334945684 aws-g1-10 m-2001

Guide for the
Evaluation of Hot
Gas, Hot Gas
Extrusion, and
Heated Tool Butt
Thermoplastic
Welds
AWS G1.10M:2001
An American National Standard

550 N.W. LeJeune Road, Miami, Florida 33126
AWS G1.10M:2001
An American National Standard
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.
Key Words—Hot gas welding, thermoplastics,
heated tool butt welding, joints,
evaluation, testing, hot gas extrusion

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
National Standards Institute. When AWS standards are either incorporated in, or made part of, documents that are
included in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carry
the full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by the
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Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be by
agreement between the contracting parties.
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
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In issuing and making this standard available, AWS is not undertaking to render professional or other services for or on
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of a competent professional in determining the exercise of reasonable care in any given circumstances.
This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.
Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringement
of any patent resulting from the use or reliance on this standard.
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
the Rules of Operation of the Technical Activities Committee. A copy of these Rules can be obtained from the American
Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126.
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appropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400;
online: http://www.copyright.com.

iii
*Advisor
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.

iv
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.

v
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.

vii
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

AWS G1.10M:2001
1
1. Scope, Purpose, and Range of
Application
1.1 These guidelines list and describe defects in welded
joints in thermoplastic materials. The objective is to
make possible a generally valid evaluation giving consid-
eration to graded quality requirements.
1.2 By classification into one of the evaluation groups in
4.1, specific defects can be excluded or kept within limits
when welded joints are produced.
1.3 The application of these guidelines and the measures
through which they can be met may be included in con-
tractual specification or form part of the generally recog-
nized specifications.
1.4 Welding Processes. Defects produced by the follow-
ing welding processes are addressed. This guide applies
to the following processes:
Abbreviation Annex
Hot gas fan (rod) welding WF VII
Hot gas speed welding WZ VII
Hot gas extrusion welding WE VIII
Heated tool butt welding HS IX
1.5 Materials. These guidelines apply to welded joints
on components and systems made from the engineering
thermoplastics listed below:
Abbreviation Material Description
ECTFE Ethylene chlorotrifluoroethylene
ETFE Ethylene tetrafluoroethylene
FEP Fluorinated ethylene-propylene
MFA Perfluoromethylvinylether
M PTFE PFA modified PTFE
PE-HD High density polyethylene (rigid PE)
PFA Perfluoroalkoxy
PP-B Polypropylene block copolymer
PP-H Polypropylene homopolymer
PP-R Polypropylene random copolymer
PTFE Polytetrafluoroethylene
PVC-C Chlorinated polyvinyl chloride
Abbreviation Material Description
PVC-HI High-impact polyvinyl chloride
PVC-U Unplasticized polyvinyl chloride (rigid PVC)
PVDF Polyvinylidene fluoride
PVDF/HFP Polyvinylidene fluoride/hexafluoropropylene
1.6 The use of these guidelines for welding other thermo-
plastic materials must be agreed upon between the cus-
tomer and the fabricator.
1.7 This standard makes use of the International System
of Units (SI).
1.8 Safety. The activities described in this document may
bring the user of this standard in contact with processes
and materials that may be hazardous to the user’s health.
Safety precautions mandated by OSHA and recommen-
dations for material handling in MSDS sheets should be
observed. The fabricator’s operating manual and safety
instructions should always be carefully studied and com-
plied with when operating equipment.
Note: This standard may involve hazardous materials, op-
erations, and equipment. This standard does not purport to
address all of the safety problems associated with its use. It
is the responsibility of the user to establish appropriate
safety and health practices. The user should determine the
applicability of any regulatory limitations prior to use.
2. Referenced Documents
Reference should be made to the latest edition of the
following documents:
ASTM C 904 Standard Terminology Relating to Chemical-
Resistant Nonmetallic Materials1
1. ASTM documents are available from the American Society
for Testing and Materials, 100 Barr Harbor Drive, West Consho-
hocken, PA 19428-2959.
Guide for the Evaluation of Hot Gas, Hot Gas Extrusion,
and Heated Tool Butt Thermoplastic Welds

