AWS G1.

10M:2001
An American National Standard

Guide for the

Evaluation of Hot
Gas, Hot Gas
Extrusion, and
Heated Tool Butt
Thermoplastic
Welds
Key Words —Hot gas welding, thermoplastics, AWS G1.10M:2001
heated tool butt welding, joints, An American National Standard
evaluation, testing, hot gas extrusion
Approved by
American National Standards Institute
February 21, 2001

Guide for the Evaluation of

Hot Gas, Hot Gas Extrusion,
and Heated Tool Butt
Thermoplastic Welds

Prepared by
AWS G1 Committee on Joining Plastics and Composites

Under the Direction of

AWS Technical Activities Committee

Approved by
AWS Board of Directors

Abstract
This standard lists and describes defects in hot gas, hot gas extrusion, and heated tool butt welded joints in thermoplastics.
Its intent is to make possible a generally valid evaluation giving consideration to graded quality requirements. This stan-
dard encompasses the classification, requirements, testing, evaluation, and acceptance of the welds. Details in recording
engineering data are described. Tables illustrating cracks, voids, solid inclusions, lack of fusion, defects of shape, and
other defects in thermoplastic welds are included. Defect features with descriptions and illustrations are compiled into
tables to aid in the evaluation of welds.

550 N.W. LeJeune Road, Miami, Florida 33126

 Statement on Use of AWS American National Standards
All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the American
Welding Society are voluntary consensus standards that have been developed in accordance with the rules of the American
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included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry
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International Standard Book Number: 0-87171-615-1
American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126
© 2001 by American Welding Society. All rights reserved
Printed in the United States of America
AWS American National Standards are developed through a consensus standards development process that brings
together volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the process
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Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.
Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in writ-
ing, to the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126
(see Annex C). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may
be rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. These
individuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpre-
tations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.
This standard is subject to revision at any time by the AWS G1 Committee on Joining of Plastics and Composites. It must
be reviewed every five years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations,
additions, or deletions) and any pertinent data that may be of use in improving this standard are required and should be ad-
dressed to AWS Headquarters. Such comments will receive careful consideration by the AWS G1 Committee on Joining
of Plastics and Composites and the author of the comments will be informed of the Committee’s response to the com-
ments. Guests are invited to attend all meetings of the AWS G1 Committee on Joining of Plastics and Composites to ex-
press their comments verbally. Procedures for appeal of an adverse decision concerning all such comments are provided in
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 Personnel
AWS G1 Committee on Joining of Plastics and Composites
J. L. Frantz, Chair Branson Ultrasonics Corp.
W. J. McMaster, Vice Chair Honeywell
J. L. Gayler, Secretary American Welding Society
*A. Benatar The Ohio State University
*F. Dibble Crest Ultrasonics
K. M. Dolan GE Plastics
*D. Grewell Branson Ultrasonics Corp.
*R. A. Grimm Edison Welding Institute
B. E. Gourley Sonics & Materials, Inc.
*F. He Eastman Kodak Co.
*K. A. Holt Dukane Corp.
*S. Hunt Motorola, Inc.
L. T. Hutton ATOFINA Chemicals
V. A. Kagan Honeywell
*W. E. Kenney Consultant
P. R. Krieger Fisher-Price, Inc.
H. L. Mikeworth Dukane Corp.
H. Moore Eastman Kodak Co.
T. O’Toole Dukane Corp.
J. Park Visteon
D. L. Pochardt 3M Co.
*K. Stratman Dukane Corp.
E. S. Stumpek EStumpek & Associates
*A. M. Summo Dukane Corp.
M. W. Wichmann E. I. du Pont de Nemours and Co.

AWS G1A Subcommittee on Hot Gas Welding and Extrusion Welding

L. T. Hutton, Chair ATOFINA Chemicals
G. Hopkins, Vice Chair Plastek Werks, Inc.
J. L. Gayler, Secretary American Welding Society
*M. D. Beamish Baker College of Owosso
A. R. Blazejewski Symalit AG
S. A. Burrows ReynoldsTech Fabricators, Inc.
D. Chandler Engiplast, Inc.
T. S. Dean Pro Poly of America, Inc.
*W. H. Drake, Jr. SW Missouri State University
*R. P. Gaspar BFGoodrich
*J. J. Gates AN-COR Industrial Plastics Inc.
G. Glein CERA Consulting
*R. A. Grimm Edison Welding Institute
*P. Habib CPF Dualam, Inc.
N. Hall E. I. du Pont de Nemours and Co.
D. K. Heffner Electrochemical Engineering and Manufacturing Co.
*Advisor

iii
 AWS G1A Subcommittee on Hot Gas Welding and Extrusion Welding (Continued)
M. G. Jolley KCH Services, Inc.
D. L. Keeler Viatec, Inc.
*W. E. Kenney Consultant
P. R. Khaladkar DuPont Engineering
L. K. Lewis DuPont Teflon® Films
*S. Linnemann RL Industries, Inc.
A. Lopez Dow Chemical
G. W. McCuaig Prolite Plastics Limited
*R. Moubarac CPF Dualam, Inc.
P. Mullen BFGoodrich
*J. E. Niesse Consultant
*J. J. Ploskonka HPG International
C. W. Renner Renner Associates, Inc.
*R. C. Reynard SCP Global Technologies
D. R. Robbins Philip Services Corp.
*A. Savitski Edison Welding Institute
B. L. Smith Met-Pro Corp.—Duall Division
*T. J. Thorpe Boeing
B. G. Waddingham Isothermal Community College
T. R. Way ReynoldsTech Fabricators, Inc.
L. Y. Woo Fabricated Plastics Limited
G. K. Worthington Tri-Mer Corp.
C. E. Zarnitz Atlas Minerals and Chemicals, Inc.
D. Ziegler Wegener NA, Inc.
*Advisor

The subcommittee would like to thank Dr. Detlef Van Hofe of DVS for his contributions to this standard.

