焊接工藝培訓(xùn)課件

1、大家好1焊接工藝培訓(xùn)23最后一個字母0123456789電源(a)交流或直流反接交流或直流交流或直流交流或直流直流反接交流或直流反接交流或直流交流或直流反接交流或直流藥皮類型(b)有機物金紅石*金紅石*金紅石*低氫低氫礦物質(zhì)低氫金紅石*電弧類型熔透(C)深適中淺淺適中適中適中適中適中藥皮中的鐵粉含量0%10%無0%10%0%10%30%50%無無50%30%50%0%10%備注: (a) E-6010是直流反接；E-6020是交流或直流 (b) E-6010是有機物藥皮；E-6020是礦物質(zhì)藥皮 (c) E-6010是深熔焊條；E-6020是熔深適中的焊條* 硬質(zhì)二氧化鈦藥皮45E7018-X

2、E焊條表示符號70焊縫金屬的抗拉強度等級，度量衡單位：psi1焊接位置8藥皮成分，熔透性，電流極性X補充要求焊接位置1平焊，橫焊，立向上焊，仰焊2平焊，橫焊4平焊，橫焊，立向下焊，仰焊碳鋼藥皮焊條（AWS A5.1/ASME SFA5.1）6等級焊條藥皮成分熔深電流極性EXXX0纖維素，硅深直流反接EXXX1纖維素，鉀深交流，直流反接EXXX2金紅石，硅一般交流，直流正接EXXX3金紅石，鉀淺交流，直流反接/直流正接EXXX4金紅石，鐵粉一般交流，直流反接/直流正接EXXX5低氫，硅一般直流反接EXXX6低氫，鉀一般交流，直流反接EXXX7鐵粉，氧化鐵一般交流，直流正接EXXX8低氫，鐵粉一般

3、交流，直流反接EXXX9氧化鐵，金紅石，鉀一般交流，直流反接/直流正接焊條型號列表7后綴補充要求-1改進E7018焊條的沖擊性能，也可用于表示改進E7024焊條的延展性。-M軍用要求-好的韌性，暴漏在空氣中時良好的防潮能力，熔敷金屬中擴散氫含量低-HX用于表示熔敷金屬中的最大擴散氫含量。列入-H4=4ml/100g補充符號8低合金鋼藥皮焊條（AWS A5.5/ASME SFA5.5）E7018-XE焊條表示符號70焊縫金屬的抗拉強度等級，度量衡單位：psi1焊接位置8藥皮成分，熔透性，電流極性X合金成分9后綴符號列表后綴合金成分后綴符號描述 -A1 碳-鉬鋼 含鉬：0.40%0.65% -B1

4、 鉻-鉬鋼 含鉻：0.40%0.65%，含鉬：0.40%0.65% -B2 鉻-鉬鋼 含鉻：1.00%1.50%，含鉬：0.40%0.65% -B2L 鉻-鉬鋼 低碳(Wc0.05%)，含鉻：1.00%1.50%，含鉬：0.40%0.65% -B3 鉻-鉬鋼 含鉻：2.00%2.50%，含鉬：0.90%1.20% -B3L 鉻-鉬鋼 低碳(Wc0.05%)，含鉻：2.00%2.50%，含鉬： 0.90%1.20% -B4L 鉻-鉬鋼 低碳(Wc0.05%)，含鉻：1.75%2.25%，含鉬：0.40%0.65% -B5 鉻-鉬鋼 含鉻：0.40%0.60%，含鉬：1.00%1.25% -B6

5、含鉻：4.60%6.00%，含鉬：0.45%0.65% -B8 含鉻：8.00%10.5%，含鉬：0.80%1.20% -C1 鎳鋼 含鎳：2.00%2.75% -C1L 鎳鋼 低碳(Wc0.05%)，含鎳：2.00%2.75% -C2 鎳鋼 低碳(Wc0.05%)，含鎳：3.00%3.75%10后綴符號列表后綴合金成分后綴符號描述 -C2L 含鎳鋼 低碳(Wc0.08%)，含鎳：3.00%3.75% -C3 含鎳鋼 含鎳：0.80%1.10% -NM 含鎳鋼 含鎳：0.80%1.10%，含鉬：0.40%0.65% -D1 含鎳、鉬 含錳：1.00%1.75%，含鉬：0.25%0.45% -D

