Page 4 to DVS 2207-11

5 Sleeve welding with an incorporated electric heating The out-of-roundness of the pipe must not exceed 1.5% of the
element outside diameter, max. 3 mm, in the welding area.
Corresponding round pressing clamps must be used if
5.1 Process description necessary.

R&D INTAKE MANIFOLDS

The joining faces (i.e. the surface of the pipe and the inside of the
fitting) overlap, are heated up to the welding temperature by
electrical energy with the aid of resistance wires positioned in the
fitting (heater spiral) and are welded in this way (see Figure 4).
machined
joining faces
In the area of the welding zone, the complete surface of the pipe
or of the pipe spigot on the fitting must be subjected to chip-
producing machining. A rotating peeling device with constant wall
thickness removal of approx. 0.2 mm should be used. Attention
must be paid to the formation of a small annular gap!
The pipe end must be deburred on the inside and outside. Chips
must be removed without touching the joining face.

The fitting may only be removed from the protective packaging

immediately before the assembly.

insert If the machined pipe surface is contaminated after the chip-

fitting depth pipe producing machining, this must be cleaned according to Section
3.2.3. In this respect, it must be ensured that no contamination is
rubbed into the welding zone. The joining face of the fitting must
be cleaned according to Section 3.2.3.

It must be possible to check the insert depth of the pipe either

joining plane
Figure 4. Sleeve welding with an incorporated electric heating element
(principle).
5.2 Welding device
It is only allowed to use welding devices which are adapted to the
parts to be welded. Preference should be given to automatic
welding devices – if at all possible, with recording. The welding
device must supply the welding parameters required for the fitting
to be welded in each case, e. g. welding time, amperage and
voltage. The device must be switched off automatically as soon
as the necessary heat quantity has been supplied to the welding
zone.
5.3 Preparation for the welding
For the manufacture of flawless welded joints, decisive
significance is attached to clean surfaces and to stress-free
installation. The assembly of fittings is facilitated by the selection
of pipes with restricted diameter tolerances according to
DIN 8077.
For axial pipe joints, the pipes must, if necessary, be cut off at a
right angle with a suitable tool. In the case of conical collapsing of
the cut edge of the pipe, the unmachined pipe must exhibit the nom-
inal diameter d at the planned insert depth, at least in the region of
the heater spiral (Figure 5). If necessary, the pipe end must be
shortened correspondingly immediately before the welding.
with a mark to be applied or using a suitable jig. The fitting must
not be tilted or pushed on to the pipe end with force (low-stress
assembly). The saddle piece must be tightly clamped on the pipe
with the aid of a suitable jig according to the information from the
manufacturer.
The contact bushes for the connection of the welding cable must
be easily accessible.
The fitting and the pipe must be at the same temperature level
before the welding. In the case of welding devices with automatic
temperature compensation, it must be ensured that the recorded
ambient temperature corresponds to the conditions at the
location of the welding. If necessary, the welding device as well
as the pipe and the fitting must be protected from (for example)
direct solar radiation.
5.4 Execution of the welding
The correct insert depth must be checked on the basis of the
mark. If necessary, suitable measures or jigs must be used in
order to prevent any changes in the positions of the components
to be welded.
Cables serve to connect the welding device with the fitting to be
welded. The welding cables must be attached in a weight-
relieved form. The contact faces must be clean. As a rule, the
welding device acquires the fitting data required for the welding
by reading in a component-specific bar code. The displayed data
(e. g. dimensions) must coincide with the component data. After
the welding operation has started, this proceeds automatically.
The welding duration is usually displayed by the welding device.
Just like the other data displayed by the device, it must also be
indicated on the welding record sheet unless the data is stored.

Pay attention to error messages! For example if the power supply

is interrupted, a prematurely terminated welding operation can be
repeated on one occasion in so far as there are no defects on the
fitting or on the welding device (error message) and the fitting
still allowed wrong manufacturer permits this. It is necessary to wait for the entire
cooling time before carrying out the welding once again.

The cables can be removed when the device has been switched
off. If there are any welding indicators on the fitting, these must
be checked. The joint may only be moved after the cooling.
Information about this is provided by the fitting manufacturer.
heater heater If the manufacturer provides any information about additional
spiral spiral cooling times (e. g. until the pressure test), attention must be paid
zone zone to this.

For a short version of the processing instructions, see the

Figure 5. Conical collapsing of the pipe end. appendix.

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