江阴东方阀门WCB+DMo堆焊工艺

1、江阴东方阀门有限公司WCB堆焊工艺评定报告汇编编号 ：PQR-20焊接方法SMAW母材牌号：WCB-GB12229/A216焊材牌号 :D507MO- GB984-1985/E410完成日期 :江阴东方阀门有限公司WCB堆焊工艺评定报告目录序号名称页数备注1WCB 钢堆焊评定试验大纲12WCB 钢堆焊工艺规程（WPS）23D507Mo 焊条质量证明书14WCB 母材质量证明书15渗透检测 (PT) 报告16硬度检测报告17侵蚀检测报告18加工后堆焊面化学成分19弯曲试验110WCB 焊接工艺评定记录 （ PQR）焊接3(含操作记录表 )11阀门密封面堆焊工艺卡112阀门零部件密封面堆焊记录1备

2、注：江阴东方阀门有限公司WCB钢堆焊工艺评定大纲一、目的：为保证 WCB 堆焊工艺评定顺利进行，特制订本大纲。二、范围：适用于 WCB 堆焊工艺。三、内容：1、焊接设备：电弧焊机 ZX 5-4002、母材： WCBGB12229/ASTM A2163、母材试样尺寸：16016010壹块4、焊条： D507Mo GB984-1985-EDCr-A2-155、D507Mo/GB984-1985-EDCr-A2-15 化学成分 (%)：CNiCrWMo硬度（ HRC） 0.2 1.010.0-16.0 2.0 2.50 386、焊条直径：3.24.07、焊前焊条烘焙：烘焙温度 300350oC，保温

3、时间 1 小时8、施焊操作记录（含工艺参数外观检验、探伤、硬度）9、侵蚀检测报告10、PT 探伤报告11、硬度测试报告12.工艺评定编号： PQR-20QW-482Jiangyin Eastern Valve Co.,Ltd江阴东方阀门有限公司焊接工艺规程 Welding Procedure Specification（ WPS）（参见ASME锅炉压力容器规范第卷ASME Boiler and Pressure Vessel Code, Section IX）公司名称 company焊接规程编号WPS No.:WPS-20修改号Revision No:焊接方法WeldingProcess(es

4、)Jiangyin Eastern Valve Co., Ltd签字人 By:Shen Genping日期Date:依据的工艺评定记录编号:Supporting PQR No(s).:E-01日期 Date:SMAW自动化等级Type(Automatic,Manual, MachineorPQR-20 Semi-Auto)Manual接头Joints (QS-402)简图2mmAftermachining接头型式 Joint DesignHardface OverlayJane figure衬垫 Backing ( 有 yes)YES(无 No )/衬垫材料 (型式 ) Backing Mat

5、erial(Type)Base Metal or Weld metal金属 不熔金属非金属 其它材料应当用简图、施工图、焊接代号或文字说明来说明被焊零件布置，需要时，可给出根部间隙和坡口详图 (根据制造者的选择，可附简图说明接头型式、焊层数和焊道的顺序。例如，对于有缺口韧性要求的焊接工艺、对于多道焊工艺等需要简图 )Sketches Production Drawings, weld symbols or written Description should show the general arrangement of the parts to be welded. Where applic

6、able, theroot spacing and the details of weld groove many be specified.母材 (Base Metals)(QW-403)P-NO.1组号 (Group No.2与 to P-NO./组号 (Group No./相焊或钢号和等级为Specification type and gradeGB12229 (A216) Gr.WCB与钢号和等级为to Specification type and grade/相焊或 化学成分和力学性能为chem. Analysis and Mech. Prop./与化学成分和力学性能为to/chem

7、. Analysis andMech.Prop./相焊厚度范围 Thickness Range：母材 Base Metal：25mm管子直径范围 (Pipe Dia, Range)：N/A其它 other角焊Fillet角焊FilletN/AAllAll填充金属 Filler Metals * (QW-404)SFA NO.5.4GB984-1985AWS NO.( 分类号 )E410-15D507MoF-NO4A-NO.6填充金属尺寸 Electrode Size5.0mm5.0mm熔敷焊缝金属厚度范围 Thickness Range2t2t焊丝焊剂 (分类号 ) Flux(class)/焊

8、剂商标名称Flux brand name/可熔化嵌条Consumable inserts/其它 Other/对于每一母材一填充金属的组合均需分别填表For each parent metal filler metal combinationall needs to fill out a form,respectivelyQW-482(续)焊接工艺规程 (WPS)WPSNO.WPS-20焊接位置 Position(QW-405)坡口的位置Groove Position1G焊接方向 Weld progression：向上 up/向下 down/角焊缝位置Fillet welding positio