6、2 含錳、鉬 含錳：1.65%2.00%，含鉬：0.25%0.45% -D3 含錳、鉬 含錳：1.00%1.80%，含鉬：0.40%0.65% -W 耐候鋼 Ni, Cr, Mo, Cu -G 未定義化學(xué)成分 -M 軍用等級 可能具有更多要求11力學(xué)性能等級級別最小抗拉強度最小屈服強度 E60XX 62000 psi (430 Mpa) 50000 psi (330 Mpa) E70XX 70000 psi (490 Mpa) 57000 psi (400 Mpa) E80XX 80000 psi (550 Mpa) 67000 psi (460 Mpa) E90XX 90000 psi (6

7、20 Mpa) 77000 psi (530 Mpa) E100XX 100000 psi (690 Mpa) 57000 psi (600 Mpa) E110XX 110000 psi (760 Mpa) 95000 psi (670 Mpa) E120XX 120000 psi (830 Mpa) 107000 psi (740 Mpa)12化學(xué)元素的作用符號名稱作用C碳 最有效的增加金屬硬度的元素Mn錳 對于金屬硬度的影響僅次于碳Si硅 還原劑，P磷 含量過高易導(dǎo)致裂紋S硫 含量過高易導(dǎo)致裂紋Cr鉻 提升金屬材料耐腐蝕性Ni鎳 提升金屬材料的低溫韌性Mo鉬 提升金屬材料的高溫強度B硼 少

8、量可提升金屬材料硬度Cu銅 耐腐蝕型弱，裂紋敏感度高Al鋁 還原劑，改進金屬材料力學(xué)性能Ti鈦 去除氧、硫、氮、碳N氮 改善金屬材料強度，不易于金屬材料的沖擊韌性Cb鈷 提升金屬材料硬度，改善金屬材料力學(xué)性能V礬 提升金屬材料硬度，改善金屬材料力學(xué)性能13141516171819202122ASME鍋爐及壓力容器規(guī)范第IX卷內(nèi)容：232425262728293031323334焊接接頭的分類35363738394041標(biāo)準(zhǔn)測試位置1G, 3G, 6G, 2F, 5F, 等式規(guī)范制定的測試用焊接位置. They are properly referred to as Test Positions

9、. 相似的描述見ISO 6947 定義PA, PC, PG, 等.421G/PA15焊縫水平軸板水平擺放5432G/PC板豎置焊縫水平軸155443F/PF or PG5456G45546Flat Positions Axis Inclination1547Start at Nominal Flat Position焊縫表面向上48平焊位置上傾角限制15Weld may incline upwardto a limit of 1549Flat Upward Inclined Limit15But the welder could be traveling down the incline. .

10、 .50Flat Downward Limit Is Implied1551Welding PositionsTabulation of Positions of Groove WeldsPositionDiagram ReferenceInclination of AxisRotation of FaceFlatA0 to 15150 to 210HorizontaB0 to 1580 to 150210 to 280OverheadC0 to 800 to 80210 to 360VerticalD15 to 8080 to 280E80 to 900 to 360How this tab

11、le and the diagram on the previous page work are shown in the following diagrams52Flat Position -Rotation About Axis1800303015021053Flat Rolled Limit Clockwise2101803054Flat Rolled Limit Clockwise21018030Equivalent to rotatingThe plate 3055Flat Rolled Limit Counterclockwise3015018056Flat Rotated Lim

12、its Not Considering Inclination6057Welding PositionsTabulation of Positions of Groove WeldsPositionDiagram ReferenceInclination of AxisRotation of FaceFlatA0 to 15150 to 210HorizontaB0 to 1580 to 150210 to 280OverheadC0 to 800 to 80210 to 360VerticalD15 to 8080 to 280E80 to 900 to 360How this table

13、and the diagram on the previous page work are shown in the following diagrams58Flat Uphill Limit Rotated156059Flat Downhill Limit Rotated1560Composite Flat Position Ranges306061Compare this range to 1G/PA. . . 6215/FLATTesting Position 1G/PA15/PAWeld Axis HorizontalPlate Horizontal5/PA30/FLAT63Flat

14、1G !64Welding PositionsTabulation of Positions of Groove WeldsPositionDiagram ReferenceInclination of AxisRotation of FaceFlatA0 to 15150 to 210Horizontal B0 to 1580 to 150 210 to 280OverheadC0 to 800 to 80210 to 360VerticalD15 to 8080 to 280E80 to 900 to 360How this table and the diagram on the pre

15、vious page work are shown in the following diagrams65Horizontal Position Axis Inclined1566Basic Horizontal Position67Horizontal Position Uphill Inclined Limit1568Horizontal Position Downhill Inclined Limit1569Welding PositionsTabulation of Positions of Groove WeldsPositionDiagram ReferenceInclinatio