iv
 Foreword
(This Foreword is not part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and
Heated Tool Butt Thermoplastic Welds, but is included for information purposes only.)
The purpose of plastics welding inspection is to determine if a plastics weldment meets the acceptance criteria of a
specific code, other standard, or other document. The plastics welding inspector must be thoroughly familiar with plas-
tics welding processes, plastics welding procedures, plastics welder qualifications, materials, the limitation of plastics
weld testing, be able to read drawings, prepare and keep records, prepare and make reports and make responsible judg-
ments. For plastics welding inspectors to be effective, the activities performed should be consistent with the require-
ments, and technical and ethical principles.
The AWS G1 Committee on Joining Plastics and Composites was formed in 1989 by industry and academic experts
interested in providing process information and test standards for rating the weldability of plastic and composite materi-
als. The G1A Subcommittee on Hot Gas Welding and Extrusion Welding was formed in 1993 to create standards for the
qualification of hot gas and heated tool plastic welding personnel. DVS 2202-1, Imperfections in thermoplastic welding
joints; features, descriptions, evaluation, was used extensively in the creation of this standard.
Comments and suggestions for the improvement of this standard are welcome. They should be sent to the Secretary,
AWS G1 Committee on Joining of Plastics and Composites, American Welding Society, 550 N.W. LeJeune Road,
Miami, FL 33126.
Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in
writing, to the Managing Director, Technical Services Division, American Welding Society (see Annex C). A formal
reply will be issued after it has been reviewed by the appropriate personnel following established procedures.

v
 Table of Contents
Page No.
Personnel .................................................................................................................................................................... iii
Foreword.......................................................................................................................................................................v
1. Scope, Purpose, and Range of Application .............................................................................................................1
2. Referenced Documents............................................................................................................................................1
3. Definitions ...............................................................................................................................................................2
4. Evaluation Groups ...................................................................................................................................................2
4.1 Classification ...................................................................................................................................................2
4.2 Criteria for Establishment ...............................................................................................................................2
5. Requirements for Welded Joints ..............................................................................................................................2
5.1 Quality Features for Classification of the Weld (Annexes VII through IX) ...................................................2
6. Details In Engineering Data.....................................................................................................................................2
7. Testing and Evaluation.............................................................................................................................................3
7.1 Evaluation........................................................................................................................................................3
7.2 Reworking Defective Welded Joints ...............................................................................................................3
7.3 Overlapping Defects........................................................................................................................................3
8. Acceptance...............................................................................................................................................................3
Annexes—Mandatory Information
Annex I—Cracks ...........................................................................................................................................................5
Annex II—Voids ............................................................................................................................................................7
Annex III—Solid Inclusions ..........................................................................................................................................9
Annex IV—Lack of Fusion..........................................................................................................................................11
Annex V—Defects of Shape ........................................................................................................................................13
Annex VI—Other Defects............................................................................................................................................15
Annex VII—Description of Evaluation Groups for Hot Gas Fan and Speed Welds ...................................................17
Annex VIII—Description of Evaluation Groups for Hot Gas Extrusion Welds..........................................................21
Annex IX—Description of Evaluation Groups for Heated Tool Butt Welds ...............................................................25
Annexes—Nonmandatory Information
Annex A—Other Documents.......................................................................................................................................29
Annex B—Document Sources .....................................................................................................................................31
Annex C—Guidelines for Preparation of Technical Inquiries for AWS Technical Committees .................................33
AWS List of Documents on Plastics Welding ..............................................................................................................35

vii
 AWS G1.10M:2001

Guide for the Evaluation of Hot Gas, Hot Gas Extrusion,

and Heated Tool Butt Thermoplastic Welds

1. Scope, Purpose, and Range of Abbreviation Material Description

Application PVC-HI High-impact polyvinyl chloride
1.1 These guidelines list and describe defects in welded PVC-U Unplasticized polyvinyl chloride (rigid PVC)
joints in thermoplastic materials. The objective is to PVDF Polyvinylidene fluoride
make possible a generally valid evaluation giving consid- PVDF/HFP Polyvinylidene fluoride/hexafluoropropylene
eration to graded quality requirements.
1.6 The use of these guidelines for welding other thermo-
1.2 By classification into one of the evaluation groups in plastic materials must be agreed upon between the cus-
4.1, specific defects can be excluded or kept within limits tomer and the fabricator.
when welded joints are produced.
1.7 This standard makes use of the International System
1.3 The application of these guidelines and the measures of Units (SI).
through which they can be met may be included in con-
tractual specification or form part of the generally recog- 1.8 Safety. The activities described in this document may
nized specifications. bring the user of this standard in contact with processes
and materials that may be hazardous to the user’s health.
1.4 Welding Processes. Defects produced by the follow-
Safety precautions mandated by OSHA and recommen-
ing welding processes are addressed. This guide applies
dations for material handling in MSDS sheets should be
to the following processes:
observed. The fabricator’s operating manual and safety
Abbreviation Annex instructions should always be carefully studied and com-
Hot gas fan (rod) welding WF VII plied with when operating equipment.
Hot gas speed welding WZ VII
Hot gas extrusion welding WE VIII Note: This standard may involve hazardous materials, op-
Heated tool butt welding HS IX erations, and equipment. This standard does not purport to
address all of the safety problems associated with its use. It
1.5 Materials. These guidelines apply to welded joints is the responsibility of the user to establish appropriate
on components and systems made from the engineering safety and health practices. The user should determine the
thermoplastics listed below: applicability of any regulatory limitations prior to use.
Abbreviation Material Description
ECTFE Ethylene chlorotrifluoroethylene
ETFE Ethylene tetrafluoroethylene 2. Referenced Documents
FEP Fluorinated ethylene-propylene
Reference should be made to the latest edition of the
MFA Perfluoromethylvinylether
following documents:
M PTFE PFA modified PTFE
PE-HD High density polyethylene (rigid PE) ASTM C 904 Standard Terminology Relating to Chemical-
PFA Perfluoroalkoxy Resistant Nonmetallic Materials1
PP-B Polypropylene block copolymer
PP-H Polypropylene homopolymer
PP-R Polypropylene random copolymer 1. ASTM documents are available from the American Society
PTFE Polytetrafluoroethylene for Testing and Materials, 100 Barr Harbor Drive, West Consho-
PVC-C Chlorinated polyvinyl chloride hocken, PA 19428-2959.

