聚乙烯电熔接头工艺缺陷与力学相关性研究

采用超声相控阵检测技术（PA）测量不同焊接时间下聚乙烯管道电熔接头热影响区边缘宽度l,并通过挤压剥离试验、傅里叶变换红外光谱（FTIR）试验和差示扫描量热（DSC）试验分别测试接头熔融区脆性剥离百分比（C_c）、官能团组成和结晶度（X_c）,最终建立接头热影响区边缘线宽度l与焊接性能H_c的对应关系,实现电熔接头焊接性能的无损评价。结果表明,随着焊接时间t的增加,接头热影响区边缘呈指数增长趋势沿金属丝向外壁移动,接头焊接性能先逐渐提高后降低。当焊接时间t=50 s时,l=2.21 mm、X_c=53.03 %,此时接头焊接性能H_c达到最大值96.21 %,当t<40 s时,l和X_c偏低,接头出现冷焊缺陷;相反,当t>70 s时,接头熔融区金属丝出现错位现象,融合面的聚乙烯分子由于高温氧化反应而出现过焊缺陷,两者都会导致接头焊接性能下降。     

聚乙烯塑料管道焊接性能的研究

研究了国内外几种不同牌号、不同密度的聚乙烯管道热板焊接的性能。结果表明:这些塑料管材的焊接性能良好。热板焊接导致了焊缝区的聚态结构发生变化,从而使焊接接头的强度略高于母体强度。不同密度聚乙烯互焊时,焊接强度介于两种聚乙烯母体强度之间。     

聚乙烯及其复合管电熔接头的失效模式与爆破压力研究

通过Abaqus有限元分析软件,建立聚乙烯（PE）及其复合管电熔接头受内压和轴向力作用下的有限元模型,分析电熔接头的应力分布规律,研究管材种类、强度对电熔接头的失效模式与爆破压力的影响规律,结合电熔接头短时爆破实验验证模型的有效性。结果表明,PE管电熔接头的失效模式是管材韧性破坏;增强热塑性复合管（RTP）电熔接头的失效模式和爆破压力受管材强度影响,随强度增加,失效模式由管材破坏转变为电熔套筒破坏,爆破压力随RTP管材强度增加先升高,随后趋于稳定。     

聚乙烯管道电熔焊接超声相控阵检测技术研究

电熔焊接是聚乙烯管道的主要连接方式之一,由于聚乙烯材料声波衰减系数较大,电熔焊接接头内部金属丝对检测干扰较大,利用常规超声检测手段很难有效检出聚乙烯电熔接头内的各类缺陷。制作了聚乙烯管道电熔焊接接头内部典型缺陷,使用超声相控阵检测技术对其进行了可靠性试验测试。结果表明,提出的超声相控阵检测技术能可靠地检测出聚乙烯电熔焊接头内的典型缺陷。     

聚乙烯管材热熔对接接头抵抗慢速裂纹扩展性能评价

采用应变硬化试验(SH)对不同焊接工艺下的聚乙烯管材热熔对接接头抵抗慢速裂纹扩展（SCG）性能进行评价。通过建立焊接温度梯度（190~250 ℃）、焊接压力梯度（0.6~1.4 MPa）和吸热时间梯度（40~140 s）试验,分析在不同焊接工艺参数条件下,不同聚乙烯管材热熔对接接头耐SCG性能的变化规律,探索冷焊及过焊2种典型缺陷对管材接头耐SCG性能的影响。结果表明,焊接温度、焊接压力和吸热时间都是影响管材热熔对接接头耐SCG性能的重要工艺参数,试验测得PE100, d_n110, SDR11型管材的最佳焊接参数为焊接温度230 ℃,焊接压力1 MPa及吸热时间100 s,当焊接参数选取过高或过低时,会造成管材接头出现过焊或冷焊缺陷,降低管材接头的耐SCG性能。     

聚乙烯电熔焊接新方法及工艺优化研究

在电熔接头相控阵检测中首次发现接头内部存在一条由超声信号组成的特征线,进一步研究表明,可以根据特征线移动速度以及特征线与电阻丝的距离变化情况,估评聚乙烯（PE）电熔接头的焊接工艺是否合适。在PE电熔接头新产品开发中采用超声检测实时录像,通过特征线的移动情况对焊接工艺参数进行优化,从而可大幅降低电熔接头的开发时间和成本。     