AWS G1.10M:2001
2
ASTM D 5162 Test Method B: Standard Practice for
Discontinuity (Holiday) Testing of Non-
conductive Protective Coating on Metallic
Substrates1
AWS A3.0 Standard Welding Terms and Definitions2
3. Definitions
The terms used in this specification are defined in
ASTM C 904, Terminology Relating to Chemical-Resistant
Nonmetallic Materials, and AWS A3.0, Standard Welding
Terms and Definitions. Exceptions, within the context of
this standard, are listed below with their definitions.
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
thermal characteristics that contribute to this condition.
shrinkage groove. Insufficiency of material on the lat-
eral edges of the weld due to the high thermal shrink-
age or expansion characteristics of thermoplastics;
this resembles an undercut or underfill weld.
spark testing. An electronic test to locate discontinuities
in a nonconductive material backed by a conductive
substrate (Reference ASTM D 5162, Test Method B).
void. An unfilled space within a weld.
4. Evaluation Groups
4.1 Classification. Specific requirements are established
for the intended service of a component, particularly re-
garding the quality of the welded joints. The following
classification is used as a basis, so that the fabricator and
inspector know the extent of the measures required for
quality control with regard to welding.
Evaluation Group Requirement Level
I High requirements for reliability
and/or intended service.
II Medium requirements for reliability
III Low requirements for reliability
2. AWS documents are available from Global Engineering Doc-
uments, An Information Handling Services Group Company, 15
Inverness Way East, Englewood, Colorado 80112-5776. Tele-
phones (800) 854-7179, (303) 397-7956; FAX (303) 397-2740;
Internet: www.global.ihs.com.
The requirements to be established for the welded joints
on a component should in each case be restricted to those
which are necessary and appropriate for the application.
4.2 Criteria for Establishment. In the establishment of
the evaluation groups, the following factors, among others,
should be taken into account:
(1) level and type of stress (for example static, dynamic)
(2) thermoplastic material (for example viscous, brittle)
(3) operating conditions (for example stationary,
mobile, environmental)
(4) production conditions (for example workshop,
construction site)
(5) potential hazards (for example hazardous gases
and/or hazardous fluids)
5. Requirements for Welded Joints
5.1 Quality Features for Classification of the Weld
(Annexes VII through IX). The requirements for classi-
fying a welded joint within a particular quality grade are
established in the evaluation groups.
In the majority of cases, requirements are established
for the joint listing specific features, and describing them
with reference to the internal and external state of the
joint. By using Annexes VII through IX, it is possible to
specify requirements for the quality of welding. Using
individual features, i.e. through the type and extent of the
defects, an evaluation of welded joints can then be under-
taken (for example, as part of the acceptance procedure
for the component).
5.1.1 Requirements for Characteristics. This covers
additional data such as:
(1) deformation resistance (for example welding factor)
(2) ductility (for example bending angle to cracking)
(3) resistance to chemical attack (for example resis-
tance factor)
5.1.2 Requirements for Post Weld Treatment. In
certain cases, it may be necessary to process the weld
joint for the following reasons:
(1) dynamic stress (for example notch-free transitions)
(2) to smooth weld surfaces (for example lining)
(3) to improve flow behavior (for example internal
beads)
(4) for technical inspection
It is advisable to test and/or evaluate the weld both before
and after machining.
6. Details in Engineering Data
Requirements for welded joints are to be specified in
the contract documentation that is binding for fabrication

AWS G1.10M:2001
3
(for example, working drawing, welding diagram), with
reference to this standard.
As a rule it is sufficient to identify a weld in accor-
dance with the following example:
WZ-VV-II
where
WZ = abbreviation for the welding process
V = welding symbol and measurements
II = evaluation group code
Should all the welded joints on a component come
under the same evaluation group, then it can be entered
in a space provided for this purpose on the drawing.
Example: All welded joints as per evaluation group II
(see 4.1).
Additional requirements for specification of the char-
acteristics of welded joints and for machining are also to
be noted in the engineering data.
7. Testing and Evaluation
Visual inspection, measurements and, where neces-
sary, suitable non-destructive or destructive testing pro-
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
pieces that are fabricated under comparable conditions.
The nature and extent of the tests, together with their
timing, are to be agreed upon between the customer and
the fabricator. The test results are to be documented.
7.1 Evaluation. The test results form the basis for the
classification of welded joints into one of the three evalu-
ation groups by welding process, in accordance with An-
nexes VII through IX. Annexes I through VI define
imperfections in weld joints, and should be used in the
evaluation and documentation process. The test reports
should be used to determine points where the results do
not correspond with the requirements. Should the com-
ponent, or individual welded joints, not correspond to the
evaluation group specified (4.1), then it or they must be
reworked.
7.2 Reworking Defective Welded Joints. When allowed
under the contract and insofar as the inspector considers
it possible, defective welded joints may be reworked.
The purpose of reworking operations is to obtain the
welded joint quality established by the requirements. If
necessary, the results should be determined by additional
testing.
7.3 Overlapping Defects. Should two or more types of
defect arise simultaneously on welded joints, the cumu-
lative effect of the individual defects may result in more
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
regards safety and quality standards because of the accu-
mulation of defects. In certain circumstances, the compo-
nent or its welded joints should be re-classified into
another evaluation group.
8. Acceptance
Insofar as tests on the welded component confirm that
it meets the requirements established in the technical
documentation, the welded component shall be consid-
ered as being accepted and documented. Should the re-
quirements not be met, and should reworking not be
possible, then the fabricator and the end user should
reach an agreement on the disposition of the welded
component.