1
AWS G1.10M:2001

ASTM D 5162 Test Method B: Standard Practice for The requirements to be established for the welded joints
Discontinuity (Holiday) Testing of Non- on a component should in each case be restricted to those
conductive Protective Coating on Metallic which are necessary and appropriate for the application.
Substrates1
4.2 Criteria for Establishment. In the establishment of
AWS A3.0 Standard Welding Terms and Definitions2 the evaluation groups, the following factors, among others,
should be taken into account:
(1) level and type of stress (for example static, dynamic)
3. Definitions (2) thermoplastic material (for example viscous, brittle)
(3) operating conditions (for example stationary,
The terms used in this specification are defined in mobile, environmental)
ASTM C 904, Terminology Relating to Chemical-Resistant (4) production conditions (for example workshop,
Nonmetallic Materials, and AWS A3.0, Standard Welding construction site)
Terms and Definitions. Exceptions, within the context of (5) potential hazards (for example hazardous gases
this standard, are listed below with their definitions. and/or hazardous fluids)
bead-stop crack. A crack occurring at the restarting of a
weld due to the thermal characteristics of an over-
stressed weld rod. Thermoplastic materials exhibit 5. Requirements for Welded Joints
thermal characteristics that contribute to this condition.
5.1 Quality Features for Classification of the Weld
shrinkage groove. Insufficiency of material on the lat- (Annexes VII through IX). The requirements for classi-
eral edges of the weld due to the high thermal shrink- fying a welded joint within a particular quality grade are
age or expansion characteristics of thermoplastics; established in the evaluation groups.
this resembles an undercut or underfill weld. In the majority of cases, requirements are established
for the joint listing specific features, and describing them
spark testing. An electronic test to locate discontinuities with reference to the internal and external state of the
in a nonconductive material backed by a conductive joint. By using Annexes VII through IX, it is possible to
substrate (Reference ASTM D 5162, Test Method B). specify requirements for the quality of welding. Using
individual features, i.e. through the type and extent of the
void. An unfilled space within a weld. defects, an evaluation of welded joints can then be under-
taken (for example, as part of the acceptance procedure
for the component).
4. Evaluation Groups 5.1.1 Requirements for Characteristics. This covers
4.1 Classification. Specific requirements are established additional data such as:
for the intended service of a component, particularly re- (1) deformation resistance (for example welding factor)
garding the quality of the welded joints. The following (2) ductility (for example bending angle to cracking)
classification is used as a basis, so that the fabricator and (3) resistance to chemical attack (for example resis-
inspector know the extent of the measures required for tance factor)
quality control with regard to welding. 5.1.2 Requirements for Post Weld Treatment. In
Evaluation Group Requirement Level certain cases, it may be necessary to process the weld
joint for the following reasons:
I High requirements for reliability (1) dynamic stress (for example notch-free transitions)
and/or intended service. (2) to smooth weld surfaces (for example lining)
II Medium requirements for reliability (3) to improve flow behavior (for example internal
and/or intended service. beads)
III Low requirements for reliability (4) for technical inspection
and/or intended service. It is advisable to test and/or evaluate the weld both before
and after machining.

2. AWS documents are available from Global Engineering Doc-

uments, An Information Handling Services Group Company, 15 6. Details in Engineering Data
Inverness Way East, Englewood, Colorado 80112-5776. Tele-
phones (800) 854-7179, (303) 397-7956; FAX (303) 397-2740; Requirements for welded joints are to be specified in
Internet: www.global.ihs.com. the contract documentation that is binding for fabrication

2
 AWS G1.10M:2001

(for example, working drawing, welding diagram), with imperfections in weld joints, and should be used in the
reference to this standard. evaluation and documentation process. The test reports
As a rule it is sufficient to identify a weld in accor- should be used to determine points where the results do
dance with the following example: not correspond with the requirements. Should the com-
ponent, or individual welded joints, not correspond to the
WZ-VV-II
evaluation group specified (4.1), then it or they must be
where reworked.
WZ = abbreviation for the welding process 7.2 Reworking Defective Welded Joints. When allowed
V = welding symbol and measurements under the contract and insofar as the inspector considers
II = evaluation group code it possible, defective welded joints may be reworked.
The purpose of reworking operations is to obtain the
Should all the welded joints on a component come welded joint quality established by the requirements. If
under the same evaluation group, then it can be entered necessary, the results should be determined by additional
in a space provided for this purpose on the drawing. testing.
Example: All welded joints as per evaluation group II
(see 4.1). 7.3 Overlapping Defects. Should two or more types of
Additional requirements for specification of the char- defect arise simultaneously on welded joints, the cumu-
acteristics of welded joints and for machining are also to lative effect of the individual defects may result in more
be noted in the engineering data. than the sum. Tests should then be carried out to ascer-
tain whether the welded joint still meets the requirements
established or whether restrictions have to be imposed as
7. Testing and Evaluation regards safety and quality standards because of the accu-
mulation of defects. In certain circumstances, the compo-
Visual inspection, measurements and, where neces- nent or its welded joints should be re-classified into
sary, suitable non-destructive or destructive testing pro- another evaluation group.
cedures are to be used to verify that the requirements for
the individual welding groups have been met. Testing
may be carried out on the welded joints of the compo-
nent. Specific characteristics can also be verified on test 8. Acceptance
pieces that are fabricated under comparable conditions.
Insofar as tests on the welded component confirm that
The nature and extent of the tests, together with their
it meets the requirements established in the technical
timing, are to be agreed upon between the customer and
documentation, the welded component shall be consid-
the fabricator. The test results are to be documented.
ered as being accepted and documented. Should the re-
7.1 Evaluation. The test results form the basis for the quirements not be met, and should reworking not be
classification of welded joints into one of the three evalu- possible, then the fabricator and the end user should
ation groups by welding process, in accordance with An- reach an agreement on the disposition of the welded
nexes VII through IX. Annexes I through VI define component.

