Installation work with a plastic pipe involves cutting and joining operations. Due to the technical properties of the material, such problems are solved more easily than in the case of metal pipes. But for the most part only experienced craftsmen are familiar with the technologies of the same cutting, although it does not cause any particular difficulties. In fact, a product of soldering a material is required, as a result of which it is possible to change the design parameters or an individual segment of the pipeline.
How to solder polypropylene? As in the case of metal welding, a special apparatus is required. This can be a small manual thermal cutter, and a massive professional installation. But in both cases, the principle of operation is the same.
Soldering tool
There are specialized single-format and multi-function press machines through which soldering is implemented. In this case, this process can be considered both as a cutting method and as a joining operation. The device itself, in its simplest versions, is a small structure with an electromechanical filling and a snap formed by metal clamps.
How to solder polypropylene using such a device? For the most part, only the correct direction of the workpiece is required from the user in accordance with the requirements of the technical process. The principle of operation of the equipment itself is to melt the pipe. The two parts heat up when in contact with metal surfaces, after which any joining action can be performed with them. In other words, the baler provides two technological functions. Firstly, this is the achievement of the temperature effect for melting polypropylene, and secondly, the precise positioning of the edges of the pipes for their correct mixing.
Preparation for work
The operation of soldering plastic materials is very delicate. In the molten state, plastic is very sensitive and susceptible, therefore, foreign particles can easily penetrate into its structure, the presence of which in the future can negatively affect the strength properties of the pipeline. Therefore, the workpieces themselves and the cutting apparatus must be thoroughly cleaned, washed and dried.
Additional devices are also being prepared, which should be at hand during the operation. For example, the question of how to solder polypropylene in hard-to-reach places often refers to special hooks and an LED flashlight. The hook will allow you to suspend the device if it is impossible to get to the place of work with the whole body and conveniently position the tool, and the flashlight will provide visibility if other light sources do not penetrate the place of work.
Stages of the operation
The complete soldering process involves 4 steps - cutting, heating, joining and cooling exposure. Each stage requires special actions from the operator, which depend on which result should be obtained.
Cutting is not done in every case, but with its help you can perform accurate cutting with the same exact subsequent connection. The advantages of thermal cutting over mechanical methods include the elimination of the risk of deformation of the integral parts of the workpiece.
How to solder polypropylene pipes to maintain their original shape? To do this, it is enough to correctly fix the pipe in the clamping rings - then the cutting insert will carefully cut and final weld. The final stage of exposure is the most critical. When performing it, it is important to correctly fix the finished part of the pipe and devote it to cooling exactly as much time as the norm requires.
Soldering technology
The soldering technique should be considered separately. In abbreviated form, without cutting, this operation is performed more often, so most devices have a design optimized specifically for this task. So, the essence of the process is that the two ends of the pipe are installed on opposite sides in the fixing rings.
Next, the operator activates the thermal exposure system. This function can be carried out both by rings, and by a cutting hot plate. Then follows the connection of the two pipe ends.
How to solder polypropylene? Unlike a welding machine for metal, soldering irons for plastic form a seam without user intervention. Maximum intervention is provided by manual models, in which the user simply presses a lever that brings two pipes together. This is done smoothly and without undue pressure - the soft molten plastic should mix, forming a single structural mass at the junction point.
Industrial soldering iron for plastic
In complex and demanding events, you may need the help of professional equipment for soldering plastic. Such models are distinguished by the ability to work with pipes of large diameters, as well as high heating intensity. Accordingly, such units are superior to manual models both in size and in the power of the electric motor. At the same time, you should not consider an industrial soldering iron as universal. It is sharpened specifically for medium and large sizes, but is not suitable for small diameters.
How to solder polypropylene in industrial equipment? The technology and principles of operation are generally the same, but each operation is performed on a separate modular station. One modular unit prepares the pipe with countersinking and trimming, the other directly cuts the plastic, the third provides heating, and the fourth is responsible for positioning the workpiece.
Soldering options
It has already been said that the quality of the result will depend on how correctly and accurately the last stage with cooling was completed. The complexity of this stage lies in the fact that it is necessary at several stages to observe the temporary exposure mode. Usually these are two stages - during the heating process and during the final hardening. Time intervals depend on the thickness of the pipe. Another factor due to temperature conditions is also taken into account.
At what temperature should solder polypropylene? Standard manual devices operate at 250-270 ° C. This is enough to bring the usual household plastic pipe to the required state within 15 minutes. As for the ratio of the diameter and the cooling time, the minimum size of 12 mm will require 4 s of waiting for direct connection, and 120 s for final exposure.
The maximum pipe diameter of 50 mm for hand-held soldering irons needs a 6-second waiting time for soldering, and hardening takes place after 240 seconds.
Features of soldering in tight corners
Work in hard-to-reach and difficult areas requires not only the use of auxiliary equipment (as already mentioned, flashlights and devices to hold the soldering iron). Corner joints also provide for a special implementation of the technology itself with the use of special consumables. But first of all, it is important to remember that cutting is carried out only at right angles, and after cutting the surfaces and ends of the ends must be degreased and cleaned with a soft abrasive.
Now we can move on to another question - how to calculate and solder corners. In this case, polypropylene is connected by means of additional nozzles, which makes adjustments to the waiting interval for the soldering moment. That is, to form an angle, you will need a fitting or adapter made of the same polypropylene. This addition also increases the time for the joint section to be drilled. With a minimum pipe diameter of 12 mm, this interval will be 5-6 s, and in the case of a 50 mm workpiece, about 20 s.
Is it possible to solder plastic pipes with polypropylene?
Operations during which the union of dissimilar pipes occurs are considered undesirable. Such designs initially lose to their homogeneous counterparts in reliability, but there are cases when traditional metal-plastic needs to be introduced into a pipeline with polypropylene. Threading in such situations will not help, so you will have to turn to soldering. However, this connection will also act only as an auxiliary tool.
Installation is carried out using a flange into which the ends of two pipes made of different materials are introduced. Soldering is needed just to prepare the polypropylene pipe for such integration. To do this, with the help of a soldering iron, the end of the plastic pipe is heated, the same fitting is put on it, after which you can proceed to connect to the metal-plastic circuit through the flange.
Soldering Errors
Errors for the most part relate to violations in the soldering technique and the selection of unsuitable materials. A common violation of technology is a deviation from a given position when connecting pipes. Departure from a straight line per millimeter already means that the connection will be of poor quality.
How to solder pipes made of polypropylene so that there is no violation of the position of the workpieces? Manual devices in this sense are the most problematic, since the lightness of the design does not contribute to the protection from vibration of the working equipment. To minimize the risk of deviation will allow additional fixing of the device with the help of heavy devices.
Conclusion
Theoretically, the method of joining plastic pipes by heat is flawless. Its main advantage is that intervention in the structure of the material alone does not lead to a decrease in its operational properties. The resulting seam has a uniform structure and will not be a weak point in the contour. The imperfection of this method rests on the practice of application. Therefore, the question arises as to how to solder polypropylene in order to achieve an optimal result.
The success of an operation, in fact, depends on two factors. Firstly, on the quality of the technical organization of the workflow - on the choice of materials, model of apparatus, consumables, etc. Secondly, on the experience of the operator. The user of the soldering iron must quickly manage the workpieces, observing both the time intervals and the accuracy of the positioning of the pipes.