Manufacture and characterization of pipes with different extrusion parameters using polymer materials with different properties

In this master's thesis, the efficiency and durability characteristics of plastic pipes used in residential heating systems were experimentally investigated by considering various extrusion manufacturing parameters. Polymer-based pipes, intended for residential use, are laid with the assistance of styrofoam within the residence and covered with screed material. Subsequently, architectural enhancements such as parquet, tiles, marble, etc., are applied based on the architectural style of the residence. The repair of local or general faults in these pipes may lead to the deterioration of the applied architectural enhancements and result in material and immaterial losses. Moreover, the repair of pipes that do not demonstrate longevity and are prone to damage in a short period negatively impacts the quality of life and well-being of individuals. In fact, water leakage in multi-story buildings due to pipe and manufacturing defects not only reduces the building's monetary value and durability but also results in energy loss in the heating system of the building. In this context, a L16 Taguchi experimental design was implemented with four different granular polymer materials, namely XP 9000 polyethylene (PE), XP 9020 PE, recycled PE, and a mixture of XP9020 with recycled PE. Four different extrusion temperatures (180°C, 200°C, 220°C, 245°C), four extrusion speeds (35 d/d, 38 d/d, 42 d/d, and 46 d/d), and four extrusion draw rates (14 m/d, 15 m/d, 16 m/d, and 17 m/d) were selected for the manufacturing process, resulting in the production of 16 pipe samples. However, only 9 samples yielded concrete pipes, while others did not meet the specified conditions. Microscopic diameter measurement, surface roughness, and flexibility were attempted to be determined on the obtained 9 pipe samples, and only one pipe sample was found to be usable. Subsequently, this sample was subjected to standard pressure, temperature, and steam tests. Ultimately, the test results of the pipe manufactured using XP 9000 PE raw material, with an extrusion temperature of 180°C, a helix speed of 38 d/d, and a draw rate of 16 m/d, were deemed meaningful in terms of usability. The obtained sample was then compared with four commercially branded pipe samples in the market in terms of temperature, pressure, surface roughness, and compression tests. As a result, it was concluded that the X pipe sample could be similar to A, B, C, and D commercial pipe samples within the scope of the thesis research.