3
 AWS G1.10M:2001

Annex I
Cracks
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

No. Designation Notes Illustrations

100 Crack Break in continuity which may occur during cooling

or through the action of stress, in the solid state

1001 Microcrack Crack having microscopic dimensions

101 Longitudinal Crack whose main direction is close to that of the

crack axis of the weld. It can be situated:
1011 • in the weld
1012 • in the fusion zone (weld junction)
1013 • in the heat-affected zone
1014 • in the base material

102 Transverse Crack whose direction is more or less perpendicular

crack to the axis of the weld. It can be situated:
1021 • in the weld
1022 • in the heat-affected zone
1023 • in the base material

103 Radiating Group of cracks issuing from a single point and

crack situated:
1031 • in the weld
1032 • in the heat-affected zone
1033 • in the base material

104 Bead-stop Crack occurring at the bead-stop, and which may be:
crack
1041 • parallel
1042 • perpendicular
1043 • radiating

(Continued)

5
AWS G1.10M:2001

Annex I—Cracks (Continued)

No. Designation Notes Illustrations

105 Group of Set of grouped cracks of any orientation, which may

disconnected be situated:
cracks
1051 • in the weld
1052 • in the heat-affected zone
1053 • in the base material

106 Branching Set of interconnected cracks in the form of branching

crack and distinguishable from the network of disconnected
cracks (105) and from radiating cracks (103). They
may be situated:
1061 • in the weld
1062 • in the heat-affected zone
1063 • in the base material

6
 AWS G1.10M:2001

Annex II
Voids
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

No. Designation Notes Illustrations

201 Gas void Void formed by gas(es)

2011 Spheroidal gas More or less spherical gas void

pore

2012 Uniformly Spheroidal gas voids regularly distributed in the

distributed weld. To be distinguished from linear voids
voids (2014).

2013 Localized Group of gas voids

(clustered)
voids

2014 Linear voids Gas voids distributed along a line parallel to the
axis of the weld

2015 Elongated Large non-spheroidal gas void whose main

void dimension is parallel to the axis of the weld
generally situated close to the root

2016 Wormhole Gas void in the form of a worm gallery in the weld,
resulting from the advance of the gases. Sometimes
in herringbone pattern. Some wormholes can open
out onto the surface.

(Continued)

7
AWS G1.10M:2001

Annex II—Voids (Continued)

No. Designation Notes Illustrations

2017 Surface pore Small gas void opening out on the surface

202 Shrinkage Void due to shrinkage of weld during solidification

void

2024 Bead-stop or Void (or depression) at pass-end not eliminated

void before or during the execution of the following pass

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 AWS G1.10M:2001

Annex III
Solid Inclusions
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

No. Designation Notes Illustrations

300 Solid inclusion Foreign solid body trapped in the weld

303 Oxides Oxides or burns trapped in the weld

inclusion

304 Sundry Particle of foreign body trapped in the weld

inclusion

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 AWS G1.10M:2001

Annex IV
Lack of Fusion
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

No. Designation Notes Illustrations

401 Lack of fusion Lack of fusion between deposited and base material
(incomplete or between two adjacent layers of deposited
fusion) material. One must distinguish between:
4011 • the lack of lateral fusion
4012 • the lack of fusion between weld passes
4013 • the lack of fusion at the root of the weld

402 Lack of Partial absence of fusion of the edges to be welded,

interior fusion allowing an unfused area to remain between these
or incomplete edges
penetration

11
 AWS G1.10M:2001

Annex V
Defects of Shape
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

No. Designation Notes Illustrations

500 Imperfect External surface displays lack of geometric
shape conformity relative to correct profile
5011 Continuous Lack of material in form of a groove extending
undercut along a certain length of the edges of the weld,
between beads or between flash
5012 Undercut Local lack of material situated on the edges of the
weld

5013 Shrinkage Insufficiency of material on the lateral edges of the

groove root

502 Excessive Excess of deposited material or excessive flash

reinforcement

503 Excessive Fault in an angle weld characterized by an

convexity exaggerated convex profile

(Continued)

13
AWS G1.10M:2001

Annex V—Defects of Shape (Continued)

No. Designation Notes Illustrations

504 Excessive melt Excess of material at the root for a weld executed
through from a single face

505 Bad Dihedral angle (α) formed by the plane tangent to

reinforcement the base and passing through the connection line is
angle too great

506 Overlap Excess of weld which spreads over the surface of

the base material, without fusion with same

507 Linear Non-observance of proposed level between two

misalignment welded pieces. This defect is generally expressed
by measurement of a level difference

508 Angular Non-observance of proposed angle between two

misalignment welded pieces

511 Underfill Local or continuous insufficiency of weld leading

to a bead profile which has shrunk relative to the
correct profile

512 Symmetry • Non-symmetrical flash

defect • Non-symmetrical angle weld

513 Irregular width Excessive variation in weld width

514 Irregular Excessive irregularity in surface of weld
surface (roughness, corrugation)
517 Poor restart Local irregularity in surface at location of a restart:
5171 • in the terminal pass
5172 • in the bottom pass

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 AWS G1.10M:2001

Annex VI
Other Defects
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

No. Designation Notes Illustrations

600 Other defects Defects not included in Annexes I, II, III, IV, and V

601 Thermal heat Superficial alteration resulting from the accidental

damage action of a source of heat. It may affect:
6011 • the weld
6012 • the heat-affected zone
6013 • the base material

603 Mechanical Local damage to the base material

damage
6031 Local damage due to an incorrect grinding or
milling
6032 Local damage due to an incorrect scraping

604 Leg length Dimensional deviation of the specified leg lengths

defect of the weld

15
 AWS G1.10M:2001

Annex VII
Description of Evaluation Groups
for Hot Gas Fan and Speed Welds
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

