UHMWPE pipe, also known as ultra-high molecular weight polyethylene pipe, is a pipe formed by continuous extrusion of ultra-high molecular weight polyethylene (UHMWPE) resin with a molecular weight greater than 2.5 million. Under the conditions of strong corrosion and high wear, the service life is 4-6 times that of steel pipes, which fully demonstrates the advantages of “energy saving, environmental protection, economy and high efficiency”.
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Type
Item
UHMW-PE
Physical Properties
Relative molecular weight/ million
2-3
Density/ (g/cm3)
0.945-0.975
Grain size/ mesh
40-200
Mechanical Properties
Tensile yield stress/ MPa
≥20
Fracture Extensibility %
300-400
Flexural Modulus/ MPa
600
Impact Strength/ (KJ/m)
>140
Rate of Wear % (23±2) ℃
≤0.4
Thermal Properties
Melting Point/ ℃
136
Distortion Temperature/ ℃
85
Thermal Conductivity/ [w/(m.v)]
8.5
Electrical Properties
Mass Resistivity/ (cm)
10
Punch Through Voltage/ (Kv/mm)
50
Dielectric Constant
2.3
High wear resistance: 4 times of Steel Pipe, 3 times of common Pe Pipe and 4 times of nylon pipe. It is proved that UHMWPE pipe is a common wear-resistant pipe for small particle slurry transportation.
High corrosion resistance: UHMWPE is saturated intermolecular structure, so its chemical stability is extremely high and can resist various corrosive media (acid, alkali, salt) and organic solvents in the environment.
Weather resistance and aging resistance: UHMWPE pipes have good weather resistance and aging resistance. Because there are very few unsaturated groups in the molecular chain of UHMWPE and the molecular weight is large, the pipe can maintain more than 70% of its mechanical properties for up to 50 years even after about 70% use.
High flexibility: The elongation at break can reach more than 400%, and there is a large bending during construction, and the subsidence of the earth’s crust can elongate up to 3 times without breaking.
High impact resistance: The impact resistance and impact energy absorption of ultra-high molecular weight polyethylene (UHMWPE) pipes rank first among plastics, and they are not easy to crack regardless of external force or internal pressure fluctuations. The impact strength is 10 times that of nylon 66 and 4 times that of polyethylene PE100.
Good energy-saving effect: The friction coefficient is 0.07-0.11 , the roughness is only 1/6 of the new steel pipe, the circulation capacity is more than 50% higher than that of steel pipe, and the inner diameter of steel pipe can be reduced by about 15% compared with that of steel pipe.
Easy to install: The weight of UHMWPE pipe is 1/8 of steel pipe, which greatly reduces the installation cost. The pipe body is directly flanged and connected with flange butt, no need to add seals; it can also be inserted into hot melt welding, with high interface strength and easy operation.
Long service life: Under the same operating conditions, the wear resistance of UHMWPE pipes is 4 to 7 times higher than that of Q235 steel pipes, or 10 times that of HDPE (PE100) pipes, and the service life of UHMWPE pipes is longer under most operating conditions Much longer.
The density of UHMWPE products is between 0.93-0.95g/cm3, which can float on water. If it is not pure UHMWPE material, the product will sink into water.
Good quality UHMWPE products will not melt and deform at 200°C, but will become soft. Inferior UHMWPE products will deform at 200 °C.
The surface of good-quality UHMWPE pipe is smooth, neat, black and bright, and the cross-sectional density is very uniform. The surface color of inferior UHMWPE pipes is dull, and the cross-sectional density is uneven.
Good UHMWPE pipe ends are smooth, uniform, and have good roundness and verticality, but poor-quality UHMWPE pipes will crack and peel off after the pipes are heated.
HDPE pipe, also known as High Density Polyethylene Pipe, is a strong, flexible piping system that is the ideal piping material of choice for many applications including fluid and gas transportation around the world. Polyethylene’s toughness, corrosion resistance, excellent chemical resistance, and light weight allow it to provide long-term, cost-effective piping systems.
Unlike decades past, today more and more companies are choosing HDPE pipe fittings because of their affordability and efficiency. Users recognize the environmentally friendly nature of HDPE pipes and thus apply it as a green solution.
