焊缝分类及其检验

TA015-000 A2/14 操作条件：包括焊缝工艺，操作者的资质，填充金属及车间的质量认证等。Operation condition: includes the welding procedure, qualification of welder, filler metal and qualification of workshop. 检验条件。 Inspection condition焊接手册规定了部分重要件的相关焊接接头的条件，并规定了其选则的等级，位置，准备及焊接。 “Welding book” for main parts, specifies conditions for related weld joints as well as the selected class, position and preparation and weld. 3 焊缝级别/ Weld class4.1 焊缝级别的划分/ Number of classes焊缝级别共分4级，用数字1至4表示，其中1级最严。There are 4 classes that are numbered from 1 to 4. Class 1 is the most severe. 3.2 焊缝级别的说明/ Definition of classes 1级焊缝/ Class 1用于那些要求符合安全规则、应力大、有振动且有脆断危险的构件上的主要焊缝。1级焊缝应进行100%的射线检验(RT)或超声波检验(UT).Main welds on workpiece conforming to safety regulations subjected to high stresses, vibrations, and risks of brittle fracture. 100% RT or UT must be done on welds of this class. 2级焊缝/ Class 2用于要求符合安全规则，但不如1级那样要求严格的主要焊缝。本级焊缝将做10%抽 样射线检验 (RT) 或超声波检验(UT)，如发现缺陷，自动增加检验比例。Main welds on workpiece conforming to safety regulations, but less stringent than class 1. 10% RT or UT should be done on welds of this class. Identification of defects will increase percentage of examination automatically. 3级焊缝/ Class 3要求部分焊透或完全焊透的对接或角接的焊缝，对这些焊缝将对第一层(道)焊缝做目视检查，对钝边处做无损探伤抽样检验。Butt or fillet weld that is required partial or complete penetration. For these welds, visual inspection should be done only for the first run, non-destructive spot check should be done for root face. 4级焊缝/ Class 4所有承受较小应力的其它焊缝。All other welds subjected to small loadings.4.3 焊缝级别的选择/ Choice of weld class根据合同文件或公司焊缝级别标准由设计部门确定。焊缝级别的选择应考虑以下因素：Design office will select the weld class according to the contract and internal standard of TAH, in the absence of such document, to the following criteria: 安全性：焊缝接头断裂对人员、设备以及周围环境的影响。 Safety: effect on people, equipment and environment due to failure of the weld jointTA015-000 A 3/14 成本：选择焊缝级别时，必须考虑此因素。Cost: an important consideration when choosing the weld class 载荷性质、强度。Load: nature and intensity of load 接头匹配类型。Joint type 修复的困难程度。Difficulty of repairing一个焊接件可以包括不同级别的焊缝 。One weldment can consist of welds of different classes.一条焊缝在其长度或厚度上可以包括不同的级别(中部1/3处，外部1/3处)，设计应在 图纸上标明不同的部分。One weld may involve several classes over its length or thickness (middle third, external third). Detail should be shown on the drawings.5 每一个级别焊缝的检验及操作条件(见表1)Inspection and execution conditions for each weld class (see table 1)5.1 焊缝的检验要求说明/ Specification of require of welds inspection5.1.1 检验的类型(超声、射线)应在检验程序上或图纸上注明。它由材料类型、厚度、几何外型及焊缝坡口来决定。Type of(UTorRT) inspection should be specified in the quality inspection plan or drawing. It depends on the material involved type, thickness and geometry as well as weld groove.5.1.2 除非在图纸上另有说明，对所有等级的焊缝，最终检验在热处理之后进行。For all welds of different classes, final inspection should be carried out after heat treatment unless otherwise specified on drawing.5.1.3 除非在合同中另有说明，抽样检验必须包括所有节点，且检验长度至少为每个焊工或 焊接操作工所焊焊缝的10%，当两个或两个以上的焊工或焊接操作工在一个接头上分别施焊 多层焊道、或双面对接接头的两面时，一处抽样检验可代表所有焊工或焊接操作工的焊接工作质量。Spot check must cover all nodes and include at least 10% the of length of each weld welded by each worker unless otherwise specified. If two or more welders carry out multi-layer passes or double-side-groove butt joint welding on one joint, result of spot check on one place can stand for quality of everywhere of the joint.5.1.4 抽样检验的位置的确定： The location of the spot check is defined by: 对于合同中要求的检验由客户代表定。 