塑料管材焊接性能的研究与比较

试验研究了两种聚乙烯煤气管材的热板焊焊接性能,其中一种管材是齐鲁石化公司新近开发成功的新牌号。在考察了焊接工艺参数与接头短时强度的基础上,本文推荐了这类材料的最适焊接工艺参数:220℃热板温度、35s热透时间和1.5×10~5Pa的焊接压力。此外,还试验了一种快速评价焊接接头质量的新方法——热处理法,这种方法与拉伸试验的方法的结果相当吻合。     

聚乙烯及其复合管道安全检测与评价方法

聚乙烯及其复合管道广泛应用于油气输送、城市燃气等能源领域,其安全性至关重要。焊接接头的安全检测及评价是聚乙烯及其复合管道系统安全的关键技术。介绍了聚乙烯管道焊接接头的无损检测原理及方法、冷焊检测技术以及缺陷分类与失效模式三方面内容。对电熔和热熔焊接接头分别采用超声相控阵和耦合聚焦技术进行超声检测,并给出了缺陷剖切与检测结果的对比图。提出了物理概念清晰、工程应用方便的冷焊超声检测方法。将电熔接头中的缺陷分为熔合面缺陷、孔洞、结构畸变和过焊。分别对含不同类型和大小缺陷的电熔接头进行力学性能测试,发现电熔接头存在三种典型的失效模式,即沿电熔套筒壁贯穿裂纹失效、熔合面失效以及沿电阻丝所在平面贯穿裂纹失效。根据试验测试与理论分析结果,提出了相应的安全评定方法。所提出的方法,填补了国内外在聚乙烯管道安全检测与评价方法方面的技术空白,提高了燃气管道的本质安全性。     

高密度聚乙烯管热熔焊接接头本构模型研究

采用实验方法研究高密度聚乙烯(PE?HD)热熔焊接接头区域的材料性能与管材本体的差异.按照ISO 21307标准方法形成热熔焊接接头后,去除内外卷边,设计接头取样方式并改进拉伸试样.通过不同应变率下管材和焊接接头的单轴拉伸试验,使用一种新的本构分析方法与Suleiman方法研究其本构模型差异,得到了模型参数随应变率变化...     

聚乙烯管材耐慢速裂纹增长性能研究进展

简要介绍了聚乙烯管材发生慢速裂纹增长(SCG)的机理,并详细介绍了影响聚乙烯管材耐SCG性能的影响因素,包括系带分子(TMs)、界面相和无定形相的活动性,以及聚乙烯管材专用料的研发和熔融加工过程中的结构与形态控制研究。     

Evaluation of polybutene electrofusion joint performance

This paper describes methods of evaluating polybutene electrofusion joints and results of mechanical strength measurements for an electrofusion joint. Suitable fusion conditions were determined qualitatively through measurement of fusion interface temperatures and observation of the fusion zone. A method of determining standard fusion conditions, based on the relation between heating time and tensile strength, is also indicated. Differences in thermal properties between polybutene and polyethylene resins are discussed. It was found that polybutene required less supplied power per unit fusion area for suitable fusion. It was also confirmed that an electrofusion joint required a cold zone.     

A review of the electrofusion joining process for polyethylene pipe systems

Electrofusion joining is now an essential and widely used method to assist in the creation of polyethylene pressure pipe systems. The process of electrofusion joining is reviewed by examining the experimental and some computer simulation literature relating to the temperature and melt pressure changes during the fusion process, and on how varying fusion time and pipe/fitting gap influences the strength of electrofusion joints. From this literature review, four key stages in the joining process are identified. First, an incubation period where the joint has no strength. Second, a joint formation and consolidation stage where an increasing joint temperature aids molecular diffusion to both increase the joint strength and promote a more ductile mode of failure. A plateau region then follows where the joint strength, and ductility, remain reasonably constant despite the fusion time increasing. This plateau is thought to allow some welding variables, such as gap, to have only a small influence on joint strength (for gap maintained within reasonable limits). Finally there is a cooling stage where the joint bridging “tie molecules” become locked into either side of the joint. It is these tie molecules that give the joint its ductility and strength. The concluding section of the review notes some of the important on-site practices that, if followed, allow electrofusion joints to acquire their good strength properties, and hence give polyethylene pressure pipe systems of a high integrity.     

