Accelerated electrofusion welding of polyethylene pipes employing a novel xylene-based conductive polymer intermediary for optimized pulse application
محورهای موضوعی : فصلنامه نانوساختارهای اپتوالکترونیکیAbdolali Rahimi Mozafari 1 , Masoomeh Emadi 2 , Bijan Honarvar 3 , Moein Nabipour 4
1 - Department of Chemical Engineering, Marvdasht Branch, Islamic Azad University, Marvdash
2 - Department of Chemistry, Marvdasht Branch, Islamic Azad University, Marvdash 2
3 - Department of Chemical Engineering, Marvdasht Branch, Islamic Azad University, Marvdash
4 - Department of Chemistry, Marvdasht Branch, Islamic Azad University, Marvdash
کلید واژه: Electrofusion, polyethylene, Xylene, field joint, TGA-DSC,
چکیده مقاله :
The natural gas is an important energy source that is increasingly being utilized due to its convenience and clean energy provision. Natural gas is safely supplied to consumers through an underground gas pipeline network made of polyethylene materials. In electrofusion, which is one of the joining methods, copper wire is used as the heating wire. However, it takes a long time for the fusion to occur because of the low electrical resistance of copper. Therefore, in this study, electrofusion with the replacement of the copper heating wire with an intermediate material containing an electrically conductive and thermally conductive polymer was performed to reduce the fusion time and improve the production during the connection of large pipes. After the fabrication of the electrofusion joint in the polyethylene pipe using the intermediate material, fusion, thermal and tensile tests were conducted. The results showed that the fusion time is shorter, and the temperature inside the pipe is higher with the increase in the current amount. The optimal welding voltage value was the one in which the melt time was short, and no deformation was observed in the pipe. Therefore, it was demonstrated that the conductive interface can be used to replace the copper heating wire.
The natural gas is an important energy source that is increasingly being utilized due to its convenience and clean energy provision. Natural gas is safely supplied to consumers through an underground gas pipeline network made of polyethylene materials. In electrofusion, which is one of the joining methods, copper wire is used as the heating wire. However, it takes a long time for the fusion to occur because of the low electrical resistance of copper. Therefore, in this study, electrofusion with the replacement of the copper heating wire with an intermediate material containing an electrically conductive and thermally conductive polymer was performed to reduce the fusion time and improve the production during the connection of large pipes. After the fabrication of the electrofusion joint in the polyethylene pipe using the intermediate material, fusion, thermal and tensile tests were conducted. The results showed that the fusion time is shorter, and the temperature inside the pipe is higher with the increase in the current amount. The optimal welding voltage value was the one in which the melt time was short, and no deformation was observed in the pipe. Therefore, it was demonstrated that the conductive interface can be used to replace the copper heating wire.
[1] M.R. Saeb, P. Wiśniewska, A. Susik, Ł. Zedler, H. Vahabi, X. Colom, J. Cañavate, A. Tercjak, K. Formela, GTR/thermoplastics blends: how do interfacial interactions govern processing and physico-mechanical properties?, Mater. 15(3) (2022) 841.
[2] G. Holden, Thermoplastic elastomers, Applied Plastics Engineering Handbook, Elsevier2024, pp. 97-113.
[3] B. Hampel, S. Monshausen, M. Schilling, Properties and applications of electrically conductive thermoplastics for additive manufacturing of sensors, TM. Tech. Mess. 84(9) (2017) 593-599.
[4] K. Periasamy, E. Kandare, R. Das, M. Darouie, A.A. Khatibi, Interfacial engineering methods in thermoplastic composites: An overview, Polymers 15(2) (2023) 415.
[5] D.-J. Kwon, Y.-J. Jang, H.H. Choi, K. Kim, G.-H. Kim, J. Kong, S.Y. Nam, Impacts of thermoplastics content on mechanical properties of continuous fiber-reinforced thermoplastic composites, Compos. B. Eng. 216 (2021) 108859.
[6] E.N. Peters, Engineering thermoplastics—materials, properties, trends, Applied plastics engineering handbook, Elsevier2017, pp. 3-26.
[7] M. Picard, A.K. Mohanty, M. Misra, Recent advances in additive manufacturing of engineering thermoplastics: challenges and opportunities, RSC adv. 10(59) (2020) 36058-36089.
