焊接培训资料WeldingtheorytrainingPPT课件.pptx

Welding theory焊接理接理论AreasAreas领域域Inthistrainingwewillcoverthemostgeneralareasof:在这个训练中,我们将介绍最通用的领域：Weldingtypes焊接类型Standards&Classes标准&级别Weldingpositions焊接位置Weldingsymbols焊接代号Calculations计算QualityAssurance质量保证2精品课件Typesofwelding类型的型的焊接接Fusion weldingisagenerictermforweldingprocesses熔焊焊接过程是一个通用的术语.thatrelyuponmeltingtojoinmaterialsofsimilar类似的,依靠融化加入材料.compositionsandmeltingpoints.成分和熔化点。3精品课件Typesofwelding类型的焊接Consumableelectrodefluxcoated自耗电极磁通涂MMA-ManualMetalArc(stickwelding)MMA-手动金属电弧(粘焊)CarbonDioxide(Amixbetweenargonandcarbondioxideisnormal)二氧化碳(氩气和二氧化碳之间的混合是正常的)MAG-MetalActiveGas杂志-金属活性气体Argon,Helium氩、氦MIG-MetalInertGas米格-金属惰性气体Argon,Helium氩、氦TIGTungstenInertGasTIG(钨极惰性气体4精品课件Standards 标准准ISO5817Qualitylevelsforimperfections缺陷质量分级ISO4063ReferenceNumbersforWeldingmethods焊接方法的参考数据ISO3834-01,-02,-03,-04Qualityrequirementsforfusionwelding.熔焊质量要求ISO9606Qualificationtestforwelders对焊工资格考试ISO2553Welded,brazedandsolderedjoints焊接,焊接和焊接接头symbolicrepresentationondrawings符号表示，图纸ISO17635Non-destructivetestingofwelds.Generalrulesfor焊缝的无损检验，一般规则metallicmaterials金属材料(AcceptancelevelscannotbeadirectinterpretationofthequalitylevelsdefinedinISO5817orISO10042.Theyarelinkedtotheoverallqualityoftheproducedbatchofwelds.).andmanymore其他，更多Welding is controlled by a numbers of Standards.焊接由数字控制的标准5精品课件Standards标准准Whydoweneedstandards?为什么我们需要标准ReduceRisk减小风险Moresustainable更可持续Improvingperformance性能提升6精品课件Weldingclasses焊 接 类General 一般一般Weldingclassasfollowing:焊接类如下SS-ENISO5817forferritematerialandstainlesssteel.对铁氧体材料和不锈钢SS-ENISO5817。SS-ENISO10042foraluminium.为铝SS-ENISO10042。Acceptanceboundary,discontinuitiesandformdeviations,seeSS-ENISO6520-1,接受边界、断层和偏差,看到SS-ENISO6520-1,table1.Welding class B 焊接类BThetransitionbetweentheweldandthebasematerialshallbeeven,andshallnot焊接和基材之间的过渡应均匀,不得haveanysharpnotches.Cratersshallbefilledinandunevennessesshallberemoved.有任何锋利的等级。陨石坑应当填写,不应删除Theweldfaceandrootfaceofbuttjointsshallhaveaplaneorslightlyconvexform.对接接头的焊缝表面和根面有一架飞机或略凸的形式Cornerjointsshallbeconvexontheoutsideandinthemainconcaveorplaneontheinside.角接头应在主凹或凸在外面和飞机TheweldfaceofT-jointsshallpreferablyhaveaconcaveorplaneform,butaslightlyconvexformisacceptable.丁字接头的焊接面最好是有一个凹形或平面形式,但略凸形式是可以接受的ThehomogeneityoftheweldshallinthemainmeettherequirementsofX-rayclass焊缝应均匀性的主要满足x射线类的要求4(blue).However,internalporesanddiscreteinclusions(slag,heavymetals,oxidesandshrinkagecavities)meetingtherequirementsofX-rayclass3(green)areacceptable.