51000DWT铸钢件焊接工艺规程说明书.doc

Welding Procedure Specification for Steel CastingJJS/WPS-2001-01铸钢件的CO2半自动气体保护焊/手工电弧焊焊接工艺规程说明书Welding Procedure SpecificationforCO2 Semi-Automatic Arc Welding / Manual Metal Arc Weldingfor Steel Casting Compiled by: 郭建华Checked by:Verified by:靖江造船厂Jingjiang Shipyard18 March, 20011范围 Scope11 焊接方法 Welding Process CO2半自动气体保护焊 / 手工电弧焊CO2 Semi-Automatic Arc Welding / Manual Metal Arc Welding12 应用范围 Application Range本说明书适用于船体铸钢件的CO2半自动气体保护焊或手工电弧焊。This Welding Procedure Specification Is Apply to the Purpose of CO2 Semi-Automatic Arc Welding or Manual Metal Arc Welding for Steel Casting.2焊接材料 Welding Consumable焊接方法welding process材料名称Material牌号Trade Name尺寸Size(mm)级别Grade制造厂ManufacturerCO2半自动气体保护焊CO2 Semi-Automatic Arc Welding药芯焊丝Flux-Cored WireSQJ501Ni1.23YSAH10天津三英焊业有限公司Tianjing Sainteagle Welding Co., LtdTWE-7111.23SAHH3YSA天泰焊材工业股份有限公司Tientai Electrode Co., Ltd气体Gas: CO2纯度Purity99%手工电弧焊Manual Metal Arc Welding焊条ElectrodeJH.E50153.2, 4.0, 5.03YH10江阴东青焊接材料有限公司Jiangyin Dongqing Welding Material Co., Ltd4接头细节 Joint Detail5焊接顺序 Welding Sequence6焊接条件 Welding Condition焊接方法Welding Procedure直径（mm）Dia of wire电流（A）Current电压（V）Voltage焊接位置Welding Position焊接速度Speed气体流量Gas flowCO2 半自动气体保护焊CO2 Semi-Automatic Arc Welding1.21402001520All1015cm/min2025l/min手工电弧焊Manual Metal Arc Welding61 焊接要求 Welding Requirement1. 焊接之前必须除去预加工边的锈蚀，油污，灰尘，潮湿等。Welding should be done after removing the rust, oil, dust, moisture etc.2. 每道焊层必须用钢丝刷清理打磨干净。Each layer should be removed slag by wire brush and grinding.3. 如果坡口用碳弧气刨开设，坡口处的碳迹必须打磨干净。If groove is air-arc gouged, grind surface of groove to smooth and to remove all trace of carbon.4. 电焊条须经烘干处理（详见6.5），未经烘干的焊条不得使用。Electrode should be dried as per section 6.5 and should not be used without drying.5. 手工焊时焊条的摆动幅度应小于所用焊条直径的3倍。Wide of weaving to be limited to less than three times of used electrode diameter.62 预热 Preheating1. 焊缝预热温度为125200（预热范围距焊缝中心为75mm），用电加热器或火焰进行加热并覆盖以绝缘毛毯，预热时必须缓慢且均匀，以避免出现裂纹和变形（每小时约60100）。Weld joint to be preheated of 125200 (measured 75mm from edge of weld groove), apply heat slowly and evenly by using electrical heating equipment and torch, then wrapped with insulation blanket (about 60 to 100 per hour max).2. 焊缝清根后必须打磨干净去除掉所有的碳化物，并按照上述工艺重新预热。After back gouging the weld joint should be grind smooth, removed all carbon and repreheated according to the above procedure.63 层间温度控制 Interpass Temperature Control较合适的层间温度为125250，其温度下限用以保证在多层焊中后道焊缝有起码的预热条件，其温度上限以避免出现热应力裂纹。通过补充加热或缓慢焊接来控制层间温度。Interpass temperature to be controlled of 125250, the lower limitation ensures at least preheat conditions during subsequent passes, the maximum limit of temperature to be absolutely controlled to avoid thermal stress cracks. Control interpass temperature by supplementary heat as per above preheat procedure or welding slowly.64 焊后热处理 Postweld Heat Treatment1. 对于大型铸钢件(如挂舵臂、艉框架、垫块、舵杆等)，可将焊缝区域用电加热设备或火焰加热到200250，保温1.5小时并覆盖以绝缘毛毯，然后使其缓慢冷却。As regards large castings such as rudder horns, stern frames, shoe pieces and rudder stocks etc, the temperature of the welding area should be heated to 200250 by electrical heating equipment and torch, then wrapped with insulation blanket, and keep the temperature for approximately 1.5 hours then allow to cool down slowly.2. 对于小型精加工铸钢件，可将焊缝区域用电加热设备或火焰加热到600650，保温1.5小时并覆盖以绝缘毛毯，然后使其缓慢冷却。As regards small castings for fine machining purpose, the temperature of the welding area should be heated to 600650 by electrical heating equipment and torch, then wrapped with insulation blanket, and keep the temperature for approximately 1.5 hours then allow to cool down slowly.65 焊接材料的管理 Control Of Welding Materials焊接结束，焊丝焊条必须返还到储藏室去。Wire should be returned to the stored house after finish welding.焊条干燥状态如下 condition for drying electrodes is as follows:焊接材料welding material标号brand烘干温度drying temp.保温conditioned temp.低氢型low hydrogenJH.E501530035080120最长使用时间 used max. Time1). 室外工作出4小时以内。Below 4hr in outdoor working.2). 室内工作出5小时以内。Below 5hr in indoor working.3). 超过以上时间焊条必须送回烘干室烘干。Over time electrode should be returned to drying room.焊接方法welding process焊接位置welding position直径(mm)dia. of wire / electrode电流(A)current电压(V)voltage焊接速度(cm/min)speed气体流量(l/min)gas flow接头细节joint detailsCO2 半自动气体保护焊CO2 Semi-Automatic Arc Welding平焊flat1.2140160253010152025横焊horizontal1.2140200152010152025立焊vertical1.21402