9、n1F、 2F预热 Preheat (QW-406)最小预热温度Preheat Temperature0最大层间温度Interpass Temperature200预热的保持方式Preheat Maintenance/(应记载采用连续加热或特殊加热法Continuous or specialheating where applicable should be record )电特性Electrical Character (QW-409)电流 AC 或 DCDC极性Polarity修改号 Rev.：E-01焊后热处理Postweld Heat Treatment(QW-407)温度范围Temp

10、. Range/时间范围Time .Range/气体 Gas (QW-408)(百分比组成Composition)气体混合比流量GasCompositionFlow Rate保护气 Shielding gas(es)/尾部保护气Gas Trailing/Shielding/背面保护气Gas Backing/EP安培 (范围 )Amps(Range)See notes伏特 Volts (Range)See notes(To fill in current and voltage separately as per welding position and thickness)钨级尺寸和类型 W

11、pole specification and typeN/A金属过渡方式 (FCAW)N/A送丝速度范围 Travel Speed (cm/min)N/A焊接技术 Technique(QW-410)直进焊或横摆焊 String or weavingstring Or weaving bead嘴孔或喷嘴尺寸 Size of welding spoutN/A打底焊道和中间焊道的清理方法(刷理或打磨等 ) Before welding or level clearanceGrinding、Burnish背面清根方法 Revise Side boot clearance typeN/A横摆方法 Swi

12、ng TypeN/A导电嘴至工作距离 Distance between electric conduction spout and workpieceN/A多道焊或单道焊（每侧） Multiple or Single passes(per side)Multiplepasses多丝焊或单丝焊 Multiple or single ElectrodesSingle electrode焊接速度 (范围 ) Travel Speed(Range) (mm/min)See notes锤击有无 Hammer ImpactNo其它 Other/Notes填充金属电流焊接速焊层焊接方法Filler Meta

13、lCurrent电压范围度范围Volt.热输入WeldWelding安培Travel种类直径极性RangeHeat InputLayer(s)TypeAmp RangespeedClassDia（ mm）Polarity（v ）J/mm（A ）Rangemm/min1-nSMAWE410-155DCRP145-20721-28104-1511164-3344Jiangyin Eastern Valve Co.,Ltd江阴东方阀门有限公司WELDING PROCEDURE QUALIFICATION RECORDS(PQR)焊接工艺评定记录（ PQR）（参见 ASME 锅炉压力容器规范第卷ASM

14、E Boiler and Pressure Vessel Code, Section IX ）Procedure Qualification Record No. /Rev 工艺评定报告编号PQR-20 /Rev:E-01Date 日期 :Page页次1 /3Welding Process(es ) 焊接方法SMAWType 类型ManualWPS No./Rev.工艺规程编号WPS-20 /Rev:E-01接头JOINTS(QW-402)2mmAfter machining（组合评定时，熔敷的焊缝金属厚度应按每种填充金属或焊接方法分别记录）(For combination qualifica

15、tions, the deposited weld metal thickness shall be recorded for each filler metal or process used.)BASE METALS(QW-403) （母材）POSTWELD HEA T TREATMENT(QW-407)焊后热处理材料规范Material Spec.A216To_型号或等级Type or GradeWCBToP-No1试件厚度Thickness of Test Coupon26mm试件直径Diameter of Test Coupon_ N/A _其它Others_ N/A _FILLER

16、 METALS(QW-404) 焊接材料 SFA 规范SFAGB984-1985( 5.4 )AWS 焊材型号AWS ClassificationD507Mo(E410-15)填充金属 F-NO.Filler Metal F-No.4焊缝金属成份A-No.Weld Metal Analysis A-No.6填充金属规格Size of Filler Metal5.0mm;焊材厂 Filler Supplier:Shanghai Bele welding Cosumable Co.,Ltd焊材 Filler Lot No.:410510焊缝金属厚度Weld Metal Thicknessmin.