Evaluation Groups

No. Feature Description I II III

External state of surface of V-welds and double V-welds

1 Crack Isolated cracks or groups of Not permissible Not permissible Not permissible
cracks with and without
branching, running
lengthwise or crosswise to
weld. They can lie:
• in the weld
• in the base material
• in the heat-affected zone

2 Welding overlap Marked deepening, which can Not permissible Locally Locally
be seen and felt, along or permissible if permissible if
between individual welding k>0 k>0
rods, caused by, for example:
• faults on die
• poor welding rod guidance

3 Undercuts Notches in base material Not permissible Locally Locally

along weld caused by, for permissible if permissible if
example: ending flat ending flat
• penetration of die edge ∆s < 0.1s, but ∆s < 0.1s, but
• machining of weld max = 1 mm max = 1 mm
• unsatisfactory edge zone
welding

4 Incomplete joint penetration Notches caused by Not permissible Not permissible Locally
incomplete weld filling at permissible in
root, due to, for example: limited numbers
• generating angle too small if ∆s < 0.1s
during edge preparation
• root gap too small
• root rod too thick
• welding force too small

(Continued)

17
AWS G1.10M:2001

Annex VII—Description of Evaluation Groups

for Hot Gas Fan and Speed Welds (Continued)

Evaluation Groups

No. Feature Description I II III

5 Incomplete joint penetration Caused by, for example: Not permissible Not permissible Locally
• inadequate edge prepara- permissible in
tion limited num-
bers if
∆s < 0.1s, but
max = 1 mm

6 Excessive melt through Caused by, for example: Locally permis- Permissible if Permissible if
• root gap too big sible in limited ∆s < 0.2s, but ∆s < 0.25s, but
• compressed stringer bead numbers if max = 3 mm max = 4 mm
∆s < 0.15s, but
max = 2 mm

7 Excessive face reinforcement Caused by, for example: Continuously Continuously Continuously
too many individual rods or permissible if permissible if permissible if
passes 0.1s < ∆s < 0.4s 0.05s < ∆s < 0 < ∆s < 0.6s
• wrong edge preparation 0.5s

8 Underfill Inadequate weld filling Not permissible Not permissible Not permissible

9 Linear misalignment For example: Permissible if Permissible if Permissible if

• different wall thicknesses e1 < 0.1s, e1 < 0.15s, e1 < 0.2s,
are not compensated e2 < 0.15s, but e2 < 0.2s, but e2 < 0.25s, but
• equal wall thicknesses are max = 2 mm max = 4 mm max = 5 mm
misaligned

10 Angular misalignment Permissible if Permissible if Permissible if

(errors of form) (Diagram) e < ± 1 mm e < ± 2 mm e < ± 4 mm

11 Weld intersections (Diagram) For example: Not permissible Not permissible Not permissible
• four-way intersection

(Continued)

18
 AWS G1.10M:2001

Annex VII—Description of Evaluation Groups

for Hot Gas Fan and Speed Welds (Continued)

Evaluation Groups

No. Feature Description I II III

12 Wavy weld surface Waviness running vertical to Locally Continuously Continuously

weld in finishing pass, caused permissible permissible permissible
by, for example:
• welding force and speed
non-uniformly distributed
13 Rough weld surface Fine open bubbles, streaks, or Isolated cases Limited areas Permissible
nodules and the like, caused permissible permissible
by, for example:
• dirty welding shoe
• hot gas temperature too
high

14 Start fault Incomplete welded cross Not permissible Small reduction Permissible
section at start or end of weld in cross section
permissible
without abrupt
transition

15 Heat damage Discoloration, nodule Not permissible Isolated cases Limited areas
formation, high-gloss weld permissible permissible
faces and similar defects

External state of weld surface of fillet welds

16 Oversized weld (Diagram) Exceeds standard fillet weld Permissible if Permissible if Permissible if
thickness of a = 0.7s b < 0.4a, but b < 0.5a, but b < 0.6a, but
(s = thickness of thinner max = 6 mm max = 9 mm max = 12 mm
member)

17 Undersized weld (Diagram) Undershoots standard fillet Not permissible Permissible if Permissible if
weld thickness of a = 0.7s nominal dimen- nominal dimen-
(s = thickness of thinner sion is a slightly sion a is under-
member) undershot shot locally
locally b < 0.3a
b < 0.15a

(Continued)

19
AWS G1.10M:2001

Annex VII—Description of Evaluation Groups

for Hot Gas Fan and Speed Welds (Continued)

Evaluation Groups

No. Feature Description I II III

18 Incompletely welded cross Weld geometry not to Not permissible Permissible if Permissible if
section standard z < 0.15a z < 0.3a

Internal state of V-welds and fillet welds

19 Pores and foreign material Numerous, dispersed, isolated Small isolated Pores and pore Pores and pore
inclusions or locally concentrated pores pores rows rows
or inclusions, e.g., due to: permissible if permissible if permissible if
• vaporization during ∆s < 0.05s ∆s < 0.1s ∆s < 0.15s
welding (water, solvent)
• dirty heated tool

20 Lack of fusion Lack of fusion running Not permissible Not permissible Not permissible
horizontally or vertically in
the weld or on the weld
edges, caused by, for
example:
• welding temperature too
low
• dirty joint faces

(Continued)

20
 AWS G1.10M:2001

Annex VIII
Description of Evaluation Groups
for Hot Gas Extrusion Welds
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

Evaluation groups

No. Feature Description I II III

External state of surface of V-welds or double V-welds

1 Crack Isolated cracks or groups of Not permissible Not permissible Not permissible
cracks with and without
branching, running
lengthwise or crosswise to
weld. They can lie:
• in the weld
• in the base material
• in the heat-affected zone

2 Undercut Continuous or local flat Not permissible Locally Locally

deformations lengthwise to permissible if permissible if
weld, caused by, for example: k>0 k>0
• fault in welding shoe
• fault in welding unit
guidance