AWS G1.10M:2001
5
(Continued)
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
1011
1012
1013
1014
Longitudinal
crack
Crack whose main direction is close to that of the
axis of the weld. It can be situated:
• in the weld
• in the fusion zone (weld junction)
• in the heat-affected zone
• in the base material
102
1021
1022
1023
Transverse
crack
Crack whose direction is more or less perpendicular
to the axis of the weld. It can be situated:
• in the weld
103
1031
1032
1033
Radiating
crack
Group of cracks issuing from a single point and
situated:
• in the weld
104
1041
1042
1043
Bead-stop
crack
Crack occurring at the bead-stop, and which may be:
• parallel
• perpendicular
• radiating
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.)

AWS G1.10M:2001
6
105
1051
1052
1053
Group of
disconnected
cracks
Set of grouped cracks of any orientation, which may
be situated:
• in the weld
106
1061
1062
1063
Branching
crack
Set of interconnected cracks in the form of branching
and distinguishable from the network of disconnected
cracks (105) and from radiating cracks (103). They
may be situated:
• in the weld
Annex I—Cracks (Continued)

AWS G1.10M:2001
7
(Continued)
201 Gas void Void formed by gas(es)
2011 Spheroidal gas
pore
More or less spherical gas void
2012 Uniformly
distributed
voids
Spheroidal gas voids regularly distributed in the
weld. To be distinguished from linear voids
(2014).
2013 Localized
(clustered)
voids
Group of gas voids
2014 Linear voids Gas voids distributed along a line parallel to the
axis of the weld
2015 Elongated
void
Large non-spheroidal gas void whose main
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.
Annex II
Voids

AWS G1.10M:2001
8
2017 Surface pore Small gas void opening out on the surface
202 Shrinkage
void
Void due to shrinkage of weld during solidification
2024 Bead-stop or
void
Void (or depression) at pass-end not eliminated
before or during the execution of the following pass
Annex II—Voids (Continued)

AWS G1.10M:2001
9
300 Solid inclusion Foreign solid body trapped in the weld
303 Oxides
inclusion
Oxides or burns trapped in the weld
304 Sundry
inclusion
Particle of foreign body trapped in the weld
Annex III
Solid Inclusions

AWS G1.10M:2001
11
401
4011
4012
4013
Lack of fusion
(incomplete
fusion)
Lack of fusion between deposited and base material
or between two adjacent layers of deposited
material. One must distinguish between:
• the lack of lateral fusion
• the lack of fusion between weld passes
• the lack of fusion at the root of the weld
402 Lack of
interior fusion
or incomplete
penetration
Partial absence of fusion of the edges to be welded,
allowing an unfused area to remain between these
edges
Annex IV
Lack of Fusion

AWS G1.10M:2001
13
(Continued)
500 Imperfect
shape
External surface displays lack of geometric
conformity relative to correct profile
5011 Continuous
undercut
Lack of material in form of a groove extending
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
groove
Insufficiency of material on the lateral edges of the
root
502 Excessive
reinforcement
Excess of deposited material or excessive flash
503 Excessive
convexity
Fault in an angle weld characterized by an
exaggerated convex profile
Annex V
Defects of Shape