17、3 mm,POSITION(QW-405) 位置坡口位置Positon of Groove1G焊接方向 (向上、向下 )Weld Progression (Uphill, Downhill)N/A其它Other/_PREHEAT(QW-406) 预热预热温度Preheat Temp.RoomTemp层间温度Interpass Temp.150其它Other/温度Temperature/时间Time/其它Other/GAS(QW-408) 保护气体Percent composition（气体成份）Gas(es)气体(Mixture) 混合比FlowRate 流量正面保护ShieldingN/AN

18、/AN/A层面保护TrailingN/AN/AN/A背面保护BackingN/AN/AN/AELECTRICAL CHARACTERISTICS(QW-409)电特性电流CurrentDC极性PolarityEP安培Amps.See notes钨极尺寸Tungsten Electrode SizeN/A其它Other/Technique(QW-410) 施焊技术焊接速度Travel SpeedSee notes不摆动或摆动String or Weave BeadString or Weave Bead摆动 OscillationN/A多道焊或单道焊（每侧）Multipass or Single

19、 Pass(per side)Multipass单丝或多丝焊Single or Multiple ElectrodesSingleElectrode其它Other/_WELDING PROCEDURE QUALIFICATION RECORDS(PQR)(Continued)PQR No. /Rev: 工艺评定编号PQR-20 /Rev:E-01Page页次2/3Notes:填充金属电流焊接速度焊层Filler MetalCurrent伏特焊接方法范围Weld安培范围 Volt备注Travel SpeedLayer(Process种类直径极性范围RangeRemarksRanges)VClas

20、sDiaPolarityAmp. RangeMm/minA1SMAWE410-15 5.0DCEP170241252SMAWE410-15 5.0DCEP170241313SMAWE410-15 5.0DCEP180251224SMAWE410-15 5.0DCEP18025128Tensile Test(QW-150)拉力试验Specimen No.WidthThicknessAreaUltimate Total LoadUltimate Unit StressType of Failure &KNMPaLocation试样号宽度厚度面积极限总载荷极限单位应力破坏性质和位置Guided-Be

21、nd Tests(QW-160)导引弯曲试验Report No : QR/JEV GY201402006Type and Figure NoResult类型和图形结果20-06-1(180side bend)Accepted20-06-2(180 side bendAccepted20-06-3(180side bend)Accepted20-06-4(180side bend)AcceptedToughness Tests(QW-170)韧性试验Specimen No.Notch LocationSpecimen SizeTest Temp.Impact Value 冲击功试样号缺口位置试样

22、尺寸试验温度J 能量%Shear 剪切断面百分比Comments:_WELDING PROCEDURE QUALIFICATION RECORDS(PQR)(Continued)PQR No. /Rev: 工艺评定编号PQR-20 /Rev:E-01Page 页次3/3硬度试验Hardness TestReport No : QR/JEVGY201402006pointHV10pointHV10PointHV10134561631115323107159121503332816013149433691651415253291016115157Hardness of Base Metal and

23、 HAZ meet NACE MR0175 HRC22 max. ; Weld hardness meet API 600化学成分检验 Chemical composition testReport No : QR/JEVGY201402004CSiMnPSCrNiMoCuAlTiVNbW0.080.410.70.0280.00.0170.0050.0040.0270.0170.010Fillet-Weld Test(QW-180)角焊缝试验结果好坏熔缝透材好坏Result-Satisfactory: YesN/ANoN/APenetration into Parent

24、Metal: YesN/ANoN/AMacro-Results 宏观试验N/AOther Tests其它试验Visual Inspection 外观检验AcceptedType of Test 试验类型Penetration testing (GY201402003)AcceptedErosion test (GY201402001)AcceptedDeposit Analysis 金相及成分分析/Welder s Name焊工姓名Miao JianfaID No. 证件tamp No.钢印号6Test conducted by 试验执行人 : Jian

25、gyin Eastern Valve Co.,LtLaboratory Test No. 试验编号PQR-20We certify that the statements in this record are correct and that the test welds were prepared, welded and tested in accordance with the requirements of Section IX of the ASME Code.兹证明本报告所述均属正确，并且试验是根据ASME 规范第 IX 卷的要求进行试件的准备、焊接和试验的。Sign(签字 )She

26、n GenpingDate(日期 )Approval ( 批准 )Liu JianqingDate(日期 )江阴东方阀门有限公司Jiangyin Eastern Valve Co., Ltd渗透探伤报告QR/JEV7.4(19)-2010Liquid Penetrant Test ReportReport No: QR/JEVGY201402003生产令号155 80 25订单号商标规格名称焊接工艺试板ProductionPO.No.BrandType of Partwelding procedure testNo.plate数量产品编号WPS-20Quantity1Product No.炉

27、号Heat No.标准试块材料探伤部位堆焊面Std TestYM-DWCB+E410InspectionMaterialOverlaying surfaceSpecimenSection渗透剂型号清洗剂型显象剂型号号Type ofDPT-5DPT-5Type ofDPT-5Type ofPenetrantDeveloperWashing渗透时间显象时间执行标准15MinDevelopin15MinAcceptableQW195Penetrant Timeg Timestandard探伤示意图：Sketch:探伤结论：Result:Measure up to standard卞良华卞晓庆2014

