焊接工艺培训

1、焊接工艺培训,碳钢药皮焊条（AWS A5.1/ASME SFA5.1）,焊条型号列表,补充符号,低合金钢药皮焊条（AWS A5.5/ASME SFA5.5）,ASME锅炉及压力容器规范第IX卷内容：,焊接接头的分类,标准测试位置,1G, 3G, 6G, 2F, 5F, 等式规范制定的测试用焊接位置. They are properly referred to as Test Positions. 相似的描述见ISO 6947 定义PA, PC, PG, 等.,1G/PA,15,焊缝水平轴,板水平摆放,5,2G/PC,板竖置,焊缝水平轴,15,5,3F/PF or PG,5,6G,455,Fla

2、t Positions Axis Inclination,15,Start at Nominal Flat Position,焊缝表面向上,WWW.SPERKOENGINEERING.COM,平焊位置上倾角限制,15,Weld may incline upward to a limit of 15,WWW.SPERKOENGINEERING.COM,Flat Upward Inclined Limit,15,But the welder could be traveling down the incline. . .,WWW.SPERKOENGINEERING.COM,Flat Downwar

3、d Limit Is Implied,15,Welding Positions,Tabulation of Positions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 HorizontaB0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15 to 8080 to 280 E80 to 900 to 360 How this table and

4、 the diagram on the previous page work are shown in the following diagrams,Flat Position -Rotation About Axis,WWW.SPERKOENGINEERING.COM,Flat Rolled Limit Clockwise,210,180,30,Flat Rolled Limit Clockwise,210,180,30,Equivalent to rotating The plate 30,WWW.SPERKOENGINEERING.COM,Flat Rolled Limit Counte

5、rclockwise,30,150,180,Flat Rotated Limits Not Considering Inclination,60,Welding Positions,Tabulation of Positions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 HorizontaB0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15

6、to 8080 to 280 E80 to 900 to 360 How this table and the diagram on the previous page work are shown in the following diagrams,Flat Uphill Limit Rotated,15,60,Flat Downhill Limit Rotated,15,Composite Flat Position Ranges,30,60,Compare this range to 1G/PA. . .,15/FLAT,Testing Position 1G/PA,15/PA,Weld

7、 Axis Horizontal,Plate Horizontal,5/PA,30/FLAT,Flat 1G !,Welding Positions,Tabulation of Positions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 Horizontal B0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15 to 8080 to 280

8、 E80 to 900 to 360 How this table and the diagram on the previous page work are shown in the following diagrams,Horizontal Position Axis Inclined,15,Basic Horizontal Position,Horizontal Position Uphill Inclined Limit,15,Horizontal Position Downhill Inclined Limit,15,Welding Positions,Tabulation of P

9、ositions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 Horizontal B0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15 to 8080 to 280 E80 to 900 to 360 How this table and the diagram on the previous page work are shown in t

10、he following diagrams,Horizontal Position Rotated,210,Start at the Flat Rolled Limits,180,30,Lets go to an end view. . . .,Horizontal End View,30,Horizontal starts where Flat ends. . . .,210,WWW.SPERKOENGINEERING.COM,Horizontal Rotates to where the plate is perpendicular to the ground,30,Horizontal

11、rotates clockwise . .,WWW.SPERKOENGINEERING.COM,Horizontal Position Rotated Limit,30,Horizontal ends here. . . .,10,90,280,70,Non-inclined Horizontal Position Limits,Starts with plate Rotated 30,70,Non-inclined Horizontal Position Limits,Finishes with plate Rotated 10 beyond perpendicular,Composite

12、Horizontal Position Limits,Compare Horizontal to 2G/PC,Test Position 2G/PC,Plates Vertical,Weld Axis Horizontal,15/PC,15/H,5/PC,-60+10/H,Horizontal 2G/PC !,80,280,Overhead Position,160 range,Basic Overhead,Face of weld is overhead!,0,Basic Overhead End View,Face of weld is overhead,0,Overhead Partia

13、l Rotation End View,Face of weld is overhead,0,Overhead Maximum Rotation End View,0,280,Face of weld on This side,Overhead Maximum Opposite Rotation End View,0,280,80,Face of weld on This side,Same Rotation in Isometric View,Basic Overhead,Face of weld is overhead,0,Face of weld is overhead,Overhead

14、 Partial Rotation Isometric View,0,Overhead Maximum Rotation Isometric View,0,280,Face of weld On this side,WWW.SPERKOENGINEERING.COM,Overhead Maximum Opposite Rotation Isometric View,0,280,80,Face of weld is on this side,Overhead PositionAxis Inclination,Basic Overhead for Inclined Axis,Face of wel

15、d is overhead,0, Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,Overhead Inclined Axis Rotation,0,0, Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,Overhead Inclined Axis Limit,0,80,Overhead Inclined Axis Limit,0,80,Weld can rotate 360 about vertical axis while inclined 10 forward tilt.,Overhe

16、ad Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead I

17、nclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld ends up back Where it started!,10,仰焊位置,280,80,0,0,80,360,10, Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,仰焊4G,Vertical P

18、osition Part 1,65 Range of Inclination From 15 to 80. Face of weld is up,15,80,Vertical Position Part 1,Range of inclination Starts at 15 Face of weld is up,15,Vertical Position Part 1,Range of inclination continues upward. . .,Greater than 15,Vertical Position Part 1,Until reaching 80,80,Vertical P

19、osition Part 2,When the “E” portion of the diagram is reached,80,Vertical Position Part 2,The “E” portion of the diagram - 360 Rotation About vertical axis,80,Vertical Position Part 2,The “E” portion of the diagram begins here. .,80,Vertical Position Part 2,Partial rotation about Vertical axis,Verti

