焊接工艺培训课件..ppt

单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,*,单击此处编辑母版标题样式,单击此处编辑母版文本样式,第二级,第三级,第四级,第五级,*,*,焊接工艺培训课件.,焊接工艺培训课件.焊接工艺培训课件.,最后一个字母,0,1,2,3,4,5,6,7,8,9,电源,(a),交流或,直流,反接,交流或,直流,交流,或,直流,交流,或,直流,直流反接,交流或,直流反接,交流或,直流,交流或,直流反接,交流或,直流,药皮类型,(b),有机物,金红石,*,金红石,*,金红石,*,低氢,低氢,矿物质,低氢,金红石,*,电弧类型,熔透,(C),深,适中,浅,浅,适中,适中,适中,适中,适中,药皮中的铁粉含量,0%,10%,无,0%,10%,0%,10%,30%,50%,无,无,50%,30%,50%,0%,10%,备注,:(a)E-6010,是直流反接；,E-6020,是交流或直流,(b)E-6010,是有机物药皮；,E-6020,是矿物质药皮,(c)E-6010,是深熔焊条；,E-6020,是熔深适中的焊条,*,硬质二氧化钛药皮,E7018-X,E,焊条表示符号,70,焊缝金属的抗拉强度等级，度量衡单位：,psi,1,焊接位置,8,药皮成分，熔透性，电流极性,X,补充要求,焊接位置,1,平焊，横焊，立向上焊，仰焊,2,平焊，横焊,4,平焊，横焊，立向下焊，仰焊,碳钢药皮焊条（,AWS A5.1/ASME SFA5.1,）,等级,焊条药皮成分,熔深,电流极性,EXXX0,纤维素，硅,深,直流反接,EXXX1,纤维素，钾,深,交流，直流反接,EXXX2,金红石，硅,一般,交流，直流正接,EXXX3,金红石，钾,浅,交流，直流反接,/,直流正接,EXXX4,金红石，铁粉,一般,交流，直流反接,/,直流正接,EXXX5,低氢，硅,一般,直流反接,EXXX6,低氢，钾,一般,交流，直流反接,EXXX7,铁粉，氧化铁,一般,交流，直流正接,EXXX8,低氢，铁粉,一般,交流，直流反接,EXXX9,氧化铁，金红石，钾,一般,交流，直流反接,/,直流正接,焊条型号列表,后缀,补充要求,-1,改进,E7018,焊条的冲击性能，也可用于表示改进,E7024,焊条的延展性。,-M,军用要求,-,好的韧性，暴漏在空气中时良好的防潮能力，熔敷金属中扩散氢含量低,-HX,用于表示熔敷金属中的最大扩散氢含量。列入,-H4=4ml/100g,补充符号,低合金钢药皮焊条（,AWS A5.5/ASME SFA5.5,）,E7018-X,E,焊条表示符号,70,焊缝金属的抗拉强度等级，度量衡单位：,psi,1,焊接位置,8,药皮成分，熔透性，电流极性,X,合金成分,后缀符号列表,后缀,合金成分,后缀符号描述,-A1,碳,-,钼钢,含钼：,0.40%0.65%,-B1,铬,-,钼钢,含铬：,0.40%0.65%,，含钼：,0.40%0.65%,-B2,铬,-,钼钢,含铬：,1.00%1.50%,，含钼：,0.40%0.65%,-B2L,铬,-,钼钢,低碳,(Wc0.05%),，含铬：,1.00%1.50%,，含钼：,0.40%0.65%,-B3,铬,-,钼钢,含铬：,2.00%2.50%,，含钼：,0.90%1.20%,-B3L,铬,-,钼钢,低碳,(Wc0.05%),，含铬：,2.00%2.50%,，含钼：,0.90%1.20%,-B4L,铬,-,钼钢,低碳,(Wc0.05%),，含铬：,1.75%2.25%,，含钼：,0.40%0.65%,-B5,铬,-,钼钢,含铬：,0.40%0.60%,，含钼：,1.00%1.25%,-B6,含铬：,4.60%6.00%,，含钼：,0.45%0.65%,-B8,含铬：,8.00%10.5%,，含钼：,0.80%1.20%,-C1,镍钢,含镍：,2.00%2.75%,-C1L,镍钢,低碳,(Wc0.05%),，含镍：,2.00%2.75%,-C2,镍钢,低碳,(Wc0.05%),，含镍：,3.00%3.75%,后缀符号列表,后缀,合金成分,后缀符号描述,-C2L,含镍钢,低碳,(Wc0.08%),，含镍：,3.00%3.75%,-C3,含镍钢,含镍：,0.80%1.10%,-NM,含镍钢,含镍：,0.80%1.10%,，含钼：,0.40%0.65%,-D1,含镍、钼,含锰：,1.00%1.75%,，含钼：,0.25%0.45%,-D2,含锰、钼,含锰：,1.65%2.00%,，含钼：,0.25%0.45%,-D3,含锰、钼,含锰：,1.00%1.80%,，含钼：,0.40%0.65%,-W,耐候钢,Ni,Cr,Mo,Cu,-G,未定义化学成分,-M,军用等级,可能具有更多要求,力学性能等级,级别,最小抗拉强度,最小屈服强度,E60XX,62000 psi (430 Mpa),50000 psi (330 Mpa),E70XX,70000 psi (490 Mpa),57000 psi (400 Mpa),E80XX,80000 psi (550 Mpa),67000 psi (460 Mpa),E90XX,90000 psi (620 Mpa),77000 psi (530 Mpa),E100XX,100000 psi (690 Mpa),57000 psi (600 Mpa),E110XX,110000 psi (760 Mpa),95000 psi (670 Mpa),E120XX,120000 psi (830 Mpa),107000 psi (740 Mpa),化学元素的作用,符号,名称,作用,C,碳,最有效的增加金属硬度的元素,Mn,锰,对于金属硬度的影响仅次于碳,Si,硅,还原剂，,P,磷,含量过高易导致裂纹,S,硫,含量过高易导致裂纹,Cr,铬,提升金属材料耐腐蚀性,Ni,镍,提升金属材料的低温韧性,Mo,钼,提升金属材料的高温强度,B,硼,少量可提升金属材料硬度,Cu,铜,耐腐蚀型弱，裂纹敏感度高,Al,铝,还原剂，改进金属材料力学性能,Ti,钛,去除氧、硫、氮、碳,N,氮,改善金属材料强度，不易于金属材料的冲击韧性,Cb,钴,提升金属材料硬度，改善金属材料力学性能,V,矾,提升金属材料硬度，改善金属材料力学性能,ASME,锅炉及压力容器规范第,IX,卷内容,：,焊接接头的分类,标准测试位置,1G,3G,6G,2F,5F,等式规范制定的测试用焊接位置,.They