蓝色)。然而,内部孔隙和离散夹杂物(矿渣、重金属、氧化物和收缩蛀牙)会议的要求x射线3班(绿色)是可以接受的。Forfilletweldsthethroatthicknessashallnotbelessthanthatstated.填角焊的焊接厚度不得少于规定。7精品课件Welding class C焊接类CHighweldingreinforcement,highrootreinforcement,visiblerootdefectsandsharpnotchesarenotpermitted.焊接加固高、根钢筋,可见根缺陷和锋利的等级是不允许的.T-jointsandcornerjointsweldedfromoneside(rootsideinaccessible)may,however,haveamoderatenotchontherootside.从一侧丁字接头和角接头焊接(根端访问),然而,有一个温和的切口在根端.ThehomogeneityofweldshallinthemainmeettherequirementsofX-rayclass3(green)accordingtotheIIWX-rayatlas.焊缝应均匀性的x射线的主要满足要求3班(绿色)根据IIWx射线地图集。Forfilletweldsthethroatthicknessashallnotbelessthanthatstated.填角焊的焊接厚度不得少于规定。Welding class D 焊接类DThesurfaceoftheweldshallbefreefromsignificantsurfacecavities,externalpores,penetrationsandoverlappedwelds.Visiblecracksandsimilardefectsarenotpermitted.焊缝表面应无明显表面蛀牙,外部毛孔,穿透及重叠焊。可见裂缝和类似的缺陷是不允许的。Forfilletweldsthethroatthicknessashallnotbelessthanthatstated.填角焊的焊接厚度不得少于规定。Weldingclasses焊接类vClass Cisthedefaultclassifadrawingismissingweldclassinformation!C类是默认焊接信息。8精品课件ReferenceNumbersforWeldingmethods焊接方法的参考数据接方法的参考数据111Manualmetalarcwelding手动金属电弧焊114Self-shieldedtubular-coredarcwelding管状空心电弧焊121Submergedarcweldingwithsolidwireelectrode(partlymechanised)与固体电极丝埋弧焊(部分机械化)125Submergedarcweldingwithtubularcoredelectrode(partlymechanised)埋弧焊用管状空心电极(部分机械化)131MIGweldingwithsolidwireelectrodeMIG焊接与固体电极丝135MAGweldingwithsolidwireelectrodeMAG焊接与固体电极丝136MAGweldingwithfluxcoredelectrodesMAG焊接通量空心电极138MAGweldingwithmetalcoredelectrodeMAG焊接用金属空心电极141TIGweldingwithsolidfillermaterial钨极惰性气体保护电弧焊与固体填充材料142AutogenousTIGwelding自钨极惰性气体保护电弧焊143TIGweldingwithtubularcoredfillermaterial钨极惰性气体保护电弧焊与管状空心填充材料145TIGweldingusingreducinggasandsolidfillermaterial(wire/rod)钨极惰性气体保护电弧焊用减少气体和固体填充材料(钢丝/杆)15Plasmaarcwelding等离子弧焊；等离子电弧焊接311Oxy-acetylenewelding氧-乙炔焊*NOTETheprinciplesofthisstandardmaybeappliedtootherfusionweldingprocesses.注意这个标准的原则可能适用于其他熔焊过程。Thisstandardcoversthefollowingmanualorpartlymechanizedweldingprocesses(referencenumbersofweldingprocessesforsymbolicrepresentationsarelistedinISO4063):这个标准涵盖以下手册或部分机械化焊接过程焊接过程(参考数字符号表示ISO4063中列出):9精品课件VisapistolpositionerWeldGunPositions焊接接枪位置位置Example1:例子1：10精品课件WeldGunPositions焊接接枪位置位置Example2:例子2：11精品课件qAfallingweldshallbeavoidedasfaraspossible!q焊缝应尽可能避免下跌!qTheweldgunshouldbeslightlypointedtowardsthethickestmaterial.Thispreventsundercuts.q焊接枪应该稍微指向最厚的材料。