3 Undercuts Notches in base material Locally Continuously Continuously

along weld, caused by, for permissible if permissible if permissible if
example: ending flat and ending flat and ending flat and
• penetration of weld shoe ∆s < 0.1s, but ∆s < 0.1s, but ∆s < 0.2s, but
edges max = 1 mm max = 2 mm max = 3 mm
• processing of edge zone

4 Inadequate edge zone welding Inadequate covering of Not permissible Locally permis- Continuously
welding groove edge on one sible with notch- permissible with
or both sides free transition notch-free
Nominal dimension: and ∆ > 2 mm transition and
∆b > 3 mm ∆b > 1 mm

(Continued)

21
AWS G1.10M:2001

Annex VIII—Description of Evaluation Groups

for Hot Gas Extrusion Welds (Continued)

Evaluation groups

No. Feature Description I II III

5 Incomplete joint penetration Notches caused by inadequate Not permissible Locally Permissible if
weld filling on root, caused permissible in ∆s < 0.1s, but
by, for example: limited num- max = 1 mm
• bend up and unwelded joint bers if
faces ∆s < 0.1s, but
• root opening too small max = 1 mm
• welding force too small
• root falling back due to
shrinkage
6 Incomplete joint penetration Caused by, for example: Not permissible Not permissible Locally
• inadequate edge permissible in
preparation limited numbers
if ∆s <0.1s, but
max = 1 mm

7 Excessive melt through Caused by, for example: Permissible if Permissible if Permissible if
• root opening too big ∆s < 0.15s, but ∆s < 0.2s, but ∆s < 0.25s, but
• welding force too great max = 2 mm max = 3 mm max = 4 mm

8 Excessive face reinforcement Finish pass too high, caused Continuously Continuously Continuously
by, for example: permissible permissible permissible if
• inadequately formed 0.1s < ∆s < 0.4s, 0.05s < ∆s < 0.5 0 < ∆s < 0.6s,
welding shoe but max = 6 mm s, but max = but max = 12
• welding force too small 9mm mm

9 Overlap Welding material overflow on Not permissible Locally permis- Continuously

one or both sides, usually sible in small permissible if
without sufficient fusion to numbers if ∆b < 5 mm
base material ∆b < 5 mm

10 Underfill Weld cross section is not Not permissible Not permissible Locally
obtained, caused by, for conditionally
example: permissible if
• shrinkage of welding filler ∆s < 0.1s, but
• inadequately formed weld- max = 1 mm
ing shoe
• welding speed too high

(Continued)

22
 AWS G1.10M:2001

Annex VIII—Description of Evaluation Groups

for Hot Gas Extrusion Welds (Continued)

Evaluation groups

No. Feature Description I II III

11 Linear misalignment (Diagram) For example: Permissible if Permissible if Permissible if

• different wall thicknesses e1 > 0.1s, e1 > 0.15s, e1 > 0.2s,
are not compensated e2 > 0.15s, but e2 > 0.2s, but e2 > 0.25s, but
max = 2 mm max = 4 mm max = 5 mm

12 Angular misalignment Length, L, of shorter side is Permissible up Permissible up Permissible up

(defects of form) (Diagram) decisive for permissible to e < ±1 mm to e < ±2 mm to e < ±4 mm
deflection

13 Weld intersections For example: Not permissible Not permissible Not permissible
• four-way intersection

14 Asymmetrical weld cover Welding shoe has been Not permissible Permissible if Locally
guided outside weld center the required conditionally
weld cross permissible if
section is not ∆s < 0.1s, but
undershot max = 1 mm

15 Wavy weld surface Caused by, for example: Locally Continuously Continuously
• welding force non- permissible permissible permissible
uniformly applied
16 Rough weld surface Fine open bubbles, streaks, or Isolated spots Limited areas Permissible
nodules and similar defects, permissible permissible
for example:
• moisture in form mass
• form mass temperature too
low

17 Start fault Incompletely welded cross Not permissible Not permissible Low reduction
section at start or end of weld in cross section
without sharp
transitions
permissible

18 Heat damage Discoloration, formation of Not permissible Isolated spots Limited areas
nodules, high-gloss weld permissible permissible
surfaces and similar defects

(Continued)

23
AWS G1.10M:2001

Annex VIII—Description of Evaluation Groups

for Hot Gas Extrusion Welds (Continued)

Evaluation groups

No. Feature Description I II III

External state of weld surfaces of fillet welds

19 Oversized weld (Diagram) Exceeding of standard fillet Permissible if Permissible if Permissible if

weld thickness of a = 0.7s b < 0.4a, but b < 0.5a, but b < 0.6a, but
(s = thickness of thinner max = 6 mm max = 9 mm max = 12 mm
member)

20 Undersized weld (Diagram) Required weld cross section Not permissible Permissible if Permissible if
is not obtained, caused by, for nominal nominal
example: dimension and dimension and
• shrinkage of welding filler slightly undershot
• inadequately formed undershot locally b < 0.3a
welding shoe locally
b < 0.15a

21 Incompletely welded weld cross Weld geometry not to Not permissible Permissible if Permissible if
section (Diagram) standard z < 0.15a z < 0.3a

22 Pores due to foreign material Numerous, dispersed, Small isolated Pores and pore Pores and pore
inclusions isolated, or locally pores rows permitted rows permitted
concentrated pores or permissible if if ∆s < 0.1s if ∆s < 0.15s
inclusions, e.g., due to: ∆s < 0.05s
• vaporization during
welding (water, solvent)
• dirty heated tool

23 Lack of fusion No fusion, or incomplete Not permissible Not permissible Locally

fusion on opposite position, conditionally
fastening points and weld permissible
sides, caused by, for example:
• dirty joint
• welding force too small
• inadequate heating

(Continued)

24
 AWS G1.10M:2001

Annex IX
Description of Evaluation Groups
for Heated Tool Butt Welds
(This Annex is a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and Heated
Tool Butt Thermoplastic Welds, and includes mandatory requirements for use with this standard.)