are properly referred to as Test Positions.,相似的描述见,ISO 6947,定义,PA,PC,PG,等,.,1G/PA,15,焊缝水平轴,板水平摆放,5,2G/PC,板竖置,焊缝水平轴,15,5,3F/PF or PG,5,6G,455,Flat Positions Axis Inclination,15,Start at Nominal Flat Position,焊缝表面向上,平焊位置上倾角限制,15,Weld may,incline upward,to a limit of 15,WWW.SPERKOENGINEERING.COM,Flat Upward Inclined Limit,15,But the welder,could be traveling,down the incline,.,WWW.SPERKOENGINEERING.COM,Flat,Downward,Limit Is Implied,15,WWW.SPERKOENGINEERING.COM,Welding Positions,Tabulation of Positions of Groove Welds,Position,Diagram Reference,Inclination of Axis,Rotation of Face,FlatA,0 to 15,150 to 210,HorizontaB0 to 1580 to 150,210 to 280,OverheadC0 to 800 to 80,210 to 360,VerticalD15 to 8080 to 280,E80 to 900 to 360,How this table and the diagram on the previous page work are shown in the following diagrams,Flat Position-Rotation About Axis,180,0,30,30,150,210,Flat Rolled Limit Clockwise,210,180,30,WWW.SPERKOENGINEERING.COM,Flat Rolled Limit Clockwise,210,180,30,Equivalent to,rotating,The plate 30,Flat Rolled Limit Counterclockwise,30,150,180,WWW.SPERKOENGINEERING.COM,Flat Rotated Limits Not Considering Inclination,60,Welding Positions,Tabulation of Positions of Groove Welds,Position,Diagram Reference,Inclination of Axis,Rotation of Face,FlatA,0 to 15,150 to 210,HorizontaB0 to 1580 to 150,210 to 280,OverheadC0 to 800 to 80,210 to 360,VerticalD15 to 8080 to 280,E80 to 900 to 360,How this table and the diagram on the previous page work are shown in the following diagrams,Flat Uphill Limit Rotated,15,60,Flat Downhill Limit Rotated,15,Composite Flat Position Ranges,30,60,Compare this range to 1G/PA.,15,/FLAT,Testing Position 1G/PA,15,/PA,Weld Axis Horizontal,Plate Horizontal,5,/PA,30,/FLAT,Flat 1G!,Welding Positions,Tabulation of Positions of Groove Welds,Position,Diagram Reference,Inclination of Axis,Rotation of Face,FlatA0 to 15,150 to 210,Horizontal,B0 to 15,80 to 150,210 to 280,OverheadC0 to 800 to 80,210 to 360,VerticalD15 to 8080 to 280,E80 to 900 to 360,How this table and the diagram on the previous page work are shown in the following diagrams,Horizontal Position Axis Inclined,15,Basic Horizontal Position,Horizontal Position Uphill Inclined Limit,15,Horizontal Position Downhill Inclined Limit,15,Welding Positions,Tabulation of Positions of Groove Welds,Position,Diagram Reference,Inclination of Axis,Rotation of Face,FlatA0 to 15,150 to 210,Horizontal,B0 to 1580 to 