焊縫返修作業(yè)指導(dǎo)書(shū)

1、.封面修 改 歷 史修改次數(shù)修訂人/部門(mén)修改內(nèi)容修改執(zhí)行日期0劉劍波第一次發(fā)行2013-4-101.0 目的Purpose 規(guī)范焊縫缺陷返修 Define requirement of welds defects are repaired.2.0 范圍Scope 適用于龐巴迪PHD Metallic parts 520043584、520043585焊接件焊縫Application range, part number 520043584 & 5200435853.0 職責(zé)Responsibility 3.1 焊工負(fù)責(zé)焊接和焊后自檢，缺陷標(biāo)記，返修操作Welder responsibl

2、e for self-check during welding and after welding, make an record also, remarking and rework the defects.3.2 焊接檢驗(yàn)員負(fù)責(zé)焊縫檢驗(yàn)和缺陷確認(rèn)，返工效果確認(rèn)Welding inspector check repaired welds and validate the rework result.3.3 焊接工程師負(fù)責(zé)返修工藝，返修過(guò)程IWE responsible for repair process and monitoring the repair procedure.4.0 流程圖

3、Flow chart 焊后檢驗(yàn)Inspection after welding返修工藝Repair process缺陷標(biāo)記，缺陷確認(rèn)Remarking defect 返修操作Repair operation返修效果確認(rèn)Rework result confirm5.0 作業(yè)內(nèi)容Process Content5.1 經(jīng)質(zhì)檢員、技術(shù)員宏觀檢查或各種探傷方法確定的下列缺陷（欠）必須進(jìn)行返修或補(bǔ)焊Below defects have to be repaired after inspection,Ø 表面氣孔、裂紋、夾渣、弧坑等深度大于0.5mm的等缺陷；Gas pore, cracks, s

4、lag, pit depth more than 0.5mm.Ø 焊縫咬邊深度大于0.5mm ，咬邊連續(xù)長(zhǎng)度大于100mm，焊縫兩側(cè)咬邊的總長(zhǎng)超過(guò)該焊縫長(zhǎng)度的10%；Undercut depth over 0.5mm, Undercut continuous length over 100mm, Undercut length over 10% of welds length on both side of seams.Ø 表面焊瘤；Overlap on the surface.Ø 打磨焊縫表面缺陷或機(jī)械損傷后的厚度小于母材的厚度。Seam surface def

5、ect after grinding or thickness is lower than base material after mechanical treatment. 5.2 缺陷的清除方法 Clearance method of defectsØ 低碳鋼或S390MPa的低合金強(qiáng)度鋼以及低合金耐熱鋼（指115CrMo等）可用碳弧氣刨消除缺陷，氣刨后熔渣必須清除干凈，方可進(jìn)行補(bǔ)焊。低合金耐熱鋼氣刨前必要時(shí)需進(jìn)行預(yù)熱。Take method of carbon arc air gouging to clean the defects for low carbon steel o

6、r S390MPa high strength low alloy steel & low-alloy heat-resistant steel，Spatter should be removed completely after gouging, then start to repair. Pre-heat treatment should be performed before gouging especially for low alloy heat-resistant steel.Ø 對(duì)S390MPa的低合金強(qiáng)度鋼以及21/4Cr-1Mo鋼在有條件的情況下，應(yīng)盡可能

7、采用機(jī)械方法，或用風(fēng)鏟、砂輪清除缺陷，若實(shí)在沒(méi)有條件時(shí)，也可以通過(guò)預(yù)熱進(jìn)行碳弧氣刨清除缺陷，但必須遵守下列規(guī)定：If condition is permission, for S390MPa high strength low alloy steel & 21/4 Cr- Mo steel, should take mechanical clean way, pneumatic chipping hammer or grinding wheel to remove defects. If condition is not permission, pre-heat and carbon

8、arc air gouging also are acceptable to remove the defects, but have to follow below rules:Ø 氣刨前的預(yù)熱溫度應(yīng)比該材料的焊接預(yù)熱溫度再提高50。 Temperature of Pre-heat treatment should higher 50than temperature of welding pre-heat before carbon arc air gouging.Ø 氣刨時(shí)嚴(yán)防滲碳，氣刨后必須將熔渣清除干凈，氣刨后形成的坡度不得大于1:3. Take strict pr

9、ecautions against cementite when gouging, the groove should 1：3 after gouging.Ø 氣刨后應(yīng)對(duì)其刨槽用肉眼認(rèn)真檢查，必要時(shí)應(yīng)進(jìn)行磁粉探傷，確認(rèn)無(wú)缺陷時(shí)，方能進(jìn)行預(yù)熱補(bǔ)焊。VT inspection after grinding, MT should be performed if it is necessary. Pre-heat and repair can be done after no defects are found.Ø 對(duì)于裂紋缺陷，必須先將裂紋的起終點(diǎn)準(zhǔn)確判斷清楚，在裂紋兩端部鉆孔控