AWS G1.10M:2001
14
504 Excessivemelt
through
Excess of material at the root for a weld executed
from a single face
505 Bad
reinforcement
angle
Dihedral angle (α) formed by the plane tangent to
the base and passing through the connection line is
too great
506 Overlap Excess of weld which spreads over the surface of
the base material, without fusion with same
507 Linear
misalignment
Non-observance of proposed level between two
welded pieces. This defect is generally expressed
by measurement of a level difference
508 Angular
misalignment
Non-observance of proposed angle between two
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
defect
• Non-symmetrical flash
• Non-symmetrical angle weld
513 Irregular width Excessive variation in weld width
514 Irregular
surface
Excessive irregularity in surface of weld
(roughness, corrugation)
517
5171
5172
Poor restart Local irregularity in surface at location of a restart:
• in the terminal pass
• in the bottom pass
Annex V—Defects of Shape (Continued)

AWS G1.10M:2001
15
600 Other defects Defects not included in Annexes I, II, III, IV, and V
601
6011
6012
6013
Thermal heat
damage
Superficial alteration resulting from the accidental
action of a source of heat. It may affect:
• the weld
• the heat-affected zone
• the base material
603
6031
6032
Mechanical
damage
Local damage to the base material
Local damage due to an incorrect grinding or
milling
Local damage due to an incorrect scraping
604 Leg length
defect
Dimensional deviation of the specified leg lengths
of the weld
Annex VI
Other Defects

AWS G1.10M:2001
17
Annex VII
Description of Evaluation Groups
for Hot Gas Fan and Speed Welds
No. Feature Description
Evaluation Groups
I II III
External state of surface of V-welds and double V-welds
1 Crack Isolated cracks or groups of
cracks with and without
branching, running
lengthwise or crosswise to
weld. They can lie:
• in the weld
Not permissible Not permissible Not permissible
2 Welding overlap Marked deepening, which can
be seen and felt, along or
between individual welding
rods, caused by, for example:
• faults on die
• poor welding rod guidance
Not permissible Locally
permissible if
k > 0
Locally
permissible if
k > 0
3 Undercuts Notches in base material
along weld caused by, for
example:
• penetration of die edge
• machining of weld
• unsatisfactory edge zone
welding
permissible if
ending flat
∆s < 0.1s, but
max = 1 mm
Locally
permissible if
ending flat
∆s < 0.1s, but
max = 1 mm
4 Incomplete joint penetration Notches caused by
incomplete weld filling at
root, due to, for example:
• generating angle too small
during edge preparation
• root gap too small
• root rod too thick
• welding force too small
Not permissible Not permissible Locally
permissible in
limited numbers
if ∆s < 0.1s
(Continued)

AWS G1.10M:2001
18
(Continued)
5 Incomplete joint penetration Caused by, for example:
• inadequate edge prepara-
tion
permissible in
limited num-
bers if
∆s < 0.1s, but
max = 1 mm
6 Excessive melt through Caused by, for example:
• root gap too big
• compressed stringer bead
Locally permis-
sible in limited
numbers if
∆s < 0.15s, but
max = 2 mm
Permissible if
∆s < 0.2s, but
max = 3 mm
Permissible if
∆s < 0.25s, but
max = 4 mm
7 Excessive face reinforcement Caused by, for example:
too many individual rods or
passes
• wrong edge preparation
Continuously
permissible if
0.1s < ∆s < 0.4s
Continuously
permissible if
0.05s < ∆s <
0.5s
Continuously
permissible if
0 < ∆s < 0.6s
8 Underfill Inadequate weld filling Not permissible Not permissible Not permissible
9 Linear misalignment For example:
• different wall thicknesses
are not compensated
• equal wall thicknesses are
misaligned
Permissible if
e1 < 0.1s,
e2 < 0.15s, but
max = 2 mm
Permissible if
e1 < 0.15s,
e2 < 0.2s, but
max = 4 mm
Permissible if
e1 < 0.2s,
e2 < 0.25s, but
max = 5 mm
10 Angular misalignment
(errors of form) (Diagram)
Permissible if
e < ± 1 mm
Permissible if
e < ± 2 mm
Permissible if
e < ± 4 mm
11 Weld intersections (Diagram) For example:
• four-way intersection
Evaluation Groups
I II III
Annex VII—Description of Evaluation Groups
for Hot Gas Fan and Speed Welds (Continued)