150,210 to 280,OverheadC0 to 800 to 80,210 to 360,VerticalD15 to 8080 to 280,E80 to 900 to 360,How this table and the diagram on the previous page work are shown in the following diagrams,Horizontal Position Rotated,80,150,70 range,210,280,70 Range,210,Start at the Flat Rolled Limits,180,30,Lets go to an,end view.,Horizontal End View,30,Horizontal starts where,Flat ends.,210,Horizontal Rotates to where the plate is perpendicular to the ground,30,Horizontal rotates,clockwise.,WWW.SPERKOENGINEERING.COM,Horizontal Position Rotated Limit,30,Horizontal ends,here.,10,90,280,WWW.SPERKOENGINEERING.COM,70,Non-inclined Horizontal Position Limits,Starts with plate,Rotated 30,70,Non-inclined Horizontal Position Limits,Finishes with plate,Rotated 10 beyond,perpendicular,Composite Horizontal Position Limits,15,15,Compare Horizontal to 2G/PC,Test Position 2G/PC,Plates Vertical,Weld Axis Horizontal,15,/PC,15,/H,5,/PC,-60,+10,/H,Horizontal 2G/PC!,80,280,Overhead Position,160 range,Basic Overhead,Face of weld,is overhead!,0,Basic Overhead End View,Face of weld,is overhead,0,Overhead Partial Rotation End View,Face of weld,is overhead,0,Overhead,Maximum Rotation,End View,0,280,Face of weld on,This side,Overhead,Maximum,Opposite Rotation End View,0,280,80,Face of weld on,This side,Same Rotation in Isometric View,Basic Overhead,Face of weld,is overhead,0,Face of weld,is overhead,Overhead Partial Rotation Isometric View,0,Overhead Maximum Rotation Isometric View,0,280,Face of weld,On this side,Overhead Maximum,Opposite,Rotation Isometric View,0,280,80,Face of weld,is on this side,WWW.SPERKOENGINEERING.COM,Overhead PositionAxis Inclination,80,280,160 range,80 range,Basic Overhead for Inclined Axis,Face of weld,is overhead,0,Overhead Inclined Axis Rotation,0,0,Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,Overhead Inclined Axis Limit,0,80,Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,Overhead Inclined Axis Limit,0,80,Weld can rotate 360,about,vertical axis,while inclined 10,forward tilt.,Overhead Inclined Axis Limit,0,Weld can rotate about,The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about,The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about,The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about,The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about,The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about,The vertical axis,10,Overhead Inclined Axis Limit,0,Weld ends up back,Where it started!,10,仰焊位置,280,80,0,0,80,360,10,仰焊,4G,Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,Vertical Position Part 