这可以防止削弱。qAgunthatispointedawayfromtheweldwillmaketheprotectivegastoflowawayfromtheweld-pool.q一把枪,指着离焊缝将使保护气体流向焊池。WeldGunPositions焊接枪位置12精品课件Symbols符号13精品课件1.Weldmethod:141=TIGwithsolidfilermaterial.焊接方法:141=TIG固体产品材料。2.Weldclass=ClassC焊接类=C类3.DesignThroatthickness=weldmeasurement2mm.设计焊接厚度=焊缝测量2毫米。4.Filletweld角焊缝5.Weldedallaround沿周边焊接的12345Symbols符号14精品课件Symbols符号15精品课件Symbols符号Atringleonthereferenceline:Atringleonthereferenceline:支撑杆参考线SpecifiesafilletweldonthearrowsideofSpecifiesafilletweldonthearrowsideofthejointthejoint指定一个角焊缝箭头的一面Atringleonthereferenceline:Atringleonthereferenceline:支撑杆参考线SpecifiesafilletweldontheothersideofSpecifiesafilletweldontheothersideofThejointThejoint指定一个角焊缝接头的另一边16精品课件4.7.3Multiplereferencelines多个参考线Twoormorereferencelineclosesttoindicateaseriesofoperations.Theoperationshallbespecifiedonthereferencelineclosesttothearrowhead.Subsequentoperationsshallbespecifiedsequentiallyontheotherreferencelines(seeFigure6)两个或两个以上的参考线接近显示一系列的操作。在指定的操作应当参考线箭头。后续操作顺序应当指定其他参考线(参见图6)NOTEForjointsrequiringmorethanoneweldtype,combinedsymbolsmayalsobeused(seeTable2)注意关节需要不止一个焊缝类型,结合符号也可以使用(见表二)a)SystemA-Arrowside(symbolonsolidcomponentofreferenceline)b)方法A-A箭头(符号参考线）C)SystemB-Arrowside(symbolbelowreferenceline)C)方法B-A箭头(符号下面的参考线)b)SystemA-otherside(symbolondashedcomponentofreferenceline)b)方法A-O箭头(符号参考线）B)SystemB-otherside(symbolabovereferenceline)B)方法B-O箭头(符号参考线）e)Sameweldproducedusingfouroptionsa)tod)e)相同的焊接生产使用四个选项)d)17精品课件Terminology术语WELD DRA WING TERMlNOLOGY:焊缝半径标注Weldleg焊脚Weldface焊缝表面Weldthroat焊缝厚度Weldgrooveradius焊缝坡口半径Rootopening（grooveweld)根部间隙(坡口焊)Weldrootface焊根的脸Weldgrooveangle焊缝坡口角度(A)FILLET WELDS 角角焊缝(B)GROOVE WELDS 坡口坡口焊缝THROAT焊高LEGSIZE焊脚尺寸FACE斜面BEVELANGLE边缘斜截角GROOVEANGLEV坡口角度LEGSIZE焊脚尺寸GROOVERADIUS根部半径ROOTOPENING根部间隙ROOTFACE根面THICKNESS厚度18精品课件a nominalthroatthicknessofthefilletweld(seealsoISO2553)角焊缝的焊缝名义厚度(参见ISO2553)A areasurroundingthegaspores周围气体毛孔B widthofweldreinforcement焊缝补强的宽度d diameterofgaspore气体孔隙直径dAdiameterofareasurroundingthegaspores直径周围气体的毛孔h heightorwidthofimperfection缺陷的高度或宽度l lengthofimperfectioninlongitudinaldirectionoftheweld焊缝缺陷在纵向方向上的长度lplengthofprojectedorcross-sectionalarea投影长度和横截面积s nominalbuttweldthickness(seealsoISO2553)名义上的对接焊缝厚度(见ISO2553)t wallorplatethickness(nominalsize)墙或板厚度(公称尺寸)wpwidthoftheweldorwidthorheightofthecross-sectionalarea焊缝的宽度或宽度或高度的横截面积z leglengthofafilletweld(seealsoISO2553)角焊缝的焊脚长度(参见ISO2553)angleofweldtoe角焊缝趾 