AWS G1.10M:2001
19
(Continued)
12 Wavy weld surface Waviness running vertical to
weld in finishing pass, caused
by, for example:
• welding force and speed
non-uniformly distributed
Locally
permissible
Continuously
permissible
Continuously
permissible
13 Rough weld surface Fine open bubbles, streaks, or
nodules and the like, caused
by, for example:
• dirty welding shoe
• hot gas temperature too
high
Isolated cases
permissible
Limited areas
permissible
Permissible
14 Start fault Incomplete welded cross
section at start or end of weld
Not permissible Small reduction
in cross section
permissible
without abrupt
transition
Permissible
15 Heat damage Discoloration, nodule
formation, high-gloss weld
faces and similar defects
Not permissible Isolated cases
permissible
Limited areas
permissible
External state of weld surface of fillet welds
16 Oversized weld (Diagram) Exceeds standard fillet weld
thickness of a = 0.7s
(s = thickness of thinner
member)
Permissible if
b < 0.4a, but
max = 6 mm
Permissible if
b < 0.5a, but
max = 9 mm
Permissible if
b < 0.6a, but
max = 12 mm
17 Undersized weld (Diagram) Undershoots standard fillet
weld thickness of a = 0.7s
member)
Not permissible Permissible if
nominal dimen-
sion is a slightly
undershot
locally
b < 0.15a
Permissible if
nominal dimen-
sion a is under-
shot locally
b < 0.3a
Evaluation Groups
I II III

AWS G1.10M:2001
20
(Continued)
18 Incompletely welded cross
section
Weld geometry not to
standard
z < 0.15a
Permissible if
z < 0.3a
Internal state of V-welds and fillet welds
19 Pores and foreign material
inclusions
Numerous, dispersed, isolated
or locally concentrated pores
or inclusions, e.g., due to:
• vaporization during
welding (water, solvent)
• dirty heated tool
Small isolated
pores
permissible if
∆s < 0.05s
Pores and pore
rows
permissible if
∆s < 0.1s
Pores and pore
rows
permissible if
∆s < 0.15s
20 Lack of fusion Lack of fusion running
horizontally or vertically in
the weld or on the weld
edges, caused by, for
example:
• welding temperature too
low
• dirty joint faces
Evaluation Groups
I II III

AWS G1.10M:2001
21
Annex VIII
for Hot Gas Extrusion Welds
Evaluation groups
I II III
External state of surface of V-welds or double V-welds
1 Crack Isolated cracks or groups of
cracks with and without
branching, running
lengthwise or crosswise to
weld. They can lie:
• in the weld
2 Undercut Continuous or local flat
deformations lengthwise to
weld, caused by, for example:
• fault in welding shoe
• fault in welding unit
guidance
permissible if
k > 0
Locally
permissible if
k > 0
3 Undercuts Notches in base material
along weld, caused by, for
example:
• penetration of weld shoe
edges
• processing of edge zone
Locally
permissible if
ending flat and
∆s < 0.1s, but
max = 1 mm
Continuously
permissible if
ending flat and
∆s < 0.1s, but
max = 2 mm
Continuously
permissible if
ending flat and
∆s < 0.2s, but
max = 3 mm
4 Inadequate edge zone welding Inadequate covering of
welding groove edge on one
or both sides
Nominal dimension:
∆b > 3 mm
Not permissible Locally permis-
sible with notch-
free transition
and ∆ > 2 mm
Continuously
permissiblewith
notch-free
transition and
∆b > 1 mm
(Continued)

AWS G1.10M:2001
22
(Continued)
5 Incomplete joint penetration Notches caused by inadequate
weld filling on root, caused
by, for example:
• bend up and unwelded joint
faces
• root opening too small
• root falling back due to
shrinkage
permissible in
limited num-
bers if
∆s < 0.1s, but
max = 1 mm
Permissible if
∆s < 0.1s, but
max = 1 mm
6 Incomplete joint penetration Caused by, for example:
• inadequate edge
preparation
permissible in
limited numbers
if ∆s <0.1s, but
max = 1 mm
7 Excessive melt through Caused by, for example:
• root opening too big
• welding force too great
Permissible if
∆s < 0.15s, but
max = 2 mm
Permissible if
∆s < 0.2s, but
max = 3 mm
Permissible if
∆s < 0.25s, but
max = 4 mm
8 Excessive face reinforcement Finish pass too high, caused
by, for example:
• inadequately formed
welding shoe
Continuously
permissible
0.1s < ∆s < 0.4s,
but max = 6 mm
Continuously
permissible
0.05s < ∆s < 0.5
s, but max =
9mm
Continuously
permissible if
0 < ∆s < 0.6s,
but max = 12
mm
9 Overlap Welding material overflow on
one or both sides, usually
without sufficient fusion to
base material
Not permissible Locally permis-
sible in small
numbers if
∆b < 5 mm
Continuously
permissible if
∆b < 5 mm
10 Underfill Weld cross section is not
obtained, caused by, for
example:
• shrinkage of welding filler
• inadequately formed weld-
ing shoe
• welding speed too high
conditionally
permissible if
∆s < 0.1s, but
max = 1 mm
Evaluation groups
I II III
Annex VIII—Description of Evaluation Groups
for Hot Gas Extrusion Welds (Continued)