Evaluation Groups

No. Feature Description I II III

External State of Joint

1 Cracks Cracks running lengthwise or Not permissible Not permissible Not permissible
crosswise to weld. They may
be located:
• in weld
• in base material
• in heat-affected zone

2 Weld undercut Continuous or local notches Not permissible Not permissible Not permissible
length-wise to weld with root
of the notch below the surface
of the base material. Caused
by, for example:
• insufficient joint pressure
• warming-up time too short
• cooling time too short

3 Notches and flutes Notches in edge of base Locally Locally Locally

material, lengthwise or cross- permissible if permissible if permissible if
wise to weld. Caused by, for ending flat and ending flat and ending flat and
example: ∆s < 0.1s, but ∆s < 0.1s, but ∆s < 0.15s, but
• clamping tools max = 0.5 mm max = 1 mm max 2 = mm
• incorrect transport
• fault in edge preparation
4 Linear misalignment Joint faces are misaligned Permissible if Permissible if Permissible if
relative to one another or e < 0.1s, but e < 0.15s, but e < 0.2s, but
thickness variations are not max = 2 mm max = 4 mm max = 5 mm
corrected

(Continued)

25
AWS G1.10M:2001

Annex IX—Description of Evaluation Groups

for Heated Tool Butt Welds (Continued)

Evaluation Groups

No. Feature Description I II III

5 Angular misalignment For example: Permissible if Permissible if Permissible if

• machine fault e < 3 mm e < 5 mm e < 7 mm
• layout fault

6 Narrow, excessive welding flash* Excessive and sharp-edged Not permissible Not permissible Not permissible
welding flash over part or all
of weld length due to wrong
welding parameters,
especially caused by:
• excessive joint pressure
with polyolefins only

7 Non-uniform welding flash Non-angular joint planes, Permissible if Permissible if Permissible if

leading to variations in form b1 > 0.7b2 b1 > 0.6 b2 b1 > 0.5b2
of welding flash over part or
all of weld length. Caused by,
for example:
• edge preparation fault
• incorrect welding unit

8 Thermal damage High-gloss welding flash face Not permissible Not permissible Not permissible
with voids or nodules, usually
associated with faulty
welding flash formation and
marked bead notches

9 Lack of fusion No fusion or incomplete Not permissible Not permissible Not permissible
fusion on joint faces, over
part or whole of weld cross
section. Caused by, for
example:
• contaminated joint faces
• oxidized joint faces
• excessive reversal time
• heated tool temperature too
low

10 Blowhole Hollow space in joint planes. Not permissible Not permissible Not permissible
Caused by, for example:
• insufficient joint pressure
• insufficient cooling time

(Continued)

26
 AWS G1.10M:2001

Annex IX—Description of Evaluation Groups

for Heated Tool Butt Welds (Continued)

Evaluation Groups

No. Feature Description I II III

11 Pores caused by inclusions of Numerous, dispersed, isolated Small isolated Pores and rows Pores and rows
foreign matter or locally concentrated pores pores of pores of pores
or inclusions. Caused by, for permissible if permissible if permissible if
example: ∆s < 0.05s ∆s < 0.10s ∆s < 0.15s
• vaporization during
welding (water, solvent)
• contaminated heated tool
face

*Classification criteria under scrutiny by DVS.

(Continued)

27
 AWS G1.10M:2001

Annex A
Other Documents
(This Annex is not a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and
Heated Tool Butt Thermoplastic Welds, but is included for information purposes only.)

A1. DVS (German Welding Society) Designation Title

Recommendations DVS 2205-3 Calculations of containers and apparatus
Supplement 3 of thermoplastics, welded joints
Designation Title
DVS 2205-4 Calculation of thermoplastic tanks and
DVS 2201-2 Testing of semi-finished products of Supplement 4 apparatuses—Welded flanges, welded
thermoplastics: Weldability—Test meth- collars—Constructive details
ods—Requirements
DVS 2205-5 Calculation of thermoplastic tanks and
DVS 2202-1 Imperfections in thermoplastic welded apparatuses; Rectangular tanks
joints—Features, description, evaluation
DVS 2207-1 Welding of thermoplastics—Heated
DVS 2203-1 Testing of Welded Joints of Thermo- tool welding of pipes, pipeline, com-
plastics semi-finished products—Test ponents and sheets made form PE-HD
Methods—Requirements
DVS 2207-3 Hot gas welding of thermoplastic poly-
DVS 2203-2 Testing of Welded Joints of Thermo- mers; panels and pipes
plastics materials: Tensile test DVS 2207-3 Hot gas welding of thermoplastic poly-
DVS 2203-3 Testing of Welded Joints of Thermo- Supplement mers; panels and pipes; welding param-
plastics; tensile impact test eters for HDPE and PP
DVS 2207-11 Welding of thermoplastics—Heated
DVS 2203-4 Testing of Welded Joints of Thermo-
tool welding of pipes, pipeline, com-
plastics plates and tubes—Tensile
ponents and sheets out of PP
creep test
DVS 2207-15 Welding of thermoplastics—Heated
DVS 2203-5 Testing of Welded Joints of Thermo- tool welding of pipes, pipeline, com-
plastics plates and tubes—Technologi- ponents and sheets out of PVDF
cal bend test
DVS 2208-1 Welding of thermoplastics—Machines
DVS 2205-2 Calculations of thermoplastic tanks and devices for the heated tool welding
and apparatus—Vertical cylindrical of pipes, pipeline components and
non-pressurized tanks sheets
DVS 2205-2 Welded static thermoplastic tanks— DVS 2209-1 Welding of thermoplastics; extrusion
Supplement 1 Installation inside of buildings welding; procedures, characteristics
DVS 2205-2 Calculation of thermoplastic tanks and DVS 2209-2 Welding of thermoplastics—Hot gas
Supplement 2 apparatus—Vertical cylindrical non- extrusion welding—Requirements for
pressurized tanks—Collecting devices welding machines and tools

29
AWS G1.10M:2001

Designation Title Designation Title

DVS 2211 Filler materials of thermoplastics— DVS 2214 Regulations for the examination of the
Scope, designation, requirements, tests specialist for plastics welding

DVS 2212-1 Examination of plastic welders exami-

nation—Group I—Hot Gas welding A2. DIN (German) Standards33
with torch separate from filler rod
Designation Title
(WF), hot gas string-bead welding
(WZ), heated tool butt welding (HS) DIN 1910 Welding—Welding of Plastics; Processes
DVS 2212-2 Examination of plastic welders— DIN 32 502 Imperfections in plastic welded joints;
Examination group II—Hot gas extru- Classification, terminology
sion welding

DVS 2213 Specialist for plastics welding— 3. DIN is the national standards institution for Germany. DIN is
Examination the German equivalent of ANSI.