Durability: HDPE pipe is durable enough to withstand high pressure applications and extreme temperature fluctuations, HDPE pipe maintains its chemical and abrasion resistance properties even under harsh environmental conditions.
Safety: The main joining technology used for HDPE pipes is heat fusion. This leak-free connection technology creates an integrated piping system where the joints are as strong as the pipe itself, providing a piping system that is durable. This not only improves the overall system performance, but also increases the safety of the surrounding environment by reducing the risk of media leakage. When performed correctly, hot melt joints will not leak and will greatly reduce the operating costs of the piping system over its service life.
High Corrosion Resistance: HDPE pipe will not corrode, nodulate, or support biological growth. HDPE pipe has a C-factor of 150 for the Pipe Design life, unlike metal pipe which suffers from internal diameter shrinkage over time. The inner diameter of HDPE tubing does not change over time, providing consistent flow without increasing pumping energy.
Cost-Effective: HDPE pipes are heat-fused to join and require no additional couplers, gaskets or fittings to join the pipes together. Due to the durability and simplicity of HDPE piping, there is no need to worry about frequent repairs or the cost of replacing parts.
Polyethylene (PE) pipe refers to the general term for thermoplastic pipes made of ethylene gas as raw material. There are different types of PE pipes including very low density, low density, cross-linked, ultra-low molecular weight, high molecular weight, medium density, ultra high molecular weight, chlorinated and linear low-density.
HDPE means a PE pipe that is dense than the basic pipe. HDPE pipes are not as flexible as regular samples because they have a high melting and impact point. During the manufacturing process, companies may add carbon black or other colors to HDPE tubing to resist UV light.
Unlike regular PE pipe, HDPE pipe is rust-resistant and resistant to internal pressure for reliable use. HDPE pipe maintains initial flow despite prevailing environmental factors.
The performance of HDPE pipe depends on raw materials, processing equipment and technology. Many manufacturers add recycled materials to pipes to reduce costs and achieve higher profits, but this greatly reduces the performance of the pipes. How to identify the quality of PE pipes? We have described 7 ways to check:
High-quality pipes: the inner and outer surfaces of PE pipes are smooth, without defects such as bubbles, dents, and impurities.
Inferior pipes: the surface is not smooth, not bright, with obvious pitting.
The qualified pipe strip milled out by the welding machine is bright in color, and it is not easy to break after repeated folding. The milled strips are whitish or have other colors, which is caused by the addition of recycled materials or uneven mixing.
High-quality pipes: the milled strips are bright in color, neat, and can be folded repeatedly without breaking.
Inferior pipes: the milled strips are darker in color and easy to break after repeated folding.
Qualified butt weld joints should have smooth and symmetrical wrapping around the pipe ring, and the depth of the wrapping should not be lower than the pipe surface. The tolerance of both sides of the outer circle of the weld is not more than 10% of the tube thickness. The wrap edge should be firm and smooth, slightly wider at the bottom. No impurities, small holes, deformation and damage caused by unfavorable aspects of the tumbling.
High-quality pipes: the flanging is flat, and it will be slightly longer after the welding seam is pressurized.
Inferior pipes: There are more pores on the welding surface, and the edge wrapping is shorter after butt welding is pressurized.
High-quality pipes: stable chemical performance, and the finished product will not have any peculiar smell.
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Inferior pipes: unstable chemical properties, unpleasant odor or odor after heating.
High-quality pipes: resistant to acid, alkali, salt and various solvents, anti-corrosion and anti-aging.
Inferior pipes: Under the action of acid, alkali, salt or detergents, various aging phenomena are prone to occur – embrittlement, cracking, molting, etc.
Elongation at break is the ratio of the length at break to the original length. The greater the elongation at break, the better the flexibility and the better the performance.
High-quality pipes: 3.5 times the original length without fracture
Inferior pipes: poor flexibility and easy to break.
OIT (Oxidative induction time) is the time for the autocatalytic oxidation reaction of the pipe to occur under higher temperature and oxygen, which can characterize the thermal degradation ability of the PE pipe during processing, storage, welding and working. The longer the OIT, the better the aging resistance of the PE pipe.
