焊接培训资料Weldingtheorytraining(1)

1、Welding theory焊接理论焊接理论AreasAreas领域领域In this training we will cover the most general areas of:在这个训练中,我们将介绍最通用的领域：Welding types 焊接类型Standards & Classes标准&级别Welding positions焊接位置Welding symbols焊接代号Calculations计算Quality Assurance质量保证Types of welding类型的焊接类型的焊接Fusion welding is a generic term for welding

2、processes熔焊焊接过程是一个通用的术语. that rely upon melting to join materials of similar类似的,依靠融化加入材料.compositions and melting points.成分和熔化点。Types of welding类型的焊接 Consumable electrode flux coated 自耗电极磁通涂MMA - Manual Metal Arc (stick welding) MMA -手动金属电弧(粘焊) Carbon Dioxide (A mix between argon and carbon dioxide

3、is normal) 二氧化碳(氩气和二氧化碳之间的混合是正常的)MAG - Metal Active Gas 杂志-金属活性气体 Argon, Helium 氩、氦MIG - Metal Inert Gas 米格-金属惰性气体 Argon, Helium 氩、氦TIG Tungsten Inert Gas TIG(钨极惰性气体 Standards 标准标准ISO 5817 Quality levels for imperfections 缺陷质量分级ISO 4063 Reference Numbers for Welding methods 焊接方法的参考数据ISO 3834-01 ,-02

4、, -03, -04 Quality requirements for fusion welding. 熔焊质量要求ISO 9606 Qualification test for welders 对焊工资格考试ISO 2553Welded, brazed and soldered joints 焊接,焊接和焊接接头symbolic representation on drawings 符号表示，图纸ISO 17635 Non-destructive testing of welds. General rules for 焊缝的无损检验，一般规则metallic materials 金属材料 (

5、Acceptance levels cannot be a direct interpretation of the quality levels defined in ISO 5817 or ISO 10042. They are linked to the overall quality of the produced batch of welds.).and many more其他，更多Welding is controlled by a numbers of Standards. 焊接由数字控制的标准Standards标准标准Why do we need standards?为什么我们

6、需要标准Reduce Risk减小风险More sustainable更可持续Improving performance性能提升Welding classes焊 接 类General 一般一般Welding class as following: 焊接类如下SS-EN ISO 5817 for ferrite material and stainless steel. 对铁氧体材料和不锈钢SS-EN ISO 5817。SS-EN ISO 10042 for aluminium. 为铝SS-EN ISO 10042。Acceptance boundary, discontinuities and

7、 form deviations,see SS-EN ISO 6520-1, 接受边界、断层和偏差,看到SS-EN ISO 6520 - 1,table 1.Welding class B 焊接类 BThe transition between the weld and the base material shall be even, and shall not焊接和基材之间的过渡应均匀,不得have any sharp notches. Craters shall be filled in and unevennesses shall be removed.有任何锋利的等级。陨石坑应当填写,

8、不应删除The weld face and root face of butt joints shall have a plane or slightly convex form.对接接头的焊缝表面和根面有一架飞机或略凸的形式Corner joints shall be convex on the outside and in the main concave or plane on the inside.角接头应在主凹或凸在外面和飞机The weld face of T-joints shall preferably have a concave or plane form, but a s

9、lightly convex form is acceptable.丁字接头的焊接面最好是有一个凹形或平面形式,但略凸形式是可以接受的The homogeneity of the weld shall in the main meet the requirements of X-ray class焊缝应均匀性的主要满足x射线类的要求4 (blue). However, internal pores and discrete inclusions (slag, heavy metals,oxides and shrinkage cavities) meeting the requirements

10、 of X-ray class 3 (green) are acceptable.蓝色)。然而,内部孔隙和离散夹杂物(矿渣、重金属、氧化物和收缩蛀牙)会议的要求x射线3班(绿色)是可以接受的。For fillet welds the throat thickness a shall not be less than that stated.填角焊的焊接厚度不得少于规定。Welding class C焊接类 CHigh welding reinforcement, high root reinforcement, visible root defects and sharpnotches are

11、 not permitted.焊接加固高、根钢筋,可见根缺陷和锋利的等级是不允许的.T-joints and corner joints welded from one side (root side inaccessible) may,however, have a moderate notch on the root side.从一侧丁字接头和角接头焊接(根端访问),然而,有一个温和的切口在根端.The homogeneity of weld shall in the main meet the requirements of X-ray class 3(green) according

12、to the IIW X-ray atlas.焊缝应均匀性的x射线的主要满足要求3班(绿色)根据IIW x射线地图集。For fillet welds the throat thickness a shall not be less than that stated.填角焊的焊接厚度不得少于规定。Welding class D 焊接类 DThe surface of the weld shall be free from significant surface cavities, externalpores, penetrations and overlapped welds. Visible