20、cal Position Part 2,More rotation about Vertical axis,Vertical Position Part 2,Even more rotation about Vertical axis,Vertical Position Part 2,Rotated 180 about Vertical axis,Vertical Position Part 2,Continuing Rotation about Vertical axis,Vertical Position Part 2,Continuing Rotation about Vertical

21、axis,Vertical Position Part 2,Continuing Rotation about Vertical axis,Vertical Position Part 2,360 of Rotation about Vertical axis completed,Vertical Position Part 3,80,280,200 Range of Rotation,Vertical Position Part 3,Start here with inclination Uphill or Downhill 15 Face of weld upward,15,Vertica

22、l Position Part 3,Rotate face while holding Inclination constant,15,Vertical Position Part 3,Continue rotating with Inclination constant,15,Vertical Position Part 3,Rotated to vertical limit Inclination constant,15,280,Vertical Position Part 3,Return to starting position Uphill or Downhill 15 Face o

23、f weld upward,15,Vertical Position Part 3,Rotate face of weld Opposite direction Inclination Constant 15,15,Vertical Position Part 3,Continue rotating Opposite direction Inclination Constant 15,15,Vertical Position Part 3,Plate near vertical Inclination Constant 15,15,Vertical Position Part 3,Plate

24、at vertical limit of rotation. Inclination Constant 15,15,80,Vertical Position Part 3,80,280,200 Range of Rotation inclined Uphill or Downhill 15,15,Vertical Position Part 3,80,280,200 Range of Rotation Inclination angle Increases,Vertical Position Part 3,280,200 Range of Rotation Inclination angle

25、Increases more. . .,80,Vertical PositionComposite,80,280,160 range,65,200,360,Welding Positions for Fillet Welds,Flat Fillet Weld,Horizontal Fillet Weld,Welding Positions for Fillet Welds,Welding Positions for Fillet Welds,Tabulation of Positions of Fillet Welds PositionDiagram ReferenceInclination

26、of AxisRotation of Face FlatA0 to 15150 to 210 Horizontal B0 to 15125 t0 150 210 to 235 OverheadC0 to 800 to125 235 to 360 VerticalD15 to 80125 to 235 E80 to 900 to 360,Welding Positions for Fillet Welds,The Horizontal Range Is smaller for fillet welds Than it is for groove welds,Welding Positions f

27、or Groove Welds,焊缝坡口的清理 UW-32规定，坡口表面应清洁，无锈皮、锈、油、油脂、等其它有害物。,管接头与壳体的焊缝 UW-16(c & d)要求，安放式管接头（abutting type）必须采用全焊透结构。当全焊透结构不能用目视检查是否焊透，必须使用衬垫。插入式管接头可以采用角焊缝或未焊透结构，但，必须从容器的内外进行焊接。 UW-16.1,Section VIII Division 1的焊接要求,UW-20管子与管板的焊接 UW-20条给出了三种管子与管板的焊缝结构，强度焊接、半强度焊接、密封焊接。强度焊用来承受全部轴向载荷；密封焊仅用于作为胀接的补充焊接，以保证密封

28、；半强度焊是根据在实际设计条件下机械和热膨胀载荷来确定其强度的。 焊前准备 切割边必须光滑、清洁。（UW-31） 点焊焊缝、无论是去除，还是保留，都必须使用评定过的焊接工艺。（UW-31） 保留于焊缝中的点焊焊缝应由评定过的焊工施焊。（UW-31） 非受压件跨过受压焊缝与受压件相焊时，非受压件必须开槽以避让焊缝、或将受压焊缝磨平。（UG-82） 当受压件焊在受压焊缝上时，焊缝必须磨平。（UG-82）,UW-27焊接方法 UW-27规定，用于Section VIII Division 1的焊接方法有以下几类： UW-27(a)弧焊或气焊 UW-27(b)压力焊 UW-27(d)销钉焊 UW-27

29、(e)电渣焊 UW-27(f)电气焊,纵缝的排列 UW-9(d)对容器各筒节纵缝之间的排列规定了要求，即要求纵缝相互错开，相距至少是较厚板厚度的5倍，否则，焊缝两侧必须至少4”（102 mm）要求进行RT检验。 焊接限制 Section VIII中关于焊接的两项限制是： 销钉焊仅用于非受压/非承载件的焊接； 电渣焊仅用于铁基和UW-5(d)给出的奥氏体钢。,UW-28焊接工艺评定 UW-28给出了对焊接工艺进行评定的要求： 使用的焊接工艺必须有记录，也就是说必须有书面的焊接工艺。 当焊接受压/受力件、用手工或半自动焊方法焊接非受压/非受力件时，使用的焊接工艺应按Section IX进行评定。

30、当用机械焊方法焊接非受压/非承力件时，使用的焊接工艺可不按Section IX进行评定。 UW-29焊工技能评定 焊接受压或受力件与受压件焊缝的焊工和焊接操作工，必须按Section IX进行技能评定。可以采用首次焊接的产品焊缝来进行技能评定，但必须仔细阅读规范，以确定是否有例外或限制。销钉焊必须在每个班开始时对焊工进行技能评定，但当采用自动焊方法焊接非受压或非受力件时，可不必进行技能评定试验。Section IX中的其它要求必须满足。,制造厂在焊接工艺评定方面的责任 制造厂/ASME持证厂的责任： 编写书面WPS； 焊接评定试板，编写焊接工艺评定记录；机械性能试验可由另一试验室进行； 列出焊接参数； 在PQR上记录焊接参数和试验结果； 制定QC体系以控制焊接评定； 对焊接质量负责； 焊接材料和母材冶金上的适应性。 UW-35焊缝咬边 UW-35讨论了纵缝和环缝的外观要求，其中提到角焊缝和坡口焊