angleofangularmisalignment角的角位移i penetrationinfilletwelds渗透在填角焊r radiusofweldtoe焊趾半径Terminology术语SymbolsinISO5817符号ISO581719精品课件Edgepreparation坡口准坡口准备TYPESOFBUTTWELDSSYMBOLIZATION类型的对接焊缝编号Thecommontypesofedgeprepartionassociatedwithabuttweldareindicatedasfollows:常见的边缘制作与对接焊缝表示如下:Squareedgepreparation直角边缘准备Singlevpreparation单边（v型）的准备Doublevpreparation双边（v型）的准备SingleUpreparation单边（U型）的准备DoubleUpreparation双边（U型）的准备Insomecasesofjointpreparation,onlyonepartisprepared,e.g.singlebevelbuttorsinglejbuttlnthesecases,thearrowpointsattheedgetobeprepared.Theverticaluprightofthesymbolisalwaystotheleftonthereferenceline.在某些情况下共同准备,只有一个部分是准备,如单斜对接或单j对接这些情况下,箭头指向边缘做好准备。垂直直立的符号总是左参考线。20精品课件Edgepreparation坡口准备21精品课件Intrusion熔深22精品课件DimensionsandCalculation尺寸尺寸计算算DIMENSIONINGOFFILLETWELDS尺寸标注的填角焊EN22553requirementsEN22553的需求a=designthroatthicknessa=设计厚度规则:设计焊接厚度(a)=腿长度x0.7(“z”)。Z=leglengthZ=脚高长度S=actualthroatthicknessS=实际焊接熔深Theleglengthofafilletweldislocaedtotheleftoftheweldsymbol(triangle).Thedimensionisinmillimetersprecededwiththeletter“z”.lfnoletterisshownonadrawing,thenassumethedimensionisleglength.角焊缝的焊脚长度是轨迹焊接符号的左边(三角形)。前面尺寸在毫米以字母“z”。如果没有显示在绘图的信,然后假设维度是腿的长度。TheEuropeansystemusesmainlythe“a”value,whiletheAmericanoneusesthe“z”value.欧洲主要系统使用“a”值,虽然美国人使用“z”值.10mmleglengthFilletweld10毫米腿角焊缝长度Asrule:DesignThroatThickness(“a”)=LegLength(“z”)x0.7.规则:设计焊接厚度(a)=腿高长度x0.7(“z”)。filletweldwith7mmdesignthroatthickness角焊缝和焊缝设计厚度7毫米23精品课件DimensionsandCalculation尺寸尺寸计算算“z”measurment=a x 1,4“z”测量=ax1,4“a”measurment=z x 0,7“a”测量=zx0、7Calulationofa(throat)canalsobedonewith:计算(喉咙)也可以用:z+z/2x0.7=a(throat)z+z/20.7=a(喉咙)24精品课件Calculateimperfections:STD5817-B计算缺陷:ISO5817-BFormula:a x 0,15+1=1,9公式:ax0,15+1=1,9Calculation:6 x 0,15+1=1,9计算:6x0,15+1=1,9Explanation:a isthroatthicknesse.ga6,thetotalthroatthicknessis8mm.Thismeansthatthedeviationis(h)2mm.ButtheSTDallowssometolerance,whichthecalculationgivesus,1,9mm.解释:一个是焊接厚度e。ga6,焊缝的总厚度是8毫米。这意味着,偏差(h)2毫米,但允许一些放宽计算,1.9毫米。Sothetotalthroatthicknesscanbe(a)6mm+(h)1,9mm=7,9mm所以总焊接厚度可以(a)6毫米+(h)1,9毫米=7,9毫米Butsincethemeasurementistotal8mm,thethroatis0,1mmtohigh.NOK!但由于测量总8毫米,喉为0,1毫米高。NOK！*hint:calculate”backwards”提示:计算工式“由后向前计算”Imperfections不完整性CBD25精品课件计算实例Pleasetakenotesandwritedownyouranswersandhowyoucametothespecificconclusion.请做笔做笔记,写下你的答案写下你的答案Theanswerisrightinfrontofyou你面前的答案是正确的Save them for your own reference!