30
 AWS G1.10M:2001

Annex B
Document Sources
(This Annex is not a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and
Heated Tool Butt Thermoplastic Welds, but is included for information purposes only.)

American Society for Testing and Materials (ASTM) DIN

100 Barr Harbor Drive DVS-Verlag GmbH
West Conshohocken, PA 19428-2959 (German Welding Society)
Telephone: 610-832-9585 Aachener Strasse 172
D-40223 Düsseldorf
American Welding Society (AWS) Germany
550 N.W. LeJeune Road Telephone: +49/211/15 91-0
Miami, FL 33126
Telephone: 800-443-9353

31
 AWS G1.10M:2001

Annex C
Guidelines for Preparation of Technical Inquiries for
AWS Technical Committees
(This Annex is not a part of AWS G1.10M:2001, Guide for the Evaluation of Hot Gas, Hot Gas Extrusion, and
Heated Tool Butt Thermoplastic Welds, but is included for information purposes only.)

C1. Introduction provision must be identified in the scope of the inquiry,

along with the edition of the standard that contains the
The AWS Board of Directors has adopted a policy provisions or that the Inquirer is addressing.
whereby all official interpretations of AWS standards
will be handled in a formal manner. Under that policy, all C2.2 Purpose of the Inquiry. The purpose of the inquiry
interpretations are made by the committee that is respon- must be stated in this portion of the inquiry. The purpose
sible for the standard. Official communication concern- can be either to obtain an interpretation of a standard re-
ing an interpretation is through the AWS staff member quirement, or to request the revision of a particular provi-
who works with that committee. The policy requires that sion in the standard.
all requests for an interpretation be submitted in writing. C2.3 Content of the Inquiry. The inquiry should be
Such requests will be handled as expeditiously as possi- concise, yet complete, to enable the committee to quickly
ble but due to the complexity of the work and the proce- and fully understand the point of the inquiry. Sketches
dures that must be followed, some interpretations may should be used when appropriate and all paragraphs, fig-
require considerable time. ures, and tables (or the Annex), which bear on the in-
quiry must be cited. If the point of the inquiry is to obtain
a revision of the standard, the inquiry must provide tech-
nical justification for that revision.
C2. Procedure
C2.4 Proposed Reply. The inquirer should, as a pro-
All inquiries must be directed to: posed reply, state an interpretation of the provision that is
Managing Director, Technical Services the point of the inquiry, or the wording for a proposed re-
American Welding Society vision, if that is what inquirer seeks.
550 N.W. LeJeune Road
Miami, FL 33126
C3. Interpretation of Provisions of
All inquiries must contain the name, address, and af- the Standard
filiation of the inquirer, and they must provide enough in-
formation for the committee to fully understand the point Interpretations of provisions of the standard are made
of concern in the inquiry. Where that point is not clearly by the relevant AWS Technical Committee. The secre-
defined, the inquiry will be returned for clarification. For tary of the committee refers all inquiries to the chairman
efficient handling, all inquiries should be typewritten and of the particular subcommittee that has jurisdiction over
should also be in the format used here. the portion of the standard addressed by the inquiry. The
subcommittee reviews the inquiry and the proposed reply
C2.1 Scope. Each inquiry must address one single provi- to determine what the response to the inquiry should be.
sion of the standard, unless the point of the inquiry in- Following the subcommittee’s development of the re-
volves two or more interrelated provisions. That sponse, the inquiry and the response are presented to the

33
AWS G1.10M:2001

entire committee for review and approval. Upon approval information that such an interpretation can be obtained
by the committee, the interpretation will be an official in- only through a written request. The Headquarters staff
terpretation of the Society, and the secretary will transmit cannot provide consulting services. The staff can, how-
the response to the inquirer and to the Welding Journal ever, refer a caller to any of those consultants whose
for publication. names are on file at AWS Headquarters.

C4. Publication of Interpretations C6. The AWS Technical Committee

All official interpretations will appear in the Welding The activities of AWS Technical Committees in regard
Journal. to interpretations, are limited strictly to the interpretation
of provisions of standards prepared by the committee or
to consideration of revisions to existing provisions on the
C5. Telephone Inquiries basis of new data or technology. Neither the committee
nor the staff is in a position to offer interpretive or con-
Telephone inquiries to AWS Headquarters concerning sulting services on: (1) specific engineering problems, or
AWS standards should be limited to questions of a gen- (2) requirements of standards applied to fabrications out-
eral nature or to matters directly related to the use of the side the scope of the document or points not specifically
Standard. The Board of Directors’ policy requires that all covered by the standard. In such cases, the inquirer
AWS staff members respond to a telephone request for should seek assistance from a competent engineer experi-
an official interpretation of any AWS standard with the enced in the particular field of interest.

34
 AWS G1.10M:2001

AWS List of Documents on Plastics Welding

AWS Designation Title

G1.2M/G1.2 Specification for Standardized Ultrasonic Welding Test Specimen for Thermoplastics
For ordering information, contact Global Engineering Documents, An Information Handling Services Group Company, 15
Inverness Way East, Englewood, Colorado 80112-5776. Telephones: (800) 854-7179, (303) 397-7956; FAX (303) 397-2740;
Internet: www.global.ihs.com.

35