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Advances in Electrofusion Welding Technology for Polymeric Pipelines: From Process Optimization to Mechanism-Driven

Bingyuan Hong1, Zhongjian Sun1, Zenan Wu2

  • 1National & Local Joint Engineering Research Center of Harbor Oil & Gas Storage and Transportation Technology, Zhejiang Key Laboratory of Petrochemical Environmental Pollution Control, Zhejiang Key Laboratory of Pollution Control for Port-Petrochemical Industry, School of Petrochemical Engineering & Environment, Zhejiang Ocean University, Zhoushan 316022, China.

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PubMed
Summary

Electrofusion welding of non-metallic pipelines is shifting from empirical methods to a mechanism-based approach. This review highlights key research on temperature fields, fusion zones, and thermo-mechanical behavior for safer energy systems.

Keywords:
electrofusion weldingpolymeric pipelinesresidual stresstemperature fieldwelding defects

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Area of Science:

  • Materials Science and Engineering
  • Mechanical Engineering
  • Energy Systems Engineering

Background:

  • Non-metallic pipelines are crucial for clean energy systems (gas, water, hydrogen).
  • Electrofusion welding is a critical joining technology for pipeline integrity and safety.
  • Current understanding often relies on empirical process control, lacking mechanistic depth.

Purpose of the Study:

  • To review research on electrofusion welding of non-metallic pipelines over the last decade.
  • To analyze fundamental technical issues: temperature fields, fusion zone, defects, and thermo-mechanical coupling.
  • To clarify the research landscape, identify knowledge gaps, and suggest future directions.

Main Methods:

  • Systematic literature review of electrofusion welding research (past 10 years).
  • Synthesis of findings on temperature evolution, molten zone characteristics, and defect formation.
  • Analysis of thermo-mechanical coupling and residual stress generation.

Main Results:

  • The field is transitioning towards a mechanism-based, process-controllable paradigm.
  • Key research areas include temperature field evolution, fusion zone development, and thermo-mechanical behavior.
  • Current hotspots focus on HDPE adaptability, process regulation, and joint reliability.

Conclusions:

  • A theoretical framework is provided to support electrofusion welding optimization.
  • Future research should focus on mechanism-driven design, intelligent defect detection, and full-life reliability assessment.
  • Enhanced understanding will improve the safety and efficiency of non-metallic pipeline systems.