舵制作工艺(中英文对照).docx

64000DWT舵叶制作工艺一、舵叶装配（The assemble of rudder）1、胎架制作(Fabrication of rudder)舵叶采用以侧板为胎架进行卧造，按图纸及样板尺寸制作胎架，并安装模板。胎架支柱必须与预埋件进行钢性连接，胎架必须标明FR0号肋位对合线和船体中心线，分段脱胎前必须将各种对合线移至舵叶上并清晰地打上洋冲。Use the side plate of rudder as jig, the jig should be assembled as the drawings and example. Pillars of the jig must be connected to embedded part directly, meanwhile the template should be assembled. Also the mark of FR0 & CL of the ship and the joining line of hull assembly should be signed clearly before the rudder leave the jig. 2、侧板上胎(side construction on the jig)将上胎板按图纸要求吊装至已交验合格的胎架上进行定位，上胎板与胎架模板需施牢固的定位焊，以防止舵叶变形。Hoisting and location the plate attached to the jig that has been accepted as the drawings, tack welding is needed between jig and side plate in case it out of shape.3、舵叶划线(Marking the rudder)舵叶上胎板的划线，必须以胎架基线为依据。The mark on the rudder must on the basis of base line of the jig.4、内部构件的预装配(the assemble of the inner construction )因舵叶的顶面大而底面小，所以水平隔板的腹板与面板的交角不相垂直，同样垂直隔板的面板和腹板的交角也不相垂直，为了保证水平隔板和垂直隔板的面板连接光顺，不出现局部的凸起或凹陷，故在进行T型隔板装焊时，需进行预拼装，待水平和垂直隔板的面板调整光顺后，装其拆分开来，将面板和腹板进行临时加强后焊接。For the top and the bottom plate of the rudder are not in the same size, the angle of the face and the web of the horizontal partition plate is not vertical. And the vertical plate has the same problem. To ensure the fair of the face of horizontal and vertical plate and no local bump and depression happened, before the assemble and welding of the T partition plate, preliminary assembles are needed. After the fairing of the face of horizontal and vertical partition plate, split it and do some temporary strengthen between face and web plate, then welding. 5、舵叶装配(the assemble of rudder)将进行过预拼装的水平隔板和垂直隔板进行定位。Location the horizontal and vertical partition plate which have been temporary strengthened.二、舵叶焊接(the welding of rudder)舵叶内部构架装配完工后，即可进行内部构件的的焊接，焊接时，先焊水平隔板与垂直隔的面板对接缝及腹板角接缝，后焊隔板与侧板之间的角接缝。焊接时注意采用双数焊工从中间向四周发散状对称焊接。The inner structure can be welded after the assembly of it. When welding, the butt welding and fillet welding between horizontal and vertical partition plate come first, second the fillet welding between partition plate and side plate. When welding, double welders are needed to welding symmetry from intermediate to all around in divergent shape. 三、铸钢件的安装(the installation of steel casting)铸钢件的定位需拉钢线，定位尺寸需满足要求。与铸钢件相对接的位置需按图纸要求开设好坡口，坡口需打磨光顺，对坡口面存在的缺陷应即时处理。Metal line is needed to location the steel casting and location dimension should reach the requirements. The groove should be prepared and make sure its fair and smooth. 四、铸钢件的焊接(the welding of steel casting)1、铸钢件的焊接采用CO2气体保护焊或低氢焊条J507手工焊,铸钢件焊接，在焊缝区域各100mm范围内，应无油水、无夹渣、无锈等，保证焊道清洁。CO2 welding or manual welding which use J507 can be used to the welding of steel casting. When welding, make sure there is no water 、oil 、slag and rust within the scope of 100mm of the welding region.2、铸钢件焊前应进行预热，预热温度120150度。Preheat the steel casting between the temperature of 120150.3、焊接开始，单面焊接23批后反面应进行碳刨清根，焊道清洁后方可进行碳刨面的焊接，后续焊缝注意对称施工，减小分段变形。In the process of welding, gouging the back when welding for 2 or 3 times. Clean the gouging place before continuing welding. Keep symmetry construction to reduce deformation.4、采用多层多道焊，每层焊道清渣后，使用小锤敲击焊缝以释放焊接应力，防止裂纹的产生。如有缺陷要及时用碳弧气刨或砂轮打磨，如铸钢件出现裂缝，应在裂纹开裂趋势的前方打止裂孔，以防止裂纹的进一步扩大，针对不同的缺陷在焊接过程中选用正确的方法进行修复处理。Adopting multi-layer and multi-passes welding . After clean the welding passes, hit the welding passes to release the welding stress in case of crack. Poor weld should be grinded and grounded in time. If there is crack happened to steel casting, stop hole is needed to stop the crack propagation. Choose the right way to deal with the different problems.5、 使用短弧焊接，每层焊接的起弧点应错开100mm左右。层间温度控制在150左右。When adapt short-act welding, staggering arcing point of each layer around 100mm. control the temperature between adjacent layers around 150。6、整个对接焊过程应在单一热周期内连续进行，而且整个焊接过程要有专人监控和检查测量并做好记录,每30分钟进行测量并记录测量结果，根据测量结果，即时调整焊接位置，以控制分段的焊接变形。The whole process should be proceeded in one hot cycle.There should be one person to monitor and record in each 30 minutes. Change the position of welding to control the shape.7、施焊完毕后采用石棉布包裹，达到缓慢冷却的效果。After the welding completed , use asbestos cloth to cover it to slow down the time of cooling.8、铸钢件的所有焊缝须经超声波探伤，如有缺陷，立即进行返修。检验合格且放置24小时后，方可进行退火处理。All welding line should be checked by ultrasonic testing, if there is poor welding, we must repairing the welds in time. Annealing 24 hours after the inspection passed.9、热处理后对焊缝进行100%超声波探伤。100% UT is needed after heat treatment to the welds.五、侧板封板(close the side plate)内部构件经检验及无损探测合格后进行侧板封板，并安装放水塞，侧板的塞焊孔在去除焊渣后用环氧树脂加复粉填平。Close the side plate when the UT inspection of the inner instructions has been completed. Installing the plug at the same time. Cleaning the slag in plug weld and fill it with epoxy resins .六、脱胎翻身(turn over the rudder on the jig)上侧板焊接处理完工后，将舵叶与胎架模板割开，使舵叶处于自由状态进行四周的水平测量并做好记录，将舵叶脱胎吊离胎架，进行上胎侧板的处理焊接。Separate the jig and rudder when the side plate complete its welds. Measure the horizontal around and write it down. Lift the rudder from the jig.七、密性(tightness)舵叶制作完工后，需进行密性试验，密性试验合格后在舵内灌气相防腐剂。Tightness test comes after the construction of rudder completed. Fill the rudder with preservative gas when the inspection of tightness test passed.附退火工艺(annealing process)退火工艺：(annealing process)1、在焊缝包括两侧100mm范围内进行去应力退火处理。Annealing the welding line and both sides of the 100mm range.2、采用电热设备加热，从室温自由加热到300，然后以100/h速度缓慢加热到575，在57525保温3.5小时。Use electric equipment to heat from room temper