Analysis of Effect of Pressure and Heat on Mechanical Characteristics of Butt Fusion Welding of Polyethylene Pipes

The butt fusion process is one of the most effective processes in welding polyethylene pipes. The heating stage is the most important step in this process. In this investigation, while the main objective was to reduce the final bead's size of the weld, 9 different experiments with different heat and pressure conditions and equal timing for each heating stage were defined. Numerical modeling of Finite Element Method (FEM) of the heating process was carried out in the computer software considering governing physical conditions in the weld to determine heat distribution as well as primary bead geometry. Subsequently, the model was compared with results from experimentations. Cross-cut of the formed primary beads at the end of the heating process were prepared and compared with results from the model. To review final quality of the weld and its mechanical characteristics, all samples were welded under equal pressure conditions. Cross-sections of beads formed at the final stage as well as some samples for tension test and impact test from all welded areas were prepared according to standard for determination of mechanical characteristics and then compared with each other. From mechanical strength perspective, the weld formed in 210°C and 0.18 MPa pressure demonstrated higher values. However, impact strength in the weld formed in 180°C was higher. By reducing pressure in a specified heating process, value of impact energy required to break the piece was reduced. Mechanical strength in heating condition 240°C was lower than all other cases. As for geometry of the formed bead; its size in 180°C and 0.03 MPa pressure in the first stage of the heating process was smaller than other cases.