AWS G1.10M:2001
23
(Continued)
11 Linear misalignment (Diagram) For example:
• different wall thicknesses
are not compensated
Permissible if
e1 > 0.1s,
e2 > 0.15s, but
max = 2 mm
Permissible if
e1 > 0.15s,
e2 > 0.2s, but
max = 4 mm
Permissible if
e1 > 0.2s,
e2 > 0.25s, but
max = 5 mm
12 Angular misalignment
(defects of form) (Diagram)
Length, L, of shorter side is
decisive for permissible
deflection
Permissible up
to e < ±1 mm
Permissible up
to e < ±2 mm
Permissible up
to e < ±4 mm
13 Weld intersections For example:
• four-way intersection
14 Asymmetrical weld cover Welding shoe has been
guided outside weld center
the required
weld cross
section is not
undershot
Locally
conditionally
permissible if
∆s < 0.1s, but
max = 1 mm
15 Wavy weld surface Caused by, for example:
• welding force non-
uniformly applied
Locally
permissible
Continuously
permissible
Continuously
permissible
16 Rough weld surface Fine open bubbles, streaks, or
nodules and similar defects,
for example:
• moisture in form mass
• form mass temperature too
low
Isolated spots
permissible
Limited areas
permissible
Permissible
17 Start fault Incompletely welded cross
section at start or end of weld
Not permissible Not permissible Low reduction
in cross section
without sharp
transitions
permissible
18 Heat damage Discoloration, formation of
nodules, high-gloss weld
surfaces and similar defects
Not permissible Isolated spots
permissible
Limited areas
permissible
Evaluation groups
I II III

AWS G1.10M:2001
24
(Continued)
External state of weld surfaces of fillet welds
19 Oversized weld (Diagram) Exceeding of standard fillet
weld thickness of a = 0.7s
member)
Permissible if
b < 0.4a, but
max = 6 mm
Permissible if
b < 0.5a, but
max = 9 mm
Permissible if
b < 0.6a, but
max = 12 mm
20 Undersized weld (Diagram) Required weld cross section
is not obtained, caused by, for
example:
• shrinkage of welding filler
• inadequately formed
welding shoe
nominal
dimension and
slightly
undershot
locally
b < 0.15a
Permissible if
nominal
dimension and
undershot
locally b < 0.3a
21 Incompletely welded weld cross
section (Diagram)
Weld geometry not to
standard
z < 0.15a
Permissible if
z < 0.3a
22 Pores due to foreign material
inclusions
Numerous, dispersed,
isolated, or locally
concentrated pores or
inclusions, e.g., due to:
• dirty heated tool
Small isolated
pores
permissible if
∆s < 0.05s
Pores and pore
rows permitted
if ∆s < 0.1s
Pores and pore
rows permitted
if ∆s < 0.15s
23 Lack of fusion No fusion, or incomplete
fusion on opposite position,
fastening points and weld
sides, caused by, for example:
• dirty joint
• inadequate heating
conditionally
permissible
Evaluation groups
I II III

AWS G1.10M:2001
25
Annex IX
for Heated Tool Butt Welds
Evaluation Groups
I II III
External State of Joint
1 Cracks Cracks running lengthwise or
crosswise to weld. They may
be located:
• in weld
• in base material
• in heat-affected zone
2 Weld undercut Continuous or local notches
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
material, lengthwise or cross-
wise to weld. Caused by, for
example:
• clamping tools
• incorrect transport
• fault in edge preparation
Locally
permissible if
ending flat and
∆s < 0.1s, but
max = 0.5 mm
Locally
permissible if
ending flat and
∆s < 0.1s, but
max = 1 mm
Locally
permissible if
ending flat and
∆s < 0.15s, but
max 2 = mm
4 Linear misalignment Joint faces are misaligned
relative to one another or
thickness variations are not
corrected
Permissible if
e < 0.1s, but
max = 2 mm
Permissible if
e < 0.15s, but
max = 4 mm
Permissible if
e < 0.2s, but
max = 5 mm
(Continued)