10、制住裂紋 的擴(kuò)展，再根據(jù)材質(zhì)、缺陷大小、返修條件等具體情況，選擇合理方法將缺陷清除，并經(jīng)著色檢查確定無(wú)缺陷后，方能進(jìn)行焊接。For crack defect, start and end of cracks should be detected clearly at first, drill hole to control the extension on the both side of the cracks, remove defects and PT inspection, then start to repair weld.Ø 不透鋼的返修，應(yīng)盡量采用間歇和分段氣刨，以減少熱

11、量輸入，并徹底清除滲碳層，露出金屬光澤后方可焊接。For the repair of stainless steel, to reduce heat energy and clean completely, gouging should in discontinuous way.Ø 返修工藝規(guī)程 Repair specificationØ 返修過(guò)程中盡量做到一次合格，同一位部的返修一般不應(yīng)超過(guò)兩次，如兩次返修仍不合格，應(yīng)視為嚴(yán)重質(zhì)量事故。應(yīng)由項(xiàng)目經(jīng)理組織焊接工程師、質(zhì)檢員、施焊焊工參與，共同分析查找原因。定出返修措施，并報(bào)焊接監(jiān)督批準(zhǔn)，方能進(jìn)行第三次返修。返修部位和返修次數(shù)

12、應(yīng)在產(chǎn)品質(zhì)量證明書(shū)中注明。當(dāng)整條焊縫割掉重新焊接時(shí)，割掉以前的返修次數(shù)在產(chǎn)品質(zhì)量證明書(shū)中可以不計(jì)在內(nèi)。Repair should be inspected by one time, rework cannot over 2 times in same position, and furthermore it is taken account into a serious quality issue if not qualified by two times repair.For the third time rework, Project management should organize

13、IWE, quality and welder analyze root reason, make a rework plan and approved by SAP.Repair quantity and position should be recorded in product quality certificate.Ø 出現(xiàn)嚴(yán)重缺陷，如裂紋等時(shí)，應(yīng)進(jìn)行質(zhì)量分析，找出原因，制訂措施后，方能進(jìn)行返修。Rework plan should be made before reworking for serious defects, such as crack.Ø 判斷缺陷部

14、位，正確選擇清除缺陷方法，確實(shí)將缺陷清除干凈后，方能進(jìn)行補(bǔ)焊。Each repair can be done after cleaning completely.Ø 須經(jīng)過(guò)同類、同組產(chǎn)品考試合格且較有經(jīng)驗(yàn)的焊工擔(dān)任，施焊時(shí)要特別精心細(xì)致。Rework should be performed by qualified welder. 5.4 返修操作RepairØ 補(bǔ)焊時(shí)，必須嚴(yán)格控制焊接規(guī)范及層間溫度，防止焊道過(guò)熱以致造成返修部位焊縫機(jī)械性能下降。應(yīng)盡量采用小規(guī)范的多層多道焊接，不允許以大幅度橫向擺動(dòng)，慢速堆焊的方法進(jìn)行補(bǔ)焊。During repair should str

15、ictly follow WPS, also include control layer temperature, to avoid decrease mechanical properties in welding area due to superheat, small range multi-pass welding will take.Ø 要特別注意起弧和收弧處的焊接質(zhì)量，多層多道焊時(shí)，每道焊接的起弧，收弧處應(yīng)盡量錯(cuò)開(kāi)。Pay attention to the quality of starts-stop, starts-stop of each layer should b

16、e crossed especially for multi-pass welding.Ø 每焊完一遍之后，要認(rèn)真清渣，發(fā)現(xiàn)缺陷，及時(shí)清除后，再繼續(xù)施焊。 Each layer should clean, no defect then continue to weld.Ø 對(duì)要求預(yù)熱的材質(zhì)，返修前必須嚴(yán)格按照規(guī)定溫度進(jìn)行預(yù)熱，返修中應(yīng)始終保持不低于所要求的預(yù)熱溫度，返修后必要時(shí)進(jìn)行后熱消氫處理。If the pre-heat treatment is request, pre-heat specification should be follow during the repair.Ø 對(duì)厚度較薄或要求外形尺寸嚴(yán)格的產(chǎn)品，返修時(shí)應(yīng)采用砂輪打磨等方法，以防變形。Grinding wheel method has to be taken to avoid deformation during rework for think thickness material or strict dimension requirement parts.Ø 返修后的補(bǔ)焊焊縫必須修磨表面，使其外形與原焊縫大體一致，不得過(guò)寬過(guò)高。Welds should be grinded after reworking to keep the shape simila