We have developed a solution to evaluate the weld quality between two plastic parts by simulating the real weld operation before actually doing it.
The device replaces one of the parts to be welded in order to simulate the welding operation. So, under real welding operation conditions, the device makes it possible to follow the evolution of the temperature over time at more than a hundred points where thermal sensors are integrated throughout the welding cycle.
This data is retrieved via an acquisition system and is then processed to map the evolution of the temperature reached at different points of the interface between the device, replacing one of the two parts to be welded, and the second part.
The temperature profile obtained by this method can then be compared to a theoretical profile inherent to a previously defined level of weld quality.
The device is simple to implement since it replaces one of the two parts to be welded without prior preparation. Its PTFE matrix, which is not weldable at the temperatures for welding polyethylenes, polyamides and polypropylene, makes the device reusable and ensures the ability to reproduce the measurements: the distribution of the thermal sensors is not altered during the heating/cooling cycles.
As such, it is possible to use this solution for various activities such as non-destructive quality control at the end of the production line for electrofusion fittings, for expertise upstream or downstream of a welding operation, or for support equipment in the development of new types of thermoplastic tubes or new electrofusion fittings, in order to reduce the costs of the test and trial phases.