacting electrical surface temperature gauges – flatness
with appropriate mass-impregnated and drained probes or – roughness of jointing surface.
contactless radiation meters 4).
The cutting tools must be manufactured in such a way that the
jointing surfaces can be produced without difficulty and without
6 Preparation of machine impermissible heating, Swarf which impedes the jointing process
should be removed (for example by suction or blow-off).
6.1 Visual assessment of function capability of welding machine
The jointing surfaces must be kept free from damage and
The functional capability of the welding machine is to be impurities (for example dust, grease, hand sweat, protective foil,
evaluated before commissioning. The welding machine and the etc.). Moreover, the components cut to size for jointing are to be
leads must be in a condition allowing for a satisfactory sequence stored in a constant climate.
of operations. The machine's service units must be inspected
and maintained at the intervals laid down by the machine
manufacturer. 8 Production of welded joints
The condition of the heated tool surface is of special importance. – Place the jointing components to be welded, cut askew (on the
In the welding area, the surface coating of the heated tool must median) to size, into the machine.
be clean, free from faults and free of damage (for example,
pimples, cracks, etc,). No residues must be present. A stretched – Press the sections against the stops and the adjustment plates
PTFE/fibreglass tissue must be in uniform contact with the unless this part of the work has been taken over by the
heated tool at the welding temperature. machine.
When a new PTFE/fibreglass tissue has been fitted, the heated – Hold the jointing components in this position and release the
tool should be operated for 0,5 hours at 280 °C, in order to clamping devices.
harden the surface. The first three welded joints produced using – Activate the welding process.
this new PTFE/ fibreglass tissue are of inferior strength and
should therefore not be used. – The welding of the jointing components is carried out by the
welding machine automatically in accordance with the welding
6.2 Setting welding parameters parameters to which the welding machine is set.
The welding parameters laid down for the section to be welded – – The welding process is completed when the clamping device
working pressures, temperatures, times and bead limitations – opens.
4)
Information can be obtained from the Casement Sections Quality Group, 2, Dyroffstraße, 5300 Bonn 1, W.Germany (tel 02 28/22 35 7M.).
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– Do not release the welded jointing components from the The maximum force values for corner welds depend on the
clamping devices and remove them from the machine until the profile geometry and the test rig. The maximum corner weld
welded joints have cooled down sufficiently. values measured, F, must not be less than the calculated limiting
values for the breaking force, Fsoll. Fsoll is calculated as follows,
– Since the weld has not yet cooled completely, as little stress as
with a failure stress of V = 35 N/mm²:
possible must be put on the joint.
F soll 2 W V
a
± e
9 After-treatment of welded joints 2 2
The welding bead should be taken off as soon as possible, once V F h
enough cooling has taken place, so as to avoid any impairment of 2W
the weld strength and appearance. Accelerated cooling, for l
example using compressed air, is not permissible and can lead to W
e
stress cracking.
a e
±
Welding beads should be removed manually or mechanically h
2 2
using suitable means. The process can have a significant
influence on the strength of the welded joint.
Some examples of factors which can reduce the strength are:
– notches in inside corner
– grooves in the visible surfaces
– streaking of surfaces.
Using polishing and cleansing agents which dissolve PVC is not
permissible, as can lead to stress cracks and discolouration.
Consult the profile manufacturer's instructions for the after-
treatment of welded joints Involving co-extruded surfaces, coated
surfaces, or surfaces laminated with foil.
The welded joints are tested using corner samples of (90 ± 1)° or Figure 5. 5HSUHVHQWDWLRQRISDUDPHWHUVIRUFDOFXODWLRQRI)VROO.
T-connections from which one side of the continuous section is
out off. The welding bead should not be removed. In this context is:
The sides of the corner under test are cut to length, at an angle of F Maximum force
(45 ± 1)°, in such a way that the neutral fibres (approximately at Fsoll Breaking force limiting value
the centre of the main chamber of the section) lie above the axis I Axial angular impulse
of rotation of the test chassis. W Section modulus in direction of stress (inside corner)
The side lengths on the internal sides (Li) can be derived from the V Failure stress (see DIN 16 830, Part 2 (at present draft)
lengths of the neutral fibres (Ln = 283 mm), minus twice the a Distance between axes of rotation; a = (400 ± 2) mm
distance of the section's internal sides from the neutral fibre (e): e Distance between critical fibre and neutral fibre
Li therefore equals 283 mm – 2e. Ln Length of neutral fibre; Ln = 283 mm.
Li Side length on internal side; Li = 283 mm – 2 ŧ e
For corners from sections with articulated asymmetrical external
h Lever arm
sides, the pressure stamp is to be adjusted to impose a uniform
stress on the profile section of the form of the external section
flank at the point of the corner (using adjustment plates as well,
for example).
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