1,65 Range of Inclination,From 15 to 80.,Face of weld is up,15,80,Vertical Position Part 1,Range of inclination,Starts at 15,Face of weld is up,15,Vertical Position Part 1,Range of inclination,continues upward.,Greater than 15,Vertical Position Part 1,Until reaching 80,80,Vertical Position,Part 2,When the“E”portion,of the,diagram is reached,80,Vertical Position Part 2,The“E”portion,of the diagram-,360 Rotation,About vertical axis,80,Vertical Position Part 2,The“E”portion of the,diagram begins here.,.,80,Vertical Position Part 2,Partial rotation about,Vertical axis,Vertical Position Part 2,More rotation about,Vertical axis,Vertical Position Part 2,Even more rotation about,Vertical axis,Vertical Position Part 2,Rotated 180 about,Vertical axis,Vertical Position Part 2,Continuing Rotation about,Vertical axis,Vertical Position Part 2,Continuing Rotation about,Vertical axis,Vertical Position Part 2,Continuing Rotation about,Vertical axis,Vertical Position Part 2,360 of Rotation about,Vertical axis completed,Vertical Position Part 3,80,280,200 Range,of Rotation,Vertical Position Part 3,Start here with inclination,Uphill or Downhill 15,Face of weld upward,15,Vertical Position Part 3,Rotate face while holding,Inclination constant,15,Vertical Position Part 3,Continue rotating with,Inclination constant,15,Vertical Position Part 3,Rotated to vertical limit,Inclination constant,15,280,Vertical Position Part 3,Return to starting position,Uphill or Downhill 15,Face of weld upward,15,Vertical Position Part 3,Rotate face of weld,Opposite direction,Inclination Constant 15,15,Vertical Position Part 3,Continue rotating,Opposite direction,Inclination Constant 15,15,Vertical Position Part 3,Plate near vertical,Inclination Constant 15,15,Vertical Position Part 3,Plate at vertical limit,of rotation.,Inclination Constant 15,15,80,Vertical Position Part 3,80,280,200 Range of,Rotation inclined,Uphill or Downhill 15,15,Vertical Position Part 3,80,280,200 Range of Rotation,Inclination angle,Increases,Vertical Position Part 3,280,200 Range of Rotation,Inclination angle,Increases more.,80,Vertical PositionComposite,80,280,160 range,65,200,360,Welding Positions for,Fillet,Welds,Flat Fillet Weld,Horizontal Fillet Weld,Welding Positions for Fillet Welds,Welding Positions for Fillet Welds,Tabulation of Positions of Fillet Welds,Position,Diagram Reference,Inclination of Axis,Rotation of Face,FlatA0 to 15150 to 210,Horizontal,B0 to 15125 t0 150,210 to 235,OverheadC0 to 800 to125,235 to 360,VerticalD15 to 80125 to 235,E80 to 900 to 360,Welding Positions for,Fillet,Welds,The Horizontal Range,Is smaller for fillet welds,Than it is for groove welds,Welding Positions for,Groove,Welds,焊缝坡口的清理,UW-32,规定，坡口表面应清洁，无锈皮、锈、油、油脂、等其它有害物。