The joining of biaxially oriented polyethylene pipes

Die-drawing techniques recently developed at Leeds University make it possible to produce oriented polymer tubes with both axial draw and hoopwise expansion. These products have increased axial stiffness, improved barrier properties, and excellent resistance to chemical reagents. Normally mechanical methods are used to join such tubes in order to preserve their orientation: however we show that electrofusion techniques produce joints of strengths such that in tensile tests, failure always occurs in the fittings, not at the joint interfaces. Optical and electron microscopy reveal different zones in the welds and indicate that only 20 percent of the wall thickness is affected by the electrofusion process. The pipe studied was biaxially drawn medium density polyethylene of outside diameter 63 mm with draw ratios of 4 in the axial direction and 2, inner hoop. Optimum welding conditions were determined using socket and saddle electrofusion fittings. The joints did not fail in a standard crush test. Careful control of welding parameters is essential in butt fusion welding when the maximum weld strength exceeds that of the undrawn polymer.     

Investigation of appropriate cooling times for electrofusion jointing of PE pipes for gas distribution

This study evaluates three types of fusion zones between electrofusion (EF) joints and pipes that were laid underground after three different cooling times following fusion. The study establishes the relationship between the cooling time and the fusion performance. The object was to determine an appropriate cooling time for EF jointing. Only a slight difference was observed in the molecular structure, e.g., the degree of crystallinity, while distinct differences were observed in deformation, morphology, and tensile creep strength. Based on these results, the effect of a temperature profile during the cooling process on the fusion zone was simulated. The simulation showed that the state of the fusion zone (melting, semi‐solid, or solid) when the pipe was laid underground was the main factor affecting the tensile creep strength, i.e. long‐term performance. These analyses provided criteria for choosing an appropriate cooling time.     

Design of electrofusion joints and evaluation of fusion strength using fusion simulation technology

Fusion simulation is one of the key techniques in designing and producing electrofusion (EF) joints for gas distribution and in evaluating fusion joint integrity. This paper describes the result of a numerical simulation of a thermal fusion process, using the finite element method. A nonlinear heat transfer computer program was used to obtain the temperature profile of a large electrofusion joint at fusion. The effects of applied voltage, heating time, wire pitch, and ambient temperature were examined for designing a 150-mm EF joint. A method to shorten the cooling time was also investigated. The fusion condition range suitable for a 150-mm EF joint was found to be slightly narrower than that suitable for a 50-mm EF joint. Examination of the effect of wire pitch revealed that if the pitch is extremely large, thermal degradation starts in the resin close to the wire before the fusion-interface strength reaches the maximum value. We have developed a program to simulate the process of closing the gap between the pipe and the joint due to resin expansion and melting after the power is supplied.     

聚乙烯管材热熔对接焊冲击性能的研究

应用仪器化冲击试验机对聚乙烯热熔对接焊的冲击性能进行了测试，并对几种实际焊接情况进行了分析。结果表明，冲击试验可以作为评价热熔焊接品质的有效方法；工程中应避免PE100、PE80与PE63的焊接；当被焊管材的标准尺寸比（SDR）不 同时，焊接部位的冲击性能大幅度下降。     

Fusion simulation of electrofusion polyethylene joints for gas distribution

Fusion simulation is one of the key techniques used in designing and producing electrofusion joints for gas distribution and in evaluating fusion joint integrity. This paper describes the results of numerical simulation of the thermal fusion process, using the finite element method. A nonlinear heat transfer computer program was used to obtain the temperature profile of an electrofusion joint at fusion. It was found that the temperature experimentally measured at the fusion interface by insertion of a thermocouple agreed with the temperature computed by fusion simulation. In addition, as both the temperature at the fusion interface and the resin temperature close to the wire corresponding to the mechanical strength of the fusion part were measured, it was confirmed that the proper heating conditions for each joint could be determined based on the results of the fusion simulation.