13、 cracks and similar defects arenot permitted.焊缝表面应无明显表面蛀牙,外部毛孔,穿透及重叠焊。可见裂缝和类似的缺陷是不允许的。For fillet welds the throat thickness a shall not be less than that stated.填角焊的焊接厚度不得少于规定。Welding classes焊接类v Class C is the default class if a drawing is missing weld class information! C类是默认焊接信息。Reference Numbers

14、 for Welding methods焊接方法的参考数据焊接方法的参考数据111Manual metal arc welding 手动金属电弧焊114Self-shielded tubular - cored arc welding 管状空心电弧焊121Submerged arc welding with solid wire electrode (partly mechanised) 与固体电极丝埋弧焊(部分机械化)125Submerged arc welding with tubular cored electrode (partly mechanised) 埋弧焊用管状空心电极(部分机

15、械化)131MIG welding with solid wire electrode MIG焊接与固体电极丝135MAG welding with solid wire electrode MAG焊接与固体电极丝136MAG welding with flux cored electrodes MAG焊接通量空心电极138MAG welding with metal cored electrode MAG焊接用金属空心电极141TIG welding with solid filler material 钨极惰性气体保护电弧焊与固体填充材料142Autogenous TIG welding

16、自钨极惰性气体保护电弧焊143TIG welding with tubular cored filler material 钨极惰性气体保护电弧焊与管状空心填充材料145TIG welding using reducing gas and solid filler material (wire/rod) 钨极惰性气体保护电弧焊用减少气体和固体填充材料(钢丝/杆)15Plasma arc welding 等离子弧焊；等离子电弧焊接311Oxy - acetylene welding 氧-乙炔焊*NOTE The principles of this standard may be applied

17、 to other fusion welding processes. 注意这个标准的原则可能适用于其他熔焊过程。This standard covers the following manual or partly mechanized welding processes (reference numbers ofwelding processes for symbolic representations are listed in ISO 4063):这个标准涵盖以下手册或部分机械化焊接过程焊接过程(参考数字符号表示ISO 4063中列出):Visa pistolpositionerWel

18、d Gun Positions焊接枪位置焊接枪位置Example 1:例子 1：Weld Gun Positions焊接枪位置焊接枪位置Example 2:例子2：q A falling weld shall be avoided as far as possible!q 焊缝应尽可能避免下跌!q The weld gun should be slightly pointed towards the thickest material. This prevents undercuts.q 焊接枪应该稍微指向最厚的材料。这可以防止削弱。 q A gun that is pointed away

19、from the weld will make the protective gas to flow away from the weld-pool.q 一把枪,指着离焊缝将使保护气体流向焊池。Weld Gun Positions焊接枪位置Symbols符号1.Weld method: 141 = TIG with solid filer material. 焊接方法:141 = TIG固体产品材料。2.Weld class = Class C 焊接类= C类3.Design Throat thickness = weld measurement 2mm. 设计焊接厚度=焊缝测量2毫米。4.F

20、illet weld 角焊缝5. Welded all around 沿周边焊接的12345Symbols符号Symbols符号Symbols符号支撑杆参考线指定一个角焊缝箭头的一面A tringle on the reference line: Specifies a fillet weld on the arrow side of the joint 支撑杆参考线指定一个角焊缝接头的另一边A tringle on the reference line: Specifies a fillet weld on the other side ofThe joint 4.7.3 Multiple

21、reference lines多个参考线Two or more reference line closest to indicate a series of operations.The operation shallbe specified on the reference line closest to the arrowhead.Subsequent operations shall be specified sequentially on the other reference lines(seeFigure6) 两个或两个以上的参考线接近显示一系列的操作。在指定的操作应当参考线箭头。

22、后续操作顺序应当指定其他参考线(参见图6)NOTE For joints requiring more than one weld type,combined symbols may also be used (see Table2)注意关节需要不止一个焊缝类型,结合符号也可以使用(见表二)a)System A-A rrow side (symbol on solid component of reference line)b)方法A-A箭头(符号参考线）C)System B-Arrow side (symbol below reference line)C) 方法 B-A箭头(符号下面的参考

23、线)b) System A-other side (symbol on dashed component of reference line)b) 方法A-O箭头(符号参考线）B) System B-other side (symbol above reference line)B) 方法B-O箭头(符号参考线）e)Same weld produced using four options a) to d) e)相同的焊接生产使用四个选项)d)Terminology术语术语WELD DRA WING TERMlNOLOGY:焊缝半径标注 Weld leg 焊脚 Weld face 焊缝表面 W

24、eld throat 焊缝厚度 Weld groove radius 焊缝坡口半径 Root opening （groove weld) 根部间隙(坡口焊) Weld root face 焊根的脸 Weld groove angle 焊缝坡口角度(A) FILLET WELDS 角角焊缝焊缝(B) GROOVE WELDS 坡口坡口焊缝焊缝THROAT焊高LEG SIZE 焊脚尺寸FACE 斜面BEVEL ANGLE边缘斜截角GROOVE ANGLEV 坡口角度LEG SIZE 焊脚尺寸GROOVE RADIUS根部半径ROOT OPENING根部间隙ROOT FACE根面THICKNESS厚