AWS G1.10M:2001
26
(Continued)
5 Angular misalignment For example:
• machine fault
• layout fault
Permissible if
e < 3 mm
Permissible if
e < 5 mm
Permissible if
e < 7 mm
6 Narrow, excessive welding flash* Excessive and sharp-edged
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,
leading to variations in form
of welding flash over part or
all of weld length. Caused by,
for example:
• edge preparation fault
• incorrect welding unit
Permissible if
b1 > 0.7b2
Permissible if
b1 > 0.6 b2
Permissible if
b1 > 0.5b2
8 Thermal damage High-gloss welding flash face
with voids or nodules, usually
associated with faulty
welding flash formation and
marked bead notches
9 Lack of fusion No fusion or incomplete
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.
Caused by, for example:
• insufficient joint pressure
• insufficient cooling time
Evaluation Groups
I II III
Annex IX—Description of Evaluation Groups
for Heated Tool Butt Welds (Continued)

AWS G1.10M:2001
27
(Continued)
11 Pores caused by inclusions of
foreign matter
Numerous, dispersed, isolated
or locally concentrated pores
or inclusions. Caused by, for
example:
• contaminated heated tool
face
Small isolated
pores
permissible if
∆s < 0.05s
Pores and rows
of pores
permissible if
∆s < 0.10s
Pores and rows
of pores
permissible if
∆s < 0.15s
*Classification criteria under scrutiny by DVS.
Evaluation Groups
I II III
Annex IX—Description of Evaluation Groups
for Heated Tool Butt Welds (Continued)

AWS G1.10M:2001
29
A1. DVS (German Welding Society)
Recommendations
Designation Title
DVS 2201-2 Testing of semi-finished products of
thermoplastics: Weldability—Test meth-
ods—Requirements
DVS 2202-1 Imperfections in thermoplastic welded
joints—Features, description, evaluation
DVS 2203-1 Testing of Welded Joints of Thermo-
plastics semi-finished products—Test
Methods—Requirements
plastics materials: Tensile test
plastics; tensile impact test
plastics plates and tubes—Tensile
creep test
plastics plates and tubes—Technologi-
cal bend test
DVS 2205-2 Calculations of thermoplastic tanks
and apparatus—Vertical cylindrical
non-pressurized tanks
DVS 2205-2 Welded static thermoplastic tanks—
Supplement 1 Installation inside of buildings
DVS 2205-2 Calculation of thermoplastic tanks and
Supplement 2 apparatus—Vertical cylindrical non-
pressurized tanks—Collecting devices
Designation Title
DVS 2205-3 Calculations of containers and apparatus
Supplement 3 of thermoplastics, welded joints
Supplement 4 apparatuses—Welded flanges, welded
collars—Constructive details
apparatuses; Rectangular tanks
DVS 2207-1 Welding of thermoplastics—Heated
tool welding of pipes, pipeline, com-
ponents and sheets made form PE-HD
DVS 2207-3 Hot gas welding of thermoplastic poly-
mers; panels and pipes
DVS 2207-3 Hot gas welding of thermoplastic poly-
Supplement mers; panels and pipes; welding param-
eters for HDPE and PP
ponents and sheets out of PP
ponents and sheets out of PVDF
DVS 2208-1 Welding of thermoplastics—Machines
and devices for the heated tool welding
of pipes, pipeline components and
sheets
DVS 2209-1 Welding of thermoplastics; extrusion
welding; procedures, characteristics
DVS 2209-2 Welding of thermoplastics—Hot gas
extrusion welding—Requirements for
welding machines and tools
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

AWS G1.10M:2001
30
Designation Title
DVS 2211 Filler materials of thermoplastics—
Scope, designation, requirements, tests
DVS 2212-1 Examination of plastic welders exami-
nation—Group I—Hot Gas welding
with torch separate from filler rod
(WF), hot gas string-bead welding
(WZ), heated tool butt welding (HS)
DVS 2212-2 Examination of plastic welders—
Examination group II—Hot gas extru-
sion welding
DVS 2213 Specialist for plastics welding—
Examination
Designation Title
DVS 2214 Regulations for the examination of the
specialist for plastics welding
A2. DIN (German) Standards3
Designation Title
DIN 1910 Welding—Welding of Plastics; Processes
DIN 32 502 Imperfections in plastic welded joints;
Classification, terminology
3. DIN is the national standards institution for Germany. DIN is
the German equivalent of ANSI.
3

