Numerical and experimental study of the electrofusion welding process of polyethylene pipes

Chebbo, Ziad; Vincent, Michel; Boujlal, Adil; Gueugnaut, D.; Tillier, Yannick

doi:10.1002/pen.23878

Cited by 27 publications

(8 citation statements)

References 20 publications

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“…Due to the risk of joule heating wire fusing, a maximum 70% duty cycle was used in validation experiments. If OFEF joints are manufactured using injection molding techniques [7], [12], [22], such that the area around the joule heating wire is completely covered with molten polyethylene, then voltage and current spikes can be minimized and a smaller variation in average power consumption is expected.…”

Section: A Results Of the Power Comparisonmentioning

confidence: 99%

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Design and Development of a Battery Powered Electrofusion Welding System for Optical Fiber Microducts

et al. 2020

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At present, optical fiber microducts are coupled together by mechanical types of joints. Mechanical joints are thick, require a large space, and reduce the installation distance in multi-microduct installation. They may leak or explode in the blown fiber installation process. Mechanical joints are subjected to time dependent deterioration under long service times beneath the earth's surface. It may start with a small leakage, followed by damage due to water freezing inside the optical fiber microduct. Optical fiber microducts are made up of high-density polyethylene, which is considered most suitable for thermoelectric welding. For thermoelectric welding of two optical fiber microducts, the welding time should be one second, and should not cause any damage to the inner structure of the microducts that are being coupled. To fulfill these requirements, an LTspice simulation model for the welding system was developed and validated. The developed LTspice model has two parts. The first part models the power input to joule heating wire and the second part models the heat propagation inside the different layers of the optical fiber microduct and surrounding joint by using electro-thermal analogy. In order to validate the simulation results, a battery powered prototype welding system was developed and tested. The prototype welding system consists of a custom-built electrofusion joint and a controller board. A 40 volt 4 ampere-hour Li-Ion battery was used to power the complete system. The power drawn from the battery was controlled by charging and discharging of a capacitor bank, which makes sure that the battery is not overloaded. After successful welding, a pull strength test and an air pressure leakage test were performed to ensure that the welded joints met the requirements set by the mechanical joints. The results show that this new kind of joint and welding system can effectively replace mechanical joints in future optical fiber duct installations.

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Section: A Results Of the Power Comparisonmentioning

confidence: 99%

“…A proper EF joint is preferably manufactured using an injection molding technique [7], [12], [22]. At an initial stage to validate the simulation results shown in Figure 11 and 12, an in-house prototype OFEF joint was fabricated on an aluminum mold as pictured in Figure 14.…”

Section: E Development Of Ofef Joint Samplesmentioning

confidence: 99%

Design and Development of a Battery Powered Electrofusion Welding System for Optical Fiber Microducts

et al. 2020

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“…Ziad Chebbo [1] analyzed the numerical simulation of polyethylene pipe welding process through experiments and 3D finite element software. NP Starostin [2,3] analyzed the thermoelastic state of polyethylene pipeline under different ambient temperatures through experiments and analyzed the temperature field law by mathematical model.…”

Section: Introductionmentioning

confidence: 99%

Quality Evaluation of Hot Melt Welding of Plastic Pipes

Wang,

2023

AJST

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In this paper, aiming at the welding quality problems of plastic pipes, finite element analysis method was used to evaluate the quality of welded joints through temperature, melting layer and stress. The results showed that: the crystallization degree and heat transfer distance of the welded surface and its heat-affected zone were different, resulting in different properties of welded joints. Stress stabilization will increase polymer apparent viscosity and reduce melt flow capacity, thus reducing residual stress.

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“…Эффективным методом решения задачи теплопроводности в областях сложной формы является метод конечных элементов [3,4]. Численное решение трехмерной задачи определения неста-ционарного температурного поля при сварке полиэтиленовых труб с помощью муфты с закладным нагревателем методом конечных элементов произведено в работе [5]. При этом для упрощения формы области вместо круглой трубы и муфты рассматривалась трехмерная задача определения температурного режима сварки двух плоских пластин, между которыми проложен закладной нагреватель.…”

Section: Introductionunclassified

Substantiation of technological operations of welding a saddle branch to polyethylene pipes at temperatures below available

Старостин¹,

Vasilieva²

2018

DREAM

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Additional branches for gas supply systems are generally installed during the completion of the construction of a gas pipeline, often falling in the autumn or winter time, when the air temperature is below the maximum allowable for welding polyethylene pipes. At ambient temperatures below minus 15 °С, it is recommended to weld polyethylene pipes under a shelter, where the temperature is maintained in the permissible temperature range.The paper proposes a mathematical model for the thermal process of welding a saddle branch to a polyethylene pipe taking into account the heat of phase transition. The corresponding threedimensional non-linear heat equation is solved by the finite element method. As an example, calculations were made for a PE 100 SDR 11 polyethylene pipe and a 100/63 saddle tap. Comparison of the calculated and experimental temperature data establishes the adequacy of the proposed mathematical model to the actual thermal process of welding a saddle branch to a polyethylene pipe.To obtain a high-quality welded joint, it is necessary to ensure that the temperature field changes according to a certain regularity in the heat-affected zone. Admissible regularity is ensured when welding is performed in the range of climatic air temperatures of above minus 15 C. In this study, examples are considered for the definition of simple technological operations that ensure such regularity at ambient temperatures below normative ones. For comparison, the dynamics of temperature fields at ambient temperatures of 20 C and minus 40 C was calculated. Technological operations necessary to weld a saddle branch at the temperatures below the standard are determined from studying the dynamics of temperature profile during the welding of the saddle branch to a polyethylene pipe at various ambient temperatures.

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Numerical and experimental study of the electrofusion welding process of polyethylene pipes

Cited by 27 publications

References 20 publications

Design and Development of a Battery Powered Electrofusion Welding System for Optical Fiber Microducts

Design and Development of a Battery Powered Electrofusion Welding System for Optical Fiber Microducts

Quality Evaluation of Hot Melt Welding of Plastic Pipes

Substantiation of technological operations of welding a saddle branch to polyethylene pipes at temperatures below available

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