,管接头及壳体的焊缝,UW-16(c&d),要求，安放式管接头（,abutting type,）必须采用全焊透结构。当全焊透结构不能用目视检查是否焊透，必须使用衬垫。插入式管接头可以采用角焊缝或未焊透结构，但，必须从容器的内外进行焊接。,UW-16.1,Section VIII Division 1,的焊接要求,UW-20,管子及管板的焊接,UW-20,条给出了三种管子与管板的焊缝结构，强度焊接、半强度焊接、密封焊接。强度焊用来承受全部轴向载荷；密封焊仅用于作为胀接的补充焊接，以保证密封；半强度焊是根据在实际设计条件下机械和热膨胀载荷来确定其强度的。,焊前准备,切割边必须光滑、清洁。（,UW-31,）,点焊焊缝、无论是去除，还是保留，都必须使用评定过的焊接工艺。（,UW-31,）,保留于焊缝中的点焊焊缝应由评定过的焊工施焊。（,UW-31,）,非受压件跨过受压焊缝与受压件相焊时，非受压件必须开槽以避让焊缝、或将受压焊缝磨平。（,UG-82,）,当受压件焊在受压焊缝上时，焊缝必须磨平。（,UG-82,）,UW-27,焊接方法,UW-27,规定，用于,Section VIII Division 1,的焊接方法有以下几类：,UW-27(a),弧焊或气焊,UW-27(b),压力焊,UW-27(d),销钉焊,UW-27(e),电渣焊,UW-27(f),电气焊,纵缝的排列,UW-9(d),对容器各筒节纵缝之间的排列规定了要求，即要求纵缝相互错开，相距至少是较厚板厚度的,5,倍，否则，焊缝两侧必须至少,4”,（,102 mm,）要求进行,RT,检验。,焊接限制,Section VIII,中关于焊接的两项限制是：,销钉焊仅用于非受压,/,非承载件的焊接；,电渣焊仅用于铁基和,UW-5(d),给出的奥氏体钢。,UW-28,焊接工艺评定,UW-28,给出了对焊接工艺进行评定的要求：,使用的焊接工艺必须有记录，也就是说必须有书面的焊接工艺。,当焊接受压,/,受力件、用手工或半自动焊方法焊接非受压,/,非受力件时，使用的焊接工艺应按,Section IX,进行评定。,当用机械焊方法焊接非受压,/,非承力件时，使用的焊接工艺可不按,Section IX,进行评定。,UW-29,焊工技能评定,焊接受压或受力件及受压件焊缝的焊工和焊接操作工，必须按,Section IX,进行技能评定。可以采用首次焊接的产品焊缝来进行技能评定，但必须仔细阅读规范，以确定是否有例外或限制。销钉焊必须在每个班开始时对焊工进行技能评定，但当采用自动焊方法焊接非受压或非受力件时，可不必进行技能评定试验。,Section IX,中的其它要求必须满足。,制造厂在焊接工艺评定方面的责任,制造厂,/ASME,持证厂的责任：,编写书面,WPS,；,焊接评定试板，编写焊接工艺评定记录；机械性能试验可由另一试验室进行；,列出焊接参数；,在,PQR,上记录焊接参数和试验结果；,制定,QC,体系以控制焊接评定；,对焊接质量负责；,焊接材料和母材冶金上的适应性。,UW-35,焊缝咬边,UW-35,讨论了纵缝和环缝的外观要求，其中提到角焊缝和坡口焊缝，其焊接后不得使母材的厚度减薄到低于最小要求厚度。另外，减薄量不得超过母材公称厚度的,10%,（最大不超过,0.8 mm,）。,Table UW-35,规定了焊缝的最大补强高。,UW-35,焊缝余高,母材公称厚度（,mm,）,B,、,C,类对接焊缝（,mm,）,其它焊缝（,mm,）,2.4,2.4,0.79,2.4 4.8,3.2,1.6,4.8 12.7,4.0,2.4,12.7 25.4,4.8,2.4,25.4 50.8,6.4,3.2,50.8 76.2,6.4,4.0,76.2 101.6,6.4,5.6,101.6 127,6.4,6.4,127,7.9,7.9,焊缝余高的打磨,余高角度对疲劳强度的影响,焊缝外观，,UHT-84,同样，制造规范产品时必须查阅规范的各个部分。在,UHT-84,中给出了一个特殊制造要求，它应取代,Part UW,予以优先执行。,UHT-84,规定，,UW-35,的要求必须满足，但对于,SA-517,除外。此材料的焊缝余高不得超过板厚的,10%,（最大不超过,3.8 mm,），不允许有任何咬边。,一般要求,如果焊缝余高过高，简单地打磨焊缝的顶部还不能满足要求，因为，打磨焊缝余高的目的是为了减少母材及焊缝之间的夹角。焊缝的余高必须与母材圆滑过渡。,UW-36,要求角焊缝应完全焊透。,UW-38,给出要求去除焊缝的缺陷。,UW-39,给出了时常在焊接工艺中忽略的操作，即敲击。敲击是用来控制变形、消除应力和提高焊接质量的手段，因此，应在,WPS,里予以说明。,产品焊接的控制,对于受压材料的焊接，制造厂必须：,按照流转卡或图纸上规定的、经评定过的,WPS,进行焊接；,使用评定过的焊工和焊接操作工；,使用,WPS,上规定的焊接材料；,在焊接过的焊缝上或旁边打上焊工钢印，或记录焊工钢印；,检查焊缝是否有缺陷；,进行要求的,NDE,。,在焊缝上或靠近焊缝开孔,UW-14,允许在焊缝上开孔，但须满足以下要求：,开孔必须符合,UG-37,的补强要求；,开孔符合,UG-36(c)(3),、但不符合,UG-37,，若此环缝在距离开孔,3,倍于开孔直径的范围内进行,RT,检验，此开孔可以开在环缝上。,按,UG-36(c)(3),不需要开孔补强的开孔，当开在焊缝附近时，如果板厚等于或小于,1.5”,（,38 mm,），此开孔必须距离焊缝至少,0.5”,（,19 mm,）。,推荐的焊材保存条件,Section II Part C,中给出了焊材的推荐保存要求。,由于各制造厂的焊材存在差异，因此，应向焊条制造厂询问具体的烘干要求。,谢谢大家！,结 语,