留作自己的参考!CalculateImperfections计算的不完美算的不完美26精品课件CalculateImperfections计算的不完美算的不完美Example1.例子1.perfect:ExcessWeldmetal完美的:焊缝余高Weldclass:C焊缝级别：Cb measuredtobe16mmb测量16毫米h measuredtobe3.1mmh测量3.1毫米Allowed excess weld h=3,4 mm允许多余的焊接余高=3，4毫米APPROVED被认可的D DB BC C27精品课件CalculateImperfections计算的不完美算的不完美D DC CB BExampIe2.例子2.Imperfection(fault):Excessivethroatthickness不完美的（缺陷）：角焊缝填充金属过厚Weldclass:B焊缝级别：Ba measuredtobe 5mm(a5ondrawing)a测量是5毫米(a5图纸)h measuredtobe3mmh测量3毫米total8mm总高8毫米Allowed throat thickness=1,75 mm(total 6,75 mm)1,25mmovertolerance.允许焊接厚度（余高）=1,75毫米(总6.75毫米)1、25毫米公差。NOT APPROVED不被肯定28精品课件CalculateImperfections计算的不完美算的不完美Exampel3.例子3.Imperfection(fault):Excessiveasymmetryoffilletweld(unevenleglength)不完美（缺陷）：过度的不对称角焊缝(不等长)Weldclass:B焊接类:Ba measuredtobe6mm(a6ondrawing)a一个测量6毫米(a6图纸)Z 2 measuredtobe 8,5mmZ2测量8、5毫米h measuredtobe2,5mmh测量是2、5毫米Allowed excess asymmetry h=2,4 mm(total 8,4 mm)0,1 mm over tolerance允许多余的不对称h=2,4毫米(8,4毫米)0,1毫米公差NOT APPROVED不被肯定D DC CB B29精品课件ValidationandQualityAssurance验证和和质量保量保证30精品课件ValidationandQualityAssurance验证和和质量保量保证Supplierrecommendations/requirements:供应商建议/要求:RighteducationTheory&Practical正确的教育理论与实践oWhattrainingdidthewelderget?焊机得到了什么培训？oWhoapprovedit?谁批准了吗?oWasitbasedonanyISOorsimilarstandards?它是基于ISO或类似的标准吗?Internalcontrolplans.BasedonstdsISO5817,ISO9606andISO2553.内部控制内部控制计划。基于划。基于stdstd的的ISO5817 ISO9606 ISO2553ISO5817 ISO9606 ISO2553。oIseverypartchecked?检查每一部分吗?oWhodoesthecontrol?谁控制?oIsthecontrolplancorrespondingtothestandards?与标准相对应的控制计划吗？EquipmentvalidationRightequipment,rightmaterial,correctmachinesettings.设备验证,对设备、材料,正确的机器设置。oArethesameweldingmachineallwaysusedforthesameproduct?是相同的焊接机一直使用同样的产品？oArethesettings(current,wirefeedingetc)documentedandsavedasreferenceforthenexttime?o设置(电流、送丝等)记录和保存为参考下次？oWhoverifymachinesettings?谁验证机设置?Deviationcontrol控制偏差oWhattodowithpartsthatarewrong?如何处理部分是错误的?oDidthemachinehavetherightsettings?这台机器有正确的设置吗?oIsthestockblockedandallpartsre-checked?焊机阻塞和所有部件进行复核?oWhatSTDsareusedtovalidateanydeviation?缺陷的用于验证偏差吗?31精品课件Defects不合格Inspection检查Scrap报废Rewritingoperatorinstructions重写操作指令Rework重做Unnecessaryprocedures非必要的操作Extraoperations(touchup,trimmingetc.)额外的操作(返工、返修等。)Inapropriateworkinstructions工作指令Equipementfailures设备故障Timelostduetoaccidents由于事故失去时间RushDeliveryCost拿什交付成本Productfieldfailure产品现场故障ExcessInventory过量库存Latedelivery延期交货Idletime停工时间Costoflostsales销售损失成本Retrofitcosts改造成本ComplaintInvestigationcost投诉调查成本32精品课件3/18/2024精品课件33