28、-10-20检测人员 /日期审核人员 /日期2014-10-20Reviewed by/DateBian XiaoqingInspector/DateBian Lianghua江阴东方阀门有限公司力学性能试验报告单Jiangyin Eastern Valve Co., Ltd.Mechanical property test reportReport No: QR/JEVGY201402002委托单位 Entrusting party焊接试验室Welding laboratory产品名称 Product namePQR-20-02工艺评定Procedure qualification钢 号 M

29、aterialWCB+E410技术要 求 Technical requirementAPI 6D试验温度 Temperature22 项目 Item检测结果RelAZAKVJ结论RmResultMPa%HVHRCResultMPa%炉号Heat No .PQR-20-02-1PQR-20-02-2PQR-20-02-3PQR-20-02-4PQR-20-02-5PQR-20-02-6PQR-20-02-7PQR-20-02-8PQR-20-02-9PQR-20-02-10PQR-20-02-11PQR-20-02-12PQR-20-02-13PQR-20-02-14PQR-20-02-1534

30、5合格 Accepted310合格 Accepted332合格 Accepted336合格 Accepted329合格 Accepted163合格 Accepted159合格 Accepted160合格 Accepted165合格 Accepted161合格 Accepted153合格 Accepted150合格 Accepted149合格 Accepted152合格 Accepted157合格 Accepted报告日期检验员卞良华审核刘建清Report Date2014-10-25Bian LianghuaApproved byLiu JianqingInspector注：本检测结果仅来样试

31、件负责Remark: The result is only for the test coupon江阴东方阀门有限公司腐蚀性测试报告Jiangyin Eastern Valve Co., Ltd.Etching test reportReport No : QR/JEV GY201402001产品名称工艺评定试板 Test couponProduct name材料牌号WCB+E410试样编号PQR-20-01MaterialTest coupon no测试内容浸蚀试验报告日期Etching test2014-10-20Test nameReport date测试步骤：Test descript

32、ion：1 将试样二端堆焊层垂直暴露断面进行打磨平整，并进行抛光处理；2 试样在硝酸与水比例1： 3 的浸蚀剂溶液中浸蚀3 分钟；3 用 5 倍放大镜对暴露断面进行100%目测检查。1. Cut the test coupon into two pcs perpendicular to alloy overlay layers, grind and polish the exposed section smooth.2. Put the two test pieces into a nitric acid and water solution ratio of 1:3 for 3 minute

33、s.3. 100 percent visual inspection to exposed section with 5 times magnifying glass.测试结果：Test result试样二个垂直暴露断面基层金属和热影响区处无裂纹，堆焊接合处完会熔合。Base metal and HAZ on the two vertical section no cracks and complete fusion on welding joints.测试结论：Test conclusion:按 ASME 规范卷焊接与补焊评定QW-183 规定，判定合格。It is acceptable a

34、ccording to ASME section ,QW-183.说明1 以上结果仅对来样负责. 1. The result is only for the test coupon.Remark2 试样保存三个月 .2. Samples remain for 3 months.测试人员卞良华审核人员刘建清日期Inspector日期2014 -10-24ApprovedLiuBian2014-10-24DatebyJianqingDateLianghuaAnalyses protocol:SampleId1:FOR WPS-20-04SampleId2:1Cr13SampleId3:Sample

35、Id4:SampleId5 :SampleId6:Date/Time of analyses:Report No: QR/JEVGY201402004CSiMnPSCrNiMoCuAlTiVNbW0.080.410.70.0280.00.0170.0050.0040.0270.017 0.010江阴东方阀门有限公司力学性能试验报告单Jiangyin Eastern Valve Co., Ltd.Mechanical property test reportReport No: QR/JEVGY201402006委托单位 Entrusting party焊接试验室产品名称

36、Product namePQR-20-06钢 号 MaterialWCB+E410技术要试验温度 Temperature22 项目 Item检测结果RmRelAResultMPaMPa%炉号Heat No .PQR-20-06-1侧弯 Side bendPQR-20-06-2侧弯 Side bendPQR-20-06-3侧弯 Side bendPQR-20-06-4侧弯 Side bendWelding laboratory工艺评定 Procedure qualification求 Technical requirementQW-163ZAKV结论HVHRCJ%ResultD=3S=180 无缺陷合格no defectUp to standard无缺陷合格no d