Attention Drawn to Splatter Issues Caused by Short Circuits in Welding Process
Short circuits and material ejection (commonly known as "smoking") are the most frequent faults on electrofusion construction sites.
Time:
2026-07-01
Author:
Short circuits and material ejection (commonly known as "smoking") are the most frequent faults on electrofusion construction sites. Industry statistics indicate that such issues account for over 40% of all electrofusion welding failures, making them a primary factor affecting construction progress and quality.
Technical experts identify several main causes for short circuits and material ejection. First, insufficient pipe insertion depth or poor axial alignment results in abnormal clearance between the pipe and fitting, preventing uniform contact between the resistance wire and the pipe surface during heating. Second, excessive out-of-roundness of the pipe end—particularly common in large-diameter pipes deformed during transport and storage—prevents tight bonding with the fitting's inner wall, causing molten material to extrude through gaps under pressure. Additionally, if the pipe surface's oxide layer is not thoroughly removed, or if moisture and contaminants are present at the joint interface, vaporization and expansion of moisture during heating can cause a sudden internal pressure surge, leading to material ejection.
Experts recommend the following preventive measures. Before welding, use a specialized scraper to evenly remove the oxide layer from the outer surface of the pipe's welding zone, controlling the scraping depth between 0.1mm and 0.2mm, with the scraping length exceeding the pipe insertion depth. It is particularly important to note that sandpaper or abrasive cloth must never be used for this purpose, as abrasive particles may become embedded in the pipe surface, causing secondary contamination. Before inserting the pipe into the fitting, clearly mark the insertion depth on the pipe's outer wall, and use dedicated clamps to secure the pipe and fitting on the same axis throughout the welding process. Choosing electrofusion fittings with embedded wiring can also effectively reduce the risk of short circuits caused by exposed and oxidized resistance wires.
More Information
What are the most critical construction steps during the electrofusion welding process?
The core of electrofusion welding lies in "cleaning, scraping, alignment, fixing, and cooling." Among these, scraping off the oxide layer is the most critical step.
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What are the key requirements for matching electrofusion fittings with pipes?
Same polymer family: Fittings and pipes must be polyethylene (PE). Do not mix PE with PVC, PP or other plastics.
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What are the compatibility requirements for electrofusion fittings?
The compatibility requirements for electrofusion fittings primarily include the following aspects:
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How to correctly select and match the specifications and materials of electrofusion fittings?
When selecting electrofusion fittings, the primary principle is to ensure a perfect match between the fitting and the pipe.
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What are the most critical construction steps during the electrofusion welding process?
The core of electrofusion welding lies in "cleaning, scraping, alignment, fixing, and cooling." Among these, scraping off the oxide layer is the most critical step.
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How to intuitively judge whether an electrofusion welded joint is qualified?
After welding and natural cooling, the joint quality can be preliminarily judged through visual inspection.
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