AWS G1.10M:2001
31
American Society for Testing and Materials (ASTM)
100 Barr Harbor Drive
West Conshohocken, PA 19428-2959
Telephone: 610-832-9585
American Welding Society (AWS)
550 N.W. LeJeune Road
Miami, FL 33126
Telephone: 800-443-9353
DIN
DVS-Verlag GmbH
(German Welding Society)
Aachener Strasse 172
D-40223 Düsseldorf
Germany
Telephone: +49/211/15 91-0
Annex B
Document Sources

AWS G1.10M:2001
33
C1. Introduction
The AWS Board of Directors has adopted a policy
whereby all official interpretations of AWS standards
will be handled in a formal manner. Under that policy, all
interpretations are made by the committee that is respon-
sible for the standard. Official communication concern-
ing an interpretation is through the AWS staff member
who works with that committee. The policy requires that
all requests for an interpretation be submitted in writing.
Such requests will be handled as expeditiously as possi-
ble but due to the complexity of the work and the proce-
dures that must be followed, some interpretations may
require considerable time.
C2. Procedure
All inquiries must be directed to:
Managing Director, Technical Services
American Welding Society
550 N.W. LeJeune Road
Miami, FL 33126
All inquiries must contain the name, address, and af-
filiation of the inquirer, and they must provide enough in-
formation for the committee to fully understand the point
of concern in the inquiry. Where that point is not clearly
defined, the inquiry will be returned for clarification. For
efficient handling, all inquiries should be typewritten and
should also be in the format used here.
C2.1 Scope. Each inquiry must address one single provi-
sion of the standard, unless the point of the inquiry in-
volves two or more interrelated provisions. That
provision must be identified in the scope of the inquiry,
along with the edition of the standard that contains the
provisions or that the Inquirer is addressing.
C2.2 Purpose of the Inquiry. The purpose of the inquiry
must be stated in this portion of the inquiry. The purpose
can be either to obtain an interpretation of a standard re-
quirement, or to request the revision of a particular provi-
sion in the standard.
C2.3 Content of the Inquiry. The inquiry should be
concise, yet complete, to enable the committee to quickly
and fully understand the point of the inquiry. Sketches
should be used when appropriate and all paragraphs, fig-
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.
C2.4 Proposed Reply. The inquirer should, as a pro-
posed reply, state an interpretation of the provision that is
the point of the inquiry, or the wording for a proposed re-
vision, if that is what inquirer seeks.
C3. Interpretation of Provisions of
the Standard
Interpretations of provisions of the standard are made
by the relevant AWS Technical Committee. The secre-
tary of the committee refers all inquiries to the chairman
of the particular subcommittee that has jurisdiction over
the portion of the standard addressed by the inquiry. The
subcommittee reviews the inquiry and the proposed reply
to determine what the response to the inquiry should be.
Following the subcommittee’s development of the re-
sponse, the inquiry and the response are presented to the
Annex C
Guidelines for Preparation of Technical Inquiries for
AWS Technical Committees

AWS G1.10M:2001
34
entire committee for review and approval. Upon approval
by the committee, the interpretation will be an official in-
terpretation of the Society, and the secretary will transmit
the response to the inquirer and to the Welding Journal
for publication.
C4. Publication of Interpretations
All official interpretations will appear in the Welding
Journal.
C5. Telephone Inquiries
Telephone inquiries to AWS Headquarters concerning
AWS standards should be limited to questions of a gen-
eral nature or to matters directly related to the use of the
Standard. The Board of Directors’ policy requires that all
AWS staff members respond to a telephone request for
an official interpretation of any AWS standard with the
information that such an interpretation can be obtained
only through a written request. The Headquarters staff
cannot provide consulting services. The staff can, how-
ever, refer a caller to any of those consultants whose
names are on file at AWS Headquarters.
C6. The AWS Technical Committee
The activities of AWS Technical Committees in regard
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
basis of new data or technology. Neither the committee
nor the staff is in a position to offer interpretive or con-
sulting services on: (1) specific engineering problems, or
(2) requirements of standards applied to fabrications out-
side the scope of the document or points not specifically
covered by the standard. In such cases, the inquirer
should seek assistance from a competent engineer experi-
enced in the particular field of interest.

AWS G1.10M:2001
35
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.

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