Clients representative in the case of inspections required in the Contract. 对于公司内部要求的检验，由公司的检验部门确定。 Inspection department of TAH in the case of inspections required by TAH.5.1.5 当发现缺陷超过规定数值时，在缺陷的两侧进行同样长度的检验。在这次检验中，发现的缺陷不超过规定值且第一次发现的缺陷已被修复，则整个焊缝通过验收。否则，对该焊工所焊的整条焊缝进行检验。TA015-000 A 4/14When defects exceeding the tolerances are disclosed, additional checking over an area of the same length should be carried out on both sides of the defective area. During the additional check, if there are no defects exceeding specified tolerances, the original defects have been repaired satisfactionary, the whole weld will be accepted. Otherwise, the whole weld welded by the welder will be checked. 5.1.6 对于有钝边的3级焊缝，应进行下列检验：For weld of class 3 with root face, the following should be done: 目视检查第一道焊缝。 Visual inspection for the first run. 用着色(PT)或磁粉(MT)检验来检验焊缝是否合格,如设计上无特殊要求,检验范围为焊缝长的10%。If there is no special requirement on design the scope of PTor MT inspect is 10% of length of weld. 5.1.7 对于角焊缝 ，在热处理之前先做着色探伤检验。 For fillet weld, PT should be carried out prior to heat treatment.TA015-000 A 5/14 表1/table1检验要求 execution conditions焊缝等级/ weld class1234依据标准standard操作者资格认证Qualification of welder有/ Yes有/ Yes有/YesASME IX 焊接工艺过程评定Qualification of welding procedure有/ Yes有/ Yes有/YesASME IX试样的机械性能试验Mechanical performance test on test piece按合同文件进行As per contract无/ None无/ NoneASME IX坡口检验Groove inspection有/ Yes无/ None 6焊接过程中Inspection during welding根部清根着色或磁粉检测/ PT or MT after back gouging目视检测Visual inspection无/ NoneASME 焊完后的焊缝检查/ Welds inspection post welding目视检查Visual Inspection after welding有/ Yes有/ Yes有/ Yes有/ Yes尺寸检验Dimensional inspection有/ Yes有/ Yes有/ Yes抽样检验 Spot check超声/射线检验UT or RT100%抽样检验 Spot check无/ None 无/ None着色或磁粉检验PT or MT100%100%抽样检验Spot check无/ None 注：对于1，2级焊缝，如无具体说明焊缝检验(超声/射线)执行超声检验。 If no specified specification weld inspection(UTorRT) is to be carried out by UT for weld class1,class2.6. 焊缝的坡口检验(见表2)/ Inspection of weld groove (see table 2) 如果在坡口上发现缺陷，依据本标准第8节修理。 If there are defects on the groove which need to be repaired in accordance with the rules of weld requirement of paragraph 8.TA015-000 A6/14表2 / table2检验要求Inspection焊缝级别/ Class123尺寸/ Dimensions坡口角度a公差Tolerance of groove angle (a)10%无背面焊缝的钝边尺寸(e)的公差Tolerane of root face size (e) For wild without sealing run1如dt/4,必须有斜面过渡长度为4d,粗糙度Ra=12.5mm；过渡长m可包括焊缝宽渡；无斜面过渡时,允许的最大值: t100时，d为3mm；t100时,d为4mm.Compulsory for all class 3 weld, if d t/4 Length 4dRoughness Ra=12,5mm；Length of required taper m which may include the width of the weld.斜面和坡口面Bevel and groove切割缺陷Cutting defects必须由合格的焊工修复。Compulsory repairs by qualified welders only表面/ Surface坡口两侧的表面宽度大于20mm范围内，应铲磨或喷丸清理干净氧化皮,油漆，油脂。Removal of scale ，painting, grease by grinding or shot blasting over 20mm width of workpiece surface on each side of groove.