16、n of AxisRotation of FaceFlatA0 to 15150 to 210Horizontal B0 to 1580 to 150210 to 280OverheadC0 to 800 to 80210 to 360VerticalD15 to 8080 to 280E80 to 900 to 360How this table and the diagram on the previous page work are shown in the following diagrams70Horizontal Position Rotated8015070 range21028

17、070 Range71210Start at the Flat Rolled Limits18030Lets go to an end view. . . .72Horizontal End View30Horizontal starts where Flat ends. . . .21073Horizontal Rotates to where the plate is perpendicular to the ground30Horizontal rotates clockwise . .74Horizontal Position Rotated Limit30Horizontal end

18、s here. . . .10902807570Non-inclined Horizontal Position LimitsStarts with plate Rotated 307670Non-inclined Horizontal Position LimitsFinishes with plate Rotated 10 beyondperpendicular77Composite Horizontal Position Limits151578Compare Horizontal to 2G/PC79Test Position 2G/PCPlates VerticalWeld Axis

19、 Horizontal15/PC15/H5/PC-60+10/H80Horizontal 2G/PC !8180280Overhead Position160 range82Basic OverheadFace of weld is overhead!083Basic Overhead End ViewFace of weld is overhead084Overhead Partial Rotation End ViewFace of weld is overhead085Overhead Maximum Rotation End View0280Face of weld onThis si

20、de86Overhead Maximum Opposite Rotation End View028080Face of weld onThis side87Same Rotation in Isometric View88Basic OverheadFace of weld is overhead089Face of weld is overheadOverhead Partial Rotation Isometric View090Overhead Maximum Rotation Isometric View0280Face of weldOn this side91Overhead M

21、aximum Opposite Rotation Isometric View028080Face of weld is on this side92Overhead PositionAxis Inclination80280160 range80 range93Basic Overhead for Inclined AxisFace of weld is overhead094Overhead Inclined Axis Rotation0095Overhead Inclined Axis Limit08096Overhead Inclined Axis Limit080Weld can r

22、otate 360 about vertical axis while inclined 10 forward tilt.97Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis1098Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis1099Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis10100Overhead Inclined Axis

23、Limit0Weld can rotate aboutThe vertical axis10101Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis10102Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis10103Overhead Inclined Axis Limit0Weld ends up back Where it started!10104仰焊位置28080008036010105仰焊4G106Vertical P

24、osition Part 165 Range of Inclination From 15 to 80.Face of weld is up1580107Vertical Position Part 1Range of inclination Starts at 15Face of weld is up15108Vertical Position Part 1Range of inclination continues upward. . . Greater than 15109Vertical Position Part 1Until reaching 80 80110Vertical Po

25、sition Part 2When the “E” portion of the diagram is reached 80111Vertical Position Part 2The “E” portion of the diagram -360 RotationAbout vertical axis80112Vertical Position Part 2The “E” portion of the diagram begins here. . 80113Vertical Position Part 2Partial rotation aboutVertical axis 114Verti

26、cal Position Part 2More rotation aboutVertical axis 115Vertical Position Part 2Even more rotation aboutVertical axis 116Vertical Position Part 2Rotated 180 aboutVertical axis 117Vertical Position Part 2Continuing Rotation aboutVertical axis 118Vertical Position Part 2Continuing Rotation aboutVertica

27、l axis 119Vertical Position Part 2Continuing Rotation aboutVertical axis 120Vertical Position Part 2360 of Rotation aboutVertical axis completed 121Vertical Position Part 380280200 Range of Rotation122Vertical Position Part 3 Start here with inclinationUphill or Downhill 15Face of weld upward15123Ve

28、rtical Position Part 3Rotate face while holding Inclination constant15124Vertical Position Part 3Continue rotating with Inclination constant15125Vertical Position Part 3Rotated to vertical limit Inclination constant15280126Vertical Position Part 3 Return to starting positionUphill or Downhill 15Face

29、 of weld upward15127Vertical Position Part 3 Rotate face of weld Opposite directionInclination Constant 1515128Vertical Position Part 3 Continue rotatingOpposite directionInclination Constant 1515129Vertical Position Part 3 Plate near verticalInclination Constant 1515130Vertical Position Part 3 Plat

30、e at vertical limitof rotation.Inclination Constant 151580131Vertical Position Part 380280200 Range of Rotation inclinedUphill or Downhill 1515132Vertical Position Part 380280200 Range of Rotation Inclination angleIncreases133Vertical Position Part 3280200 Range of Rotation Inclination angleIncrease

