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

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.