[8] K. Patel, S.H. Chikkali, S. Sivaram, Ultrahigh molecular weight polyethylene: Catalysis, structure, properties, processing and applications, Prog. Polym. Sci 109 (2020) 101290.
[9] D.B. Malpass, Introduction to industrial polyethylene: properties, catalysts, and processes, John Wiley & Sons2010.
[10] M. An, B. Cui, X. Duan, Preparation and applications of linear low-density polyethylene, J. Phys. Conf. Ser., IOP Publishing, 2022, p. 012009.
[11] P. Olesik, M. Godzierz, M. Kozioł, J. Jała, U. Szeluga, J. Myalski, Structure and mechanical properties of high-density polyethylene composites reinforced with glassy carbon, Mater. 14(14) (2021) 4024.
[12] L. Li, L. Zhong, K. Zhang, J. Gao, M. Xu, Temperature dependence of mechanical, electrical properties and crystal structure of polyethylene blends for cable insulation, Mater. 11(10) (2018) 1922.
[13] M. Guseva, V. Gerasin, B. Shklyaruk, V. Dubinskiy, Relation between thermal effects and structural changes under deformation of thermoplastics, Polymer 144 (2018) 18-32.
[14] C. Mandolfino, E. Lertora, C. Gambaro, Effect of cold plasma treatment on surface roughness and bonding strength of polymeric substrates, KEM 611 (2014) 1484-1493.
[15] J. De Freese, J. Holtmannspötter, S. Raschendorfer, T. Hofmann, End milling of Carbon Fiber Reinforced Plastics as surface pretreatment for adhesive bonding–effect of intralaminar damages and particle residues, J. Adhes (2018).
[16] M.S. Alavijeh, R. Scott, F. Seviaryn, R.G. Maev, Application of a chord transducer for ultrasonic detection and characterisation of defects in MDPE butt fusion joints, INSIGHT 64(10) (2022) 560-565.
[17] M. Shafiei Alavijeh, R. Scott, F. Seviaryn, R.G. Maev, Using machine learning to automate ultrasound-based classification of butt-fused joints in medium-density polyethylene gas pipes, J. Acoust. Soc. Am. 150(1) (2021) 561-572.
[18] R.A. Mencos, Electrofusion pipe fittings, methods, and systems, Google Patents, 2020.
[19] A.H. Elsheikh, Applications of machine learning in friction stir welding: Prediction of joint properties, real-time control and tool failure diagnosis, Eng. Appl. Artif. Intell. 121 (2023) 105961.
[20] V.K. Stokes, Experiments on the hot-tool welding of three dissimilar thermoplastics, Polymer 39(12) (1998) 2469-2477.
[21] S. Pimputkar, J. McCoy, J. Stets, Technical reference on saddle-heat-fusion joining of polyethylene gas pipes. Volume 2. Topical report, July 1989-January 1992, Battelle, Columbus, OH (United States), 1992.
[22] M. Troughton, M. Spicer, F. Hagglund, Development of ultrasonic phased array inspection of polyethylene pipe joints, PVP Conference, American Society of Mechanical Engineers, 2012, pp. 285-293.
[23] A. Guilpin, G. Franciere, L. Barton, M. Blacklock, M. Birkett, A Numerical and experimental study of adhesively-bonded polyethylene pipelines, Polymers 11(9) (2019) 1531.
[24] H.A. Mehrabi, J. Bowman, Electrofusion welding of cross-linked polyethylene pipes, Iranian Polymer Journal 6 (1997) 195-204.
[25] G.C. Onuegbu, C. Onuoha, Transport behaviour of xylene through compatibilized low density polyethylene composite, European Journal of Engineering and Technology Vol 5(3) (2017).
[26] R. Kolisnyk, M. Korab, M. Iurzhenko, O. Masiuchok, Y. Mamunya, Development of heating elements based on conductive polymer composites for electrofusion welding of plastics, Journal of Applied Polymer Science 138(20) (2021) 50418.
[27] J. Bowman, A review of the electrofusion joining process for polyethylene pipe systems, Polymer Engineering & Science 37(4) (1997) 674-691.
