钢结构制作焊接型材及轧制型材拼接工艺.doc

钢结构制作焊接型材及轧制型材拼接工艺Welded Shapes and Rolled Shapes Splicing Procedure1. 目的（Object）考虑到市场上部分轧制型材、板材规格尺寸无法满足工程中所需尺寸要求，必须由工厂自己拼接制作，达到工程中所需规格尺寸。因此，为保证拼接质量满足工程技术要求，保证拼接过程规范有序进行，特拟定此工艺；Considering the specification and dimensions of rolled sections and plates in market cannot meet requirements of this project, to meet the requirements of dimensions these plates and section need to be built-up in workshop. This procedure is prepared to ensure that the quality of splice meets technical requirements and the process is standard and ordered.2. 要求（Requirement）2.1 如遇工程中板材构件宽度或长度尺寸超过原材料采购尺寸，工厂进行拼接时，需保证板宽度的最小拼接尺寸不允许低于300mm，长度最小不应小于600mm；翼缘板不允许有横向拼缝；If the components width or the length are exceed raw material size ,when splicing ensure the minimum splice size of plate width not less than 300mm,the length not less than 600mm. It is not allowed to splice flange plate in landscape orientation2.2 焊接H型钢翼缘板拼缝与腹板拼缝的间距不应小于200mm；翼缘板拼接长度不应小于2倍的板宽；腹板拼接宽度不应小于300mm，长度不应小于600mm；While welding H-shapes ,between web plate and flange pitch length not less than 200mm, the splice length of flange shall be at least twice width of plate, the web plate splice width not less than 300mm,the length not less than 600mm2.3 轧制型材可直接进行拼接，但拼接长度不得小于1000mm；Rolled shapes can directly splice, but the splice length not less than 1000mm 2.4 梁长度不大于15m，拼缝只允许在梁两端1/3处且只允许各有1条；梁长度在15m35m，翼缘板与腹板允许各有三条拼缝，但绝对不允许在梁中间及中间左右各1m范围内有拼缝；The length of girder is not exceed 15mm ,splice weld is only permitted at 1/3 of girder both ends and only have a permit ;girder length at 15m 35m, flange and web permit each of three splice weld ,but between girder and between about each length of 1m have splice weld are not absolutely allowed 2.5 梁上附件不允许焊接在拼缝位置，要求错缝不应小于100mm；如满足不了，则在焊接附件前要对主件拼缝进行NDE检查；Girder attachment is not allowed to be welded at the location of splice welds, the requirement of staggered weld not less than 100mm;if it is not satisfied ,the main pieces splice weld should be NDE tested prior to weld attachment 2.6 槽钢腹板和翼缘的两道焊缝需全焊透，要求坡口角度到位，首件剖开检查焊接质量Channel steel web and flange of double-pass welds should complete penetration ,require right groove , the first piece shall cut open to check welding quality 2.7 非图纸要求工厂增加的对接焊缝，必须按照全熔透焊缝焊接及检验，焊接和检验按照本工程批准的焊接工艺和MITP执行；Increasing butt welds are not drawing requirement , must be performed in accordance with full penetration weld ,weld and inspection in accordance with approved welding procedure and MITP of this project2.8 如工程中对母材焊接有热处理要求时，拼接焊缝焊后热处理需按本工程焊后热处理工艺执行； If the base metal needs heat treatment , PWHT must be performed in accordance with Post weld Heat Treatment Procedure2.9 组合型钢对接焊缝和角焊缝都采用埋弧焊接进行焊接；Built-up shapes butt weld and fillet weld shall be welded by submerged arc welding 3. 程序（Procedure）3.1下料 Plate Cutting 1根据制作祥图制作H型钢板料图，然后将板料图拷贝到等离子或火焰切割数控设备进行切割下料，长度较短板厚小于14mm的板料用机械剪切进行下料。（Prepare the plate drawings of the H-shapes in accordance with the shop detail drawings, and then copy the plate drawings into plasma/NC flame cutting machine for cutting. The plates that are short and no thicker than 14mm shall be cut by shearing machine.）2钢板的切割面或剪切面应无裂纹、夹渣、分层和大于1mm的缺棱；（The cut surface or shear surface of the plates shall be free from crack, slag, lamination or waney that is larger than 1mm.）3下料时要保证板料的尺寸的精确性,严格按下列公差执行：（While cutting plates, the accuracy of the plate dimensions must be ensured and the following tolerance must be followed: ）气割的允许偏差（mm）Tolerance for gas cutting项 目 Item允 许 偏 差 Allowable Tolerance零件宽度、长度 Width/Length of the parts3.0切割面平面度Evenness of cut surface0.05t, 且不应大于2.0 0.05t, 2.0割纹深度 Depth of cutting veins0.3局部缺口深度Depth of local notch1.0备注：t为切割面板厚。Note：t: thickness of cutting plate. 机械剪切的允许偏差 (mm) Tolerance for mechanical shearing项 目 Item允 许 偏 差 Allowable Tolerance零件宽度、长度 Width/Length of the parts3.0边缘缺棱 waney edge1.0型钢端部垂直度 End verticality2.03.2组装（Assembly）1 组装岗位在进行组装H型钢前，严格按照H型钢生产命令单上的组装尺寸将下好的板料进行组装；（Before assembling H-shapes, the workers must assembly the plates first in accordance with the assembly dimensions on the production orders.）2 组装H型钢时如翼缘板宽度相同时应先将腹板组立到任意翼缘板上，之后再将组装好的T型翻身再组装另一块翼缘板，如两翼缘板宽度不同先组窄翼缘；（While assembling H-shapes, the web plates shall be spot-welded onto either of the flange plate first if both of the flange plates are of the same width; then turn around the “T” shapes and assemble another flange plate. If the two flange plates are different in width, the narrow one shall be assembled first.）3 焊接H, C, L,T型钢的允许偏差按下表执行；Allowable tolerance for built-up H, C, L, T shapes (mm)表4 焊接H, C, L,T型钢的允许偏差 (mm) Table 4 Allowable tolerance for built-up H, C, L, T shapes (mm)项目Item允许偏差Allowable tolerance图列Legend长度LL6000+2.0L6000+4.0宽度BB2001.0B2002.0高度HH5001.0500H10002.0H10003.0腹板中心偏移Eccentricity of webSB200B/100B2002.0翼缘板倾斜度Inclination of flangePB200B/100B2002.0弯曲度Tortuosity-L/2000，与3.0扭曲Torsion-H/250，与3.0端部垂直度Perpendicularity of the end facee-1.6%H或1.6%B,与2.0翼缘板和腹板平面度Planeness of flange & webF-2.03.3焊接（Welding）1.所有的H型钢用埋弧焊设备进行焊接，焊接操作严格按照WPS焊接工艺执行，使用的焊剂、修补使用的焊条，必须按照焊材管理办法对其进行烘培，焊接顺序为1234执行如下图1：（All H-shapes shall be welded by SAW, which must be performed in accordance with the requirements of WPS. The flux and electrode used in repair must be baked in accordance with Management Measures of Welding Consumables. The welding shall proceed in the sequence of Chart 1:） Chart 1 2.H型钢埋弧焊缝尺寸必须按照生产命令单上规定执行，焊缝表面不得有裂纹、焊瘤、气孔、夹渣、电弧擦伤、未焊满等缺陷。所有H型钢端头必须对其焊缝进行包角处理。The weld