How are you tell HDPE from UHMW ?
This question should clarify plate and pipe. There are HDPE plate and UHMW plate, there are HDPE pipe and UHMW pipe. These can be verified through related tests.
Without test, how to tell apart UHMW pipe from HDPE pipe visually?
Straight pipe UHMW Vs HDPE: uhmwpe pipe can be only extruded with entire one color (pipe in black, or pipe in red, etc, without any other color strip shown on pipe surface), while, HDPE pipe can with blue or orange strip on black surface. See comparison pictures:
When HDPE pipe is made in back without blue strip, how to tell them apart from UHMWPE pipe?
One method is to check the stub end welding ring. Originated from their molecular weight differences, HDPE pipe can not get flanging stub end by heating to pipe itself, it should be welded to a stub end. However, UHMWPE has a much longer polymer chains, with a more higher bond strength internally, thus, UHMWPE can get its flanging stub by heating to pipe end itself.
UHMW sheets are versatile polyethylene materials valued across industries for their low friction, high durability, and chemical resistance. They can be further customized to meet precise specifications, opening new doors for specialized applications. This article will explore the customization process - tailoring UHMW sheets for your specific needs.
We’ll start by understanding UHMW properties that make customization so effective. Next, we’ll overview popular custom options like precision cutting, thickness changes, and unique shapes.
With the right expertise, virtually anything is possible! We’ll walk through real custom application examples that highlight the importance of bespoke UHMW solutions across sectors. Finally, we’ll detail the steps to start your own UHMW customization journey to get products made to order for your needs.
What Are UHMW Sheets?
UHMW sheets, short for ultra high molecular weight polyethylene sheets, are engineered thermoplastic materials noted for abrasion resistance and slipperiness. Their long polymer chains serve up outstanding toughness for demanding applications.
These sheets excel in roles from chutes and tanks to conveyor guards and equipment lining across industries like food processing, aviation, packaging, and more. They are available in standard panels and can be machined to specification.
Properties and Advantages of UHMW Sheets
Some standout UHMW sheet capabilities:
This exceptional balance makes UHMW a top material when friction or corrosion pose challenges. It permits innovative solutions impossible with other materials.
The next sections overview popular ways UHMW sheets can be tailored to order. While standard sheets suit many uses from wear strips to barrier panels “out of the box”, customization unlocks next-level performance.
Custom Cut UHMW Sheets to Specific Sizes
One of the simplest and most requested customizations is sizing standard UHMW sheets to exact dimensions. While common sheet dimensions are 48” x 96”, custom length, width, and shapes accommodate unique equipment and installations not fitting this pattern.
Precision cutting via waterjet and machining trim sheets to exact sizes with minimal material waste. Custom sawing, punching, drilling, and milling ensure components match existing spaces or machines perfectly.
Tailoring Thickness for Specific Applications
UHMW sheets come in standard thicknesses from 1/16” to over 2”. But non-standard dimensions between or beyond this range are possible when design constraints demand it.
Thicker sheets withstand heavier loads, while thinner sheets suit tight clearances. Dialing in thickness as needed balances strength, weight, and fit for individual applications. Consider a thin custom liner to ameliorate metal-on-metal wear versus a thick sheet for impact protection.
Precision Cutting for Complex Shapes
For situations requiring complex UHMW sheet geometries, intricate contours or holes are no match for precision cutting techniques. Waterjets cut sheets to exact 2D profiles without contact while CNC routers carve precise 3D forms.
These advanced methods shape even puzzle-like interlocking pieces with tight tolerances. This permits streamlined installation of custom chutes, tanks, guards and more in existing structures.
Having covered common customizations like sizing, machining, and shaping, we’ll now showcase real examples where application-specific tailoring proves invaluable.
Bespoke Solutions for Industry-Specific Needs
Every sector has unique challenges driving the need for tailored UHMW products made to order. A clean room demands vastly different equipment than a food plant or oil field. Only customized components satisfy these niche operational demands.
For instance, solar panel manufacturers utilize thin UHMW sheet overlays to protect junction boxes from outdoor weathering without adding bulk. Shipping companies integrate impact-absorbing UHMW barriers shaped to delivery truck geometries to prevent cargo shifting and damage.
