焊接工藝培訓(xùn)

1、最后最后一個(gè)一個(gè)字母字母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(jī)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(wú)0%10%0%10%30%50%無(wú)無(wú)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(jī)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E7018-XE焊條表示符號(hào)焊

2、條表示符號(hào)70焊縫金屬的抗拉強(qiáng)度等級(jí)，度量衡單位：psi1焊接位置8藥皮成分，熔透性，電流極性X補(bǔ)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）等級(jí)等級(jí)焊條藥皮成分焊條藥皮成分熔深熔深電流極性電流極性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E

3、XXX8低氫，鐵粉一般交流，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(hào)列表后綴后綴補(bǔ)充要求補(bǔ)充要求-1改進(jìn)E7018焊條的沖擊性能，也可用于表示改進(jìn)E7024焊條的延展性。-M軍用要求-好的韌性，暴漏在空氣中時(shí)良好的防潮能力，熔敷金屬中擴(kuò)散氫含量低-HX用于表示熔敷金屬中的最大擴(kuò)散氫含量。列入-H4=4ml/100g補(bǔ)充符號(hào)低合金鋼藥皮焊條（AWS A5.5/ASME SFA5.5）E7018-XE焊條表示符號(hào)焊條表示符號(hào)70焊縫金屬的抗拉強(qiáng)度等級(jí)，度量衡單位：psi1焊接位置8藥皮成分，熔透性，電流極性X合金成分后綴符號(hào)列表后綴符號(hào)列表后綴合金成分后綴符號(hào)描述

4、-A1 碳-鉬鋼 含鉬：0.40%0.65% -B1 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：0.4

5、0%0.60%，含鉬：1.00%1.25% -B6 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%后綴符號(hào)列表后綴符號(hào)列表后綴合金成分后綴符號(hào)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

6、含錳：1.00%1.75%，含鉬：0.25%0.45% -D2 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(jí) 可能具有更多要求力學(xué)性能等級(jí)力學(xué)性能等級(jí)級(jí)別最小抗拉強(qiáng)度最小屈服強(qiáng)度 E60XX 62000 psi (430 Mpa) 50000 psi (330 Mpa) E70XX 70000 psi (490 Mpa) 57000 psi (400 Mpa) E80XX 80000 psi (550 Mpa) 6700

7、0 psi (460 Mpa) E90XX 90000 psi (620 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)化學(xué)元素的作用化學(xué)元素的作用符號(hào)名稱作用C碳 最有效的增加金屬硬度的元素Mn錳 對(duì)于金屬硬度的影響僅次于碳Si硅 還原劑，P磷 含量過(guò)高易導(dǎo)致裂紋S硫 含量過(guò)高易導(dǎo)致裂紋Cr鉻 提升金屬材

8、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(qiáng)度B硼 少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(jìn)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(qiáng)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ASME鍋爐及壓力容器規(guī)范第IX卷內(nèi)容：焊接接頭的分類標(biāo)準(zhǔn)測(cè)試位置標(biāo)準(zhǔn)測(cè)試位置1G, 3G, 6G, 2F, 5F, 等式規(guī)范制定的測(cè)試用焊接位置. They are properly referred to as Test Positions. 相似的描述見(jiàn)ISO 6

9、947 定義PA, PC, PG, 等.1G/PA15焊縫水平軸板水平擺放2G/PC板豎置焊縫水平軸153F/PF or PG56G455Flat Positions Axis Inclination15Start at Nominal Flat Position焊縫表面向上WWW.SPERKOENGINEERING.COM平焊位置上傾角限制15Weld may incline upwardto a limit of 15WWW.SPERKOENGINEERING.COMFlat Upward Inclined Limit15But the welder could be traveling

10、down the incline. . .WWW.SPERKOENGINEERING.COMFlat Downward Limit Is Implied15Welding 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

11、8080 to 280E80 to 900 to 360How this table and the diagram on the previous page work are shown in the following diagramsFlat Position -Rotation About Axis18003030150210WWW.SPERKOENGINEERING.COMFlat Rolled Limit Clockwise21018030Flat Rolled Limit Clockwise21018030Equivalent to rotatingThe plate 30WWW

12、.SPERKOENGINEERING.COMFlat Rolled Limit Counterclockwise30150180Flat Rotated Limits Not Considering Inclination60Welding PositionsTabulation of Positions of Groove WeldsPositionDiagram ReferenceInclination of AxisRotation of FaceFlatA0 to 15150 to 210HorizontaB0 to 1580 to 150210 to 280OverheadC0 to

13、 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 diagramsFlat Uphill Limit Rotated1560Flat Downhill Limit Rotated15Composite Flat Position Ranges3060Compare this range to 1G/PA. . . 15/FLATTesting Posit