粗糙度/ Roughness磨或机加工：/ Grinding or machining： Ra=12.5mm目视检查Visual inspection必须/ Compulsory无损探伤检验/ NDT test铸钢/cast steel着色或磁份探伤检验PT or MTGB9443-88GB7233-87and according to related standardGB9443-88GB7233-87and according to related standardGB9443-88GB7233-87and according to related standard超声波探伤检验/UT射线探伤检验/RT板材、锻件/ plate or forging着色探伤检验/PT所有厚度必须检验Compulsoryt 50必须检验Compulsory for thickness50目视检验，如怀疑的话In the case of doubt during visual examination超声波探伤检验/UTGB2970-91,GB6402-91及相关标准and according to related standard说明：由铸钢制造者检验，进厂后按设计要求标准进行复验。NDT inspection shall be done at manufacturer site. After receipt, shall take receipt inspection by design requirement at TAH.超声波检验由钢板(锻件)生产者依据合同要求进行检验，进厂后复验。UT is carried out at steel makers factory in accordance with requirements of contract, and TAH will perform re-inspection after receive the material.TA015-000 A7/14 表三/table 3检验要求Inspection焊缝级别/ Classes1234纵向焊缝longitudianl weldb t/20bmax.=3b t/20bmax.=3b t/20bmax.=4b t/20bmax.=8c t/10c max.=3c t/10c max.=3c t/10+1c max.=4c t/10+1c max.=8圆周焊缝 Girth weldb t/20+1bmax.=4b t/20+1bmax.=4b t/20+1bmax.=5b t/20+1bmax.=9c t/10+1c max.=4c t/10+1c max.=4c t/10+1c max.=5c t/10+1c max.=9 h1 1L1 10 h1 1 L1 5 h1 1 L1 5 h1 1 L1 3对纵焊缝 h/L 1/4对环焊缝 h/L 1/3当焊缝宽度L20 Smax=3当焊缝宽度L$20mm S1+L/10 Smax=5ge/10+1gmax=3ge/10+1gmax=4ge/10+2 gmax=5ge/10+3 gmax=6e=0et/10emax.=4对仰焊焊缝et/10emax.=1et/10emax.=2K0.5K1m1=0m10.5长10 m10.5长20m11说明：(1) 除非特殊说明，管道内所有横切水流方向的焊缝，焊缝余高必须限制在2mm内，未焊 满应限制在t/10内且最大值 为2mm.(2)7. 接头验收标准/ Acceptance criteria of welding joint7.1 目视检查：外形-尺寸/ Visual inspection: appearance dimensions7.1.1 对接焊缝(见表三)/ But weld (see table 3)TA015-000 A8/14表5/table 5检验要求/ Inspection级别/ Classes1234典型焊缝/ Typical joint要求焊透的焊缝Full penetration weld有钝边的焊缝Weld with root faceJ t/20+2Jmax=4J t/20+2Jmax=5t为两工件中较小的厚度t= smaller thickness0.7h1/h21.4无要求Without requirement测量g值大于或等于图纸尺寸(说明) Measured size “g”: size on drawing sg/5sg/4sg/3无要求Without requirementKt/20KMax=0.5Kt/20KMax=1Kt/20KMax=1Kt/20KMax=1t 为两工件中较小的厚度t= smaller thickness说明：(1) 对于可宏观检查熔深的焊缝，焊喉的尺寸可降低与熔深相当的量，但降 低的最大值为2mm. In so far as penetration can be proven by macrographic test. the throat thickness may be reduced by the amount of this penetration, with maximum of 2mm.(2) 对于高载荷区域，图纸上标明K=0。(例如：固定导叶与座环的焊接)For some welds subjected to high load, k=0 should be specified on drawing (for example: weld between stay-vane/ring and stay ring)Unless otherwise stated,in all welds located in water ducts transverse to the flow direction:weld reinforcement is limited to +2mm and incomplete filling is limited to e/10 with a maxinum of 2 mm.(2) 对于高载荷件的焊缝 ，设计部门应提出要求，(例如：k=0 等)，并在图纸上标明。For some welds subjected to high load, design office should specify on drawing (for example: k=0).7.1.2 T型接头(见表5)/ T-joints (see table 5)TA015-000 A9/14t3mmt/103mmt6mm0.4mm6mm50mm1.5mm7.2 无损探伤/ NDT7.2.1 射线检验/ RT 焊缝的射线照相显示出下列条型显示缺陷特征应判定为不合格，应按8“焊缝修复规则”进行返修，并重新进行射线照相。Indications of the following strip type are unacceptable, and should be repaired according to 8 . Regulations about how to repair weld, and re-tested by RT.(1) 任何显示特征为裂纹或未熔合或未焊透的区域。Any are with indications of crack or lack of fusion.(2) 任何其它条型显示长度大于下列值: Any strip shape indications whose size are greater than the following value s are to be considered: 6.3mm 当t 19mm 6.3mm for t57mm 19mm for t57mm其中:t=除去允许的焊缝余高后的焊缝厚度,对于两不等厚零件的对接焊缝,t 等于两者 中较薄者,若全焊透焊缝包括角焊缝,则该角焊的厚度应计入t内。