Pharmaceutical processors design interlocking anti-microbial UHMW machine guards with minimal crevices to contain powders while enabling washdowns. Other sectors use thick custom UHMW chutes, funnels, and star wheels fitting tightly into existing lines to improve product flows.
In each situation, standard products fall short and custom fabrication steps in to optimize performance.
Custom Design and Features
Pushing customization further, additive features molded or integrated into custom sheets solve specific problems. Backlighting panels for human-machine interfaces, embedded sensors to monitor wear, magnets for quick install/removal, or RFID tracking for inventory management exemplify stepping beyond basic fabrication.
Built-in lighting illuminates status indicators or hazmat warnings. Conductive elements prevent static electricity in sensitive environments. Antimicrobial, non-stick, conductive, and fire-retardant custom formulations serve niche regulatory demands. Such value-adding attributes tailor standard UHMW to truly one-of-a-kind solutions.
Case Studies: Custom Applications in Action
Below we showcase two case studies highlighting custom UHMW sheet solutions and the value gained:
Smooth Curved Chutes Reduce Particle Damage
A cereal manufacturer required improved transport chutes from bulk hoppers to truck loading stations. However, standard straight chutes allowed cereal flakes to catch and break during transfer. Damaged particles decreased food quality and processing yields.
Engineers designed a system of curved UHMW sheets strategically molded into smooth half-pipe profiles directing particles for gentle handling. The custom chutes eliminated flake damage, increased process volumes, and saved costs.
Watertight Hatch Covers Withstand Extreme Storms
A marine research company analyzes sea life using underwater drones. However, launching/retrieving the drones through standard hatches allowed seawater ingress past certain depths, shorting internal electronics.
technicians fabricated custom dual-contour UHMW hatch lids that compressed against matings flanges when submerged. The shaped geometry enabled a 100% watertight seal keeping seawater out under crushing pressures found + feet underwater.
These examples demonstrate the scope of possibilities with expertly tailored UHMW solutions. While meeting unique specifications takes experience, the performance benefits make projects worthwhile.
We’ve now seen custom UHMW applications in action across industries. But how does one start their own project? Here we detail the steps from initial inquiries through to shipping end products.
Step-by-Step Guide to Customization
The tailored UHMW process looks like:
Working with Experts for Tailored Solutions
Navigating the custom process requires expertise across plastics fabrication, machining, QA, and applications know-how. As experts in UHMW parts and products since , www.beeplastic.com has the experience necessary to tackle unique challenges. Our fully equipped in-house manufacturing means projects never leave our facility from design through to shipping.
Lean on our team for responsive solutions tailored your needs from one-off prototypes to full scale production orders. Detailed project management every step ensures specifications are met on-time and on-budget.
Ensuring Quality and Precision in Customization
With tight tolerances common for custom items, quality assurance is paramount before, during and after machining. We verify melted polymer grades, measure sheet thickness, density, and verification of CNC programs. Our ISO certified processes control precision at sub-millimeter levels along entire production chains. Contact www.beeplastic.com to start a conversation around your own custom desires or technical obstacles needing specialty solutions.
Before concluding, we’ll explore several innovative applications where custom UHMW solutions enable results not otherwise possible.
Exploring Unique Projects and Solutions
The specialty fabrication techniques discussed above empower truly novel inventions. For instance:
These innovations highlight how customization liberates designers from off-the-shelf limitations.
Custom UHMW Sheets in Advanced Applications
As a high-performance plastic able handle aggressive environments, UHMW suits many advanced applications including:
Only tailored UHMW solutions satisfy such extreme yet precise scenarios. Contact us to brainstorm your specific vision.
Customization unlocks game-changing potential from versatile UHMW sheets across every industry. Simple sizing adjustments or truly advanced engineered features enable next-generation performances not possible otherwise. By tweaking thickness, machining precision profiles, or molding custom geometries, standard sheets transform into specialized solutions pushing boundaries.
While customization requires additional planning and expense compared to off-the-shelf purchases, the long-term benefits outweigh initial investments in most cases. By investing in meaningful expertise and the right fabrication technologies, custom UHMW provides a value-multiplier saving customers time, money and driving innovation over the long run.