14、ion 1G/PA15/PAWeld Axis HorizontalPlate Horizontal5/PA30/FLATFlat 1G !Welding 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

15、to 280E80 to 900 to 360How this table and the diagram on the previous page work are shown in the following diagramsHorizontal Position Axis Inclined15Basic Horizontal PositionHorizontal Position Uphill Inclined Limit15Horizontal Position Downhill Inclined Limit15Welding PositionsTabulation of Positi

16、ons of Groove WeldsPositionDiagram ReferenceInclination 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 d

17、iagramsHorizontal Position Rotated8015070 range21028070 Range210Start at the Flat Rolled Limits18030Lets go to an end view. . . .Horizontal End View30Horizontal starts where Flat ends. . . .210WWW.SPERKOENGINEERING.COMHorizontal Rotates to where the plate is perpendicular to the ground30Horizontal r

18、otates clockwise . .WWW.SPERKOENGINEERING.COMHorizontal Position Rotated Limit30Horizontal ends here. . . .109028070Non-inclined Horizontal Position LimitsStarts with plate Rotated 3070Non-inclined Horizontal Position LimitsFinishes with plate Rotated 10 beyondperpendicularComposite Horizontal Posit

19、ion Limits1515Compare Horizontal to 2G/PCTest Position 2G/PCPlates VerticalWeld Axis Horizontal15/PC15/H5/PC-60+10/HHorizontal 2G/PC !80280Overhead Position160 rangeBasic OverheadFace of weld is overhead!0Basic Overhead End ViewFace of weld is overhead0Overhead Partial Rotation End ViewFace of weld

20、is overhead0Overhead Maximum Rotation End View0280Face of weld onThis sideOverhead Maximum Opposite Rotation End View028080Face of weld onThis sideSame Rotation in Isometric ViewBasic OverheadFace of weld is overhead0Face of weld is overheadOverhead Partial Rotation Isometric View0Overhead Maximum R

21、otation Isometric View0280Face of weldOn this sideWWW.SPERKOENGINEERING.COMOverhead Maximum Opposite Rotation Isometric View028080Face of weld is on this sideOverhead PositionAxis Inclination80280160 range80 rangeBasic Overhead for Inclined AxisFace of weld is overhead0 Sperko Engineering 2005WWW.SP

22、ERKOENGINEERING.COMOverhead Inclined Axis Rotation00 Sperko Engineering 2005WWW.SPERKOENGINEERING.COMOverhead Inclined Axis Limit080Overhead Inclined Axis Limit080Weld can rotate 360 about vertical axis while inclined 10 forward tilt.Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axi

23、s10Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis10Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis10Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis10Overhead Inclined Axis Limit0Weld can rotate aboutThe vertical axis10Overhead Inclined Axi

24、s Limit0Weld can rotate aboutThe vertical axis10Overhead Inclined Axis Limit0Weld ends up back Where it started!10仰焊位置28080008036010 Sperko Engineering 2005WWW.SPERKOENGINEERING.COM仰焊4GVertical Position Part 165 Range of Inclination From 15 to 80.Face of weld is up1580Vertical Position Part 1Range o

25、f inclination Starts at 15Face of weld is up15Vertical Position Part 1Range of inclination continues upward. . . Greater than 15Vertical Position Part 1Until reaching 80 80Vertical Position Part 2When the “E” portion of the diagram is reached 80Vertical Position Part 2The “E” portion of the diagram

26、-360 RotationAbout vertical axis80Vertical Position Part 2The “E” portion of the diagram begins here. . 80Vertical Position Part 2Partial rotation aboutVertical axis Vertical Position Part 2More rotation aboutVertical axis Vertical Position Part 2Even more rotation aboutVertical axis Vertical Positi

27、on Part 2Rotated 180 aboutVertical axis Vertical Position Part 2Continuing Rotation aboutVertical axis Vertical Position Part 2Continuing Rotation aboutVertical axis Vertical Position Part 2Continuing Rotation aboutVertical axis Vertical Position Part 2360 of Rotation aboutVertical axis completed Ve

28、rtical Position Part 380280200 Range of RotationVertical Position Part 3 Start here with inclinationUphill or Downhill 15Face of weld upward15Vertical Position Part 3Rotate face while holding Inclination constant15Vertical Position Part 3Continue rotating with Inclination constant15Vertical Position

29、 Part 3Rotated to vertical limit Inclination constant15280Vertical Position Part 3 Return to starting positionUphill or Downhill 15Face of weld upward15Vertical Position Part 3 Rotate face of weld Opposite directionInclination Constant 1515Vertical Position Part 3 Continue rotatingOpposite direction