25、度a nominal throat thickness of the fillet weld (see also ISO 2553) 角焊缝的焊缝名义厚度(参见ISO 2553)A area surrounding the gas pores 周围气体毛孔B width of weld reinforcement 焊缝补强的宽度d diameter of gas pore 气体孔隙直径dA diameter of area surrounding the gas pores 直径周围气体的毛孔h height or width of imperfection 缺陷的高度或宽度l length

26、of imperfection in longitudinal direction of the weld 焊缝缺陷在纵向方向上的长度lp length of projected or cross-sectional area 投影长度和横截面积s nominal butt weld thickness (see also ISO 2553) 名义上的对接焊缝厚度(见ISO 2553)t wall or plate thickness (nominal size) 墙或板厚度(公称尺寸)wp width of the weld or width or height of the cross-

27、sectional area 焊缝的宽度或宽度或高度的横截面积z leg length of a fillet weld (see also ISO 2553) 角焊缝的焊脚长度(参见ISO 2553) angle of weld toe 角焊缝趾 angle of angular misalignment 角的角位移i penetration in fillet welds 渗透在填角焊r radius of weld toe 焊趾半径Terminology术语Symbols in ISO5817符号ISO5817Edge preparation坡口准备坡口准备TYPES OF BUTTWE

28、LDS SYMBOLIZATION类型的对接焊缝编号The common types of edge prepartion associated with a butt weld are indicated as follows:常见的边缘制作与对接焊缝表示如下:Square edge preparation直角边缘准备Single v preparation单边（v型）的准备Double v preparation双边（v型）的准备Single U preparation单边（U型）的准备Double U preparation双边（U型）的准备In some cases of joint

29、preparation,only one part is prepared,e.g.single bevel butt or single j butt ln these cases,the arrow points at the edge to be prepared.The vertical upright of the symbol is always to the left on the reference line.在某些情况下共同准备,只有一个部分是准备,如单斜对接或单j对接这些情况下,箭头指向边缘做好准备。垂直直立的符号总是左参考线。Edge preparation坡口准备Int

30、rusion熔深Dimensions and Calculation尺寸计算尺寸计算DIMENSIONING OF FILLET WELDS尺寸标注的填角焊EN 22553 requirementsEN 22553的需求a = design throat thicknessa = 设计厚度规则:设计焊接厚度(a)=腿长度x0.7(“z”)。Z = leg lengthZ = 脚高长度S = actual throat thicknessS =实际焊接熔深The leg length of a fillet weld is locaed to the left of the weld symbo

31、l (triangle).The dimension is in millimeters preceded with the letter “z”.lf no letter is shown on a drawing,then assume the dimension is leg length.角焊缝的焊脚长度是轨迹焊接符号的左边(三角形)。前面尺寸在毫米以字母“z”。如果没有显示在绘图的信,然后假设维度是腿的长度。The European system uses mainly the “a”value,while the American one uses the “z”value.欧洲主

32、要系统使用“a”值,虽然美国人使用“z”值.10mm leg length Fillet weld 10毫米腿角焊缝长度As rule:Design Throat Thickness(“a”)=Leg Length(“z”)x0.7.规则:设计焊接厚度(a)=腿高长度x0.7(“z”)。fillet weld with 7mm design throat thickness角焊缝和焊缝设计厚度7毫米Dimensions and Calculation尺寸计算尺寸计算“z” measurment = a x 1,4 “z”测量=a x 1,4“a” measurment = z x 0,7 “a

33、”测量 = z x 0、7Calulation of a (throat) can also be done with: 计算(喉咙咙)也可以用:z + z / 2 x 0.7 = a (throat)z + z / 20.7 = a(喉咙咙)Calculate imperfections: STD 5817-B 计算缺陷: ISO5817-BFormula: a x 0,15 + 1 = 1,9 公式: a x 0,15 + 1 = 1,9Calculation: 6 x 0,15 + 1 = 1,9 计算: 6 x 0,15 + 1 = 1,9Explanation: a is throa

34、t thickness e.g a6, the total throat thickness is 8mm. Thismeans that the deviation is (h)2 mm. But the STD allows some tolerance, which the calculationgives us, 1,9 mm.解释:一个是焊接厚度e。g a6,焊缝的总厚度是8毫米。这意味着,偏差(h)2毫米,但允许一些放宽计算, 1.9毫米。 So the total throat thickness can be (a)6mm + (h)1,9mm = 7,9mm所以总焊接厚度可以

35、(a)6毫米+(h)1,9毫米= 7,9毫米But since the measurement is total 8 mm, the throat is 0,1mm to high. NOK!但由于测量总8毫米