Where: t=weld thickness, exclusive of allowable reinforcement; for butt joint weld, t=the smaller thickness; for full penetration weld, inclusive of fillet weld, t includes weld throat. (3) 任何在一直线上的显示在12t的长度内累计长度小于t者，但相邻缺陷间的间距超出6倍者除外，被认为是一个连续缺陷。 Aggregate length of inclusion small than t orT for a welded length of:12t.twe inclusionAre considered as a single continuous defect when separated by a distance small than:6 times the length of the smaller inclusion. 焊缝中圆形显示的验收标准Acceptance criterion for round indications(1) 圆形显示是指射线照片上最大长度等于或小于三倍宽度的显示。这些显示可以是圆形、椭圆形、圆锥形或不规则形状，还可以带有尾部。当评定一个显示的大小时，应该包括该尾部。显示可能有焊缝 中的任何缺陷产生，例如：气孔、夹杂或加钨。Round indication is indication with maximum length that is less than 3 times of width. Round indication can be round, ellipse, cone and irregular shape, and sometimes, it can have a tail. When decide size of an indication, its tail should be included. Indications can be different kinds of defects, such as porosity, slag and tungsten inclusion etc. (2) 只有超过下列尺寸的圆形显示才计作缺陷： Only indications with the following size can be considered as defects:TA015-000 A10/14其中：t=除去允许的焊缝余高后的焊缝厚度，对于两不等厚零件的对接焊缝，t等于两者中较薄者， 若全焊透焊缝包括角焊缝，则该角焊缝的厚度应计入t内。Where: t=weld thickness, exclusive of allowable reinforcement; for butt joint weld, t=the smaller thickness; for full penetration weld, inclusive of fillet weld, t includes weld throat. (3) 任何显示的最大许可尺寸应为t/4和4mm中的较小者。但与相邻显示相距25.4mm或 更远的单个显示例外，它可以等于t/3和6mm中的较小者。对t大于50mm，单个显示的最大许可尺寸应增加到9mm.For any indication with the greatest size over e/4 with a maximum of 4mm is unacceptable.for indication separated by more than 25mm from the next one: maximum allowed size : for e50 t/3 with max=6; for e 50 max=9.(4) 在长度等于12t内显示各直径的总和小于t时，线状排列圆形显示是合格的。图示参见 ASME VIII 附录4。For aggregate length of indications of 12t, if sum of diameters of each indication is less than t, round indications with linear array is qualified. See ASME VIII Appendix 4.(5) 相邻圆形显示之间的距离不是决定验收或拒收的因素，但对单个显示或各组线状排列的显示距离的要求除外。Distance between two neighboring round indications is not a factor to decide acceptation or rejection, except single indication or clustered indications with linear array.(6) 性质为缺陷的圆形显示不应超过ASME 第VIII 卷附录4示图中所示的尺寸。这些图表示了圆形显示的最大密集度的合格范围。各厚度的图代表的是150mm长实尺的射线照 片，不应放大或缩小。If a round indication is a defect, its dimension should not exceed dimension on drawings showed in ASME VIII Appendix 4. On the drawings, range of qualified density of round indications is specified. Drawings with different thicknesses stand for 1:1 radiographic photos with length of 150mm, so the photos should not be magnified or reduced. (7) 当t小于6mm时，在长为150mm的焊缝上圆形显示数量不应超过12个。在长度小于150mm的焊缝 上，允许显示的数量应成比例的减少。When t is less than 6mm, number of round indications should not exceed 12 for a weld of length of 150mm; and can be decreased in proportion when weld length is less than 150mm. (8) 合格的密集性显示长度不应超过25mm 或2t中的较小者。 在有一群以上密 集性显示 时，其长度之和在150mm焊缝长度上不应超过25mm。Length of acceptable cluster of indications should not exceed 25mm or 2t, whichever is smaller. If there are more than one cluster of indications, total length of clusters should not exceed 25mm for a weld of 150mm long. 7.2.2 超声波检验/UT 超声波检验的操作及试验设备的校准见ASME V中相关条款。 See relevant articles of ASME V for operation and equipment of UT. 