31、s more. . . 80134Vertical PositionComposite 80280160 range65200360135Welding Positions for Fillet Welds136Flat Fillet Weld137Horizontal Fillet Weld138Welding Positions for Fillet Welds139Welding Positions for Fillet WeldsTabulation of Positions of Fillet WeldsPositionDiagram ReferenceInclination of

32、AxisRotation of FaceFlatA0 to 15150 to 210Horizontal B0 to 15125 t0 150210 to 235OverheadC0 to 800 to125235 to 360VerticalD15 to 80125 to 235E80 to 900 to 360140Welding Positions for Fillet WeldsThe Horizontal RangeIs smaller for fillet weldsThan it is for groove welds141Welding Positions for Groove

33、 Welds142143144145146焊縫坡口的清理UW-32規(guī)定，坡口表面應(yīng)清潔，無銹皮、銹、油、油脂、等其它有害物。管接頭與殼體的焊縫UW-16(c & d)要求，安放式管接頭（abutting type）必須采用全焊透結(jié)構(gòu)。當(dāng)全焊透結(jié)構(gòu)不能用目視檢查是否焊透，必須使用襯墊。插入式管接頭可以采用角焊縫或未焊透結(jié)構(gòu)，但，必須從容器的內(nèi)外進行焊接。UW-16.1Section VIII Division 1的焊接要求147UW-20管子與管板的焊接UW-20條給出了三種管子與管板的焊縫結(jié)構(gòu)，強度焊接、半強度焊接、密封焊接。強度焊用來承受全部軸向載荷；密封焊僅用于作為脹接的補充焊接，以保證密

34、封；半強度焊是根據(jù)在實際設(shè)計條件下機械和熱膨脹載荷來確定其強度的。焊前準(zhǔn)備切割邊必須光滑、清潔。（UW-31） 點焊焊縫、無論是去除，還是保留，都必須使用評定過的焊接工藝。（UW-31）保留于焊縫中的點焊焊縫應(yīng)由評定過的焊工施焊。（UW-31）非受壓件跨過受壓焊縫與受壓件相焊時，非受壓件必須開槽以避讓焊縫、或?qū)⑹軌汉缚p磨平。（UG-82）當(dāng)受壓件焊在受壓焊縫上時，焊縫必須磨平。（UG-82）148UW-27焊接方法UW-27規(guī)定，用于Section VIII Division 1的焊接方法有以下幾類：UW-27(a)弧焊或氣焊UW-27(b)壓力焊UW-27(d)銷釘焊UW-27(e)電渣焊U

35、W-27(f)電氣焊149縱縫的排列UW-9(d)對容器各筒節(jié)縱縫之間的排列規(guī)定了要求，即要求縱縫相互錯開，相距至少是較厚板厚度的5倍，否則，焊縫兩側(cè)必須至少4”（102 mm）要求進行RT檢驗。焊接限制Section VIII中關(guān)于焊接的兩項限制是： 銷釘焊僅用于非受壓/非承載件的焊接； 電渣焊僅用于鐵基和UW-5(d)給出的奧氏體鋼。150UW-28焊接工藝評定UW-28給出了對焊接工藝進行評定的要求： 使用的焊接工藝必須有記錄，也就是說必須有書面的焊接工藝。當(dāng)焊接受壓/受力件、用手工或半自動焊方法焊接非受壓/非受力件時，使用的焊接工藝應(yīng)按Section IX進行評定。當(dāng)用機械焊方法焊接非

36、受壓/非承力件時，使用的焊接工藝可不按Section IX進行評定。UW-29焊工技能評定焊接受壓或受力件與受壓件焊縫的焊工和焊接操作工，必須按Section IX進行技能評定?？梢圆捎檬状魏附拥漠a(chǎn)品焊縫來進行技能評定，但必須仔細閱讀規(guī)范，以確定是否有例外或限制。銷釘焊必須在每個班開始時對焊工進行技能評定，但當(dāng)采用自動焊方法焊接非受壓或非受力件時，可不必進行技能評定試驗。Section IX中的其它要求必須滿足。151制造廠在焊接工藝評定方面的責(zé)任制造廠/ASME持證廠的責(zé)任：編寫書面WPS；焊接評定試板，編寫焊接工藝評定記錄；機械性能試驗可由另一試驗室進行；列出焊接參數(shù)；在PQR上記錄焊接參數(shù)和試驗結(jié)果；制定QC體系以控制焊接評定；對焊接質(zhì)量負責(zé)；焊接材料和母材冶金上的適應(yīng)