30、Inclination Constant 1515Vertical Position Part 3 Plate near verticalInclination Constant 1515Vertical Position Part 3 Plate at vertical limitof rotation.Inclination Constant 151580Vertical Position Part 380280200 Range of Rotation inclinedUphill or Downhill 1515Vertical Position Part 380280200 Rang

31、e of Rotation Inclination angleIncreasesVertical Position Part 3280200 Range of Rotation Inclination angleIncreases more. . . 80Vertical PositionComposite 80280160 range65200360Welding Positions for Fillet WeldsFlat Fillet WeldHorizontal Fillet WeldWelding Positions for Fillet WeldsWelding Positions

32、 for Fillet WeldsTabulation of Positions of Fillet WeldsPositionDiagram ReferenceInclination of 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 360Welding Positions for Fillet WeldsThe Horizont

33、al RangeIs smaller for fillet weldsThan it is for groove weldsWelding Positions for Groove Welds焊縫坡口的清理焊縫坡口的清理UW-32規(guī)定，坡口表面應(yīng)清潔，無(wú)銹皮、銹、油、油脂、等其它有害物。管接頭與殼體的焊縫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(jìn)行焊接。 UW-16.1Section VIII Divisio

34、n 1的焊接要求的焊接要求UW-20管子與管板的焊接管子與管板的焊接UW-20條給出了三種管子與管板的焊縫結(jié)構(gòu)，強(qiáng)度焊接、半強(qiáng)度焊接、密封焊接。強(qiáng)度焊用來(lái)承受全部軸向載荷；密封焊僅用于作為脹接的補(bǔ)充焊接，以保證密封；半強(qiáng)度焊是根據(jù)在實(shí)際設(shè)計(jì)條件下機(jī)械和熱膨脹載荷來(lái)確定其強(qiáng)度的。焊前準(zhǔn)備焊前準(zhǔn)備 切割邊必須光滑、清潔。（UW-31） 點(diǎn)焊焊縫、無(wú)論是去除，還是保留，都必須使用評(píng)定過(guò)的焊接工藝。（UW-31） 保留于焊縫中的點(diǎn)焊焊縫應(yīng)由評(píng)定過(guò)的焊工施焊。（UW-31） 非受壓件跨過(guò)受壓焊縫與受壓件相焊時(shí)，非受壓件必須開(kāi)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(shí)，焊縫必

35、須磨平。（UG-82）UW-27焊接方法焊接方法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UW-27(f)電氣焊縱縫的排列縱縫的排列UW-9(d)對(duì)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(cuò)開(kāi)，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(jìn)行RT檢驗(yàn)。焊接限制焊接限制Section VIII中關(guān)于焊接的兩項(xiàng)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。UW-28焊接工

36、藝評(píng)定焊接工藝評(píng)定UW-28給出了對(duì)焊接工藝進(jìn)行評(píng)定的要求： 使用的焊接工藝必須有記錄，也就是說(shuō)必須有書(shū)面的焊接工藝。 當(dāng)焊接受壓/受力件、用手工或半自動(dòng)焊方法焊接非受壓/非受力件時(shí)，使用的焊接工藝應(yīng)按Section IX進(jìn)行評(píng)定。 當(dāng)用機(jī)械焊方法焊接非受壓/非承力件時(shí)，使用的焊接工藝可不按Section IX進(jìn)行評(píng)定。UW-29焊工技能評(píng)定焊工技能評(píng)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(jìn)行技能評(píng)定?？梢圆捎檬状魏附拥漠a(chǎn)品焊縫來(lái)進(jìn)行技能評(píng)定，但必須仔細(xì)閱讀規(guī)范，以確定是否有例外或限制。銷釘焊必須在每個(gè)班開(kāi)始時(shí)對(duì)焊工進(jìn)行技能評(píng)定，但當(dāng)采用自動(dòng)焊方法焊接非受壓或非受力件時(shí)，可不必進(jìn)行技能評(píng)定試驗(yàn)。Section IX中的其它要求必須滿足。制造廠在焊接工藝評(píng)定方面的責(zé)任制造廠在焊接工藝評(píng)定方面的責(zé)任制造廠制造廠/ASME持證廠的責(zé)任： 編寫(xiě)書(shū)面WPS； 焊接評(píng)定試板，編寫(xiě)焊接工藝評(píng)定記錄；機(jī)械性能試驗(yàn)可由另一試驗(yàn)室進(jìn)行； 列出焊接參數(shù)； 在PQR上記錄焊接參數(shù)和試驗(yàn)結(jié)果； 制定QC體系以控制焊接評(píng)定； 對(duì)焊接質(zhì)量負(fù)責(zé)； 焊接材料和母材冶金上的適應(yīng)性。UW-35焊縫咬邊焊縫咬邊UW