验收标准/ Acceptance standard(1) 产生大于20%参考基准讯号的缺陷都应进行审查，直至操作人员能确定这些缺陷的形状、特征和位置。All indications giving an echo higher than 20% of reference echo will be analyzed to determine their shape, nature, position and to appraise them according to the following criteria.TA015-000 A11/14(2) 被判定为裂纹或未熔合或未焊透的显示，不论其长度如何，都是不合格的。Defects such as cracks, lack of fusion, and incomplete penetration are considered unacceptable whatever their length may be. (3) 如果显示超过参考基准的振幅，其长度超过下列范围的其它缺陷是不合格的：Defects are unacceptable if their amplitude is greater than the reference level and if their length exceeds the following values: t57mm 19mm 其中：t=除去允许的焊缝余高后的焊缝厚度，对于两不等厚零件的对接焊缝，t等于两 者中较薄者，若全焊透焊缝包括角焊缝，则该角焊缝的腰高应计入t内。 Where: t=weld thickness, exclusive of allowable reinforcement; for butt joint weld, t=the smaller thickness; for full penetration weld, inclusive of fillet weld, t includes weld throat. 7.2.3 磁粉检验 MT inspection 磁痕的评定 Appraise of indication(1) 磁粉滞留会显示出磁痕。所有这种磁痕并非必然都是缺陷，因为表面过分粗糙、磁导率的变化等都可能产生类似的磁痕。磁痕是机械缺陷的证据。只有磁痕尺寸大于1.6mm的磁痕才计为缺陷。When magnetic particle detain on workpiece, there will be a mark, but its not all the marks are defects , because some marks may be due to too rough surface or change magnetic conductivity. Magnetic mark is proof of mechanical defects. Only when size of magnetic mark is over 1.6mm, can the mark be considered as defect. (2) 线性磁痕是指长度大于宽度三倍的磁痕。Linear magnetic mark is mark whose length is more than 3 times of width. (3) 圆形磁痕是指长度等于或小于宽度三倍的圆形或椭圆形磁痕。Round magnetic mark is mark whose length is equal to or less than 3 times of width.(4) 任何有问题或可疑的磁痕应重新检验，确定它是否是需要考虑的。Any doubtable magnetic mark or mark in question should be re-checked and determine if they are defects. 验收标准/ Acceptance standard(1) 所有被检验的表面不应有算作缺陷的线性磁痕。All inspected surfaces should not have linear magnetic mark that should be repaired. (2) 所有被检验的表面不应有大于4.5mm算作缺陷的圆形磁痕。All the inspected surfaces should not have round magnetic mark more than 4.5mm that should be repaired.(3)所有被检验表面，在同一直线上，不应有边缘至边缘相距小于或等于1.6mm的4个或更多的圆形显示。 All inspected surfaces ,there is no 4 or more round marks aligned and separated by at least 1.6mm (from border to border)that should be repaires.(4) 缺陷的磁痕可能大于引起磁痕的缺陷。然而，磁痕的尺寸是验收评定的基础。Mark of defect may be bigger than the defect, but we can appraise the defect on basis of the mark.7.2.4 渗透检验/PT inspection 显示的评定/ Appraisal of indicationTA015-000 A12/14(1) 显示是机械缺陷的证据，只有尺寸大于1.6mm的显示才计为缺陷。Indication is proof of mechanical defect. Only indication whose size is more than 1.6mm can be considered as defect. (2) 线性显示是指长度大于宽度三倍的显示。Linear indication is indication whose length is more than 3 times of width. (3) 圆形显示是指长度等于或小于宽度三倍的圆形或椭圆形显示。Round indication is indication whose length is equal to or less than 3 times of width. (4) 任何有问题或可疑的显示应重新检验，确定它们是否计为缺陷。Any doubtable indication or indication in question should be re-checked and determine if they are defects. 验收标准/ Acceptance standard(1) 所有被检验的表面不应有计为缺陷的线性显示。All inspected surfaces should not have linear indication that should be repaired.(2) 所有被 检验的表面不应有大于4.5mm算作缺陷的圆形显示。All inspected surfaces should not have round magnetic mark that is more than 4.5mm and should be repaired. (3)所有被检验表面，在同一直线上，不应有边缘至边缘相距小于或等于1.6mm的4个或更多的圆形显示。A