The invention provides a carbon fiber reinforced plastic electrofusion fitting and a self-monitoring method of strain for the fitting. Carbon fiber filled polymer is used to fabricate the fitting to improve the mechanical strength of the fitting. The fitting comprises an electrofusion fitting body embedded with a resistance heating wire and two terminals arranged on the electrofusion fitting body and connected to the two ends of the resistance heating wire respectively. For the self-monitoring of strain, at least one pair of electrodes are set on the surface of the electrofusion fitting. The resistance change between electrodes caused by fitting deformation due to temperature change or mechanical loading during operation can be measured, and could be further used for structural health monitoring of the electrofusion fitting. The combination of mechanical enhancement and strain sensing of the electrofusion fitting can improve the performance and reliability of plastic pipelines.

A cover for a housing of a vehicle and a method of sealing a cover to the housing, where in at least one example, the cover comprises a cover body configured to cover an opening of the housing and to engage the housing at an interface around the opening. The cover may comprise a heating element embedded within the cover body and operable to at least partially melt a portion of the cover body as a part of a process for sealing the cover to the housing. The portion of the cover body may deform and conform to an interface feature at the mating surface of the housing due to the at least partial melting of the portion of the cover body, and, in some examples, the heating element may be configured to fail and be inoperable.

A plastic tank is comprised of two parts, a base and a top, that are permanently joined to each other by welding at a circumferential joint formed by two mating flanges of the parts. Fusion weld elements are captured on the faying surfaces of the flanges of the assembled parts, and the elements melted by internal heating of metal portions of the elements. Before heating of the elements, the flanges are gripped by a clamp which applies a resilient force which, during welding, causes the flanges to move toward each other and thereby a good weld joint is formed.

A plastic tank is comprised of two parts, a base and a top, that are permanently joined to each other by welding at a circumferential joint formed by two mating flanges of the parts. Fusion weld elements are captured on the faying surfaces of the flanges of the assembled parts, and the elements are melted by internal heating of metal portions of the elements. Two spaced apart circumferential welds which define an annular space are formed. The pressure within the annular space is changed in a test procedure to verify the integrity of the welds.

A tapping saddle for a plastic main pipe carrying a medium includes a stub having a central axis, a saddle piece, and a drill. The drill is configured to be moved axially in the stub. A heating element geometry, which is used for welding the tapping saddle to a main tube outer circumference, is arranged on an inside diameter of the saddle piece. The heating element geometry has a winding having an outer winding region and an inner winding region. In the inner winding region, the winding extends in meandering loops along a circle concentric with the central axis of the stub.

A heat shrink component includes a heat shrink layer and a heating unit in thermal contact with at least a part of the heat shrink layer and heating the heat shrink layer to a heat shrink temperature. The heating unit includes an electrically conductive lead formed of copper and/or aluminum and having an electrical conductivity of more than 3.Math.10.sup.7 S/m. The heat shrink component has a first dimension in an expanded state and a second dimension in a shrunk state after heating. The first dimension is larger than the second dimension.

A method and apparatus for inspecting a fusion joint is provided. The apparatus includes a processor, an ultrasound (US) probe in communication with the processor, and a database comprising classification rules. The processor is configured to generate an initial set of US scanning positions about the fusion joint based on information of at least one of the US probe and the fusion joint; measure, via the US probe, a US pulse-echo spectrum from at least two of the initial US scanning positions; compare each measured US pulse-echo spectrum with one or more known US pulse-echo spectrums; classify each measured US pulse-echo spectrum according to the classification rules; and evaluate an aggregate of measured US pulse-echo spectrums to determine if the fusion joint is defective.

The invention relates to a process (100) for manufacturing an object (1) made of thermoplastic polymer composite from at least two parts (10) made of thermoplastic polymer composite, said thermoplastic polymer composite comprising a fibrous reinforcement and a thermoplastic polymer matrix, said process comprising the steps of:

arranging (120) the two parts (10) made of thermoplastic polymer composite adjacently or overlapping at an assembly interface zone (11), and

heating (130) to melt the thermoplastic polymer matrix at said assembly interface zone (11), so as to form an object (1) made of thermoplastic polymer composite comprising a welded interface (12).

A pipeline system is enclosed including unlined or plastic lined pipes. A mechanical metal to metal connection is employed that can provide a fluid tight seal. A pipe coupling may be employed to span the connection. Plastic lined pipes can have their plastic liners connected to form a fluid tight bladder. Electro fusion may be employed.

The invention provides improvements to electrofusion fitting methods that allow for continuity and repeatability of welds between an electrofusion fitting and a pipe lining (or stand-alone pipe). An electrofusion fitting for joining sections of lined pipe has heating elements configured to create at least one weld between the electrofusion fitting and a pipe lining. However, prior to the weld step taking place the electrofusion fitting is heated and expands accordingly to ensure contact with the pipe lining. Preheating the electrofusion fitting also provides a predetermined starting temperature for the fitting and the lining which results in improved fusion cycle reliability. Furthermore, the need for clamps or support frames to support the electrofusion fitting in situ is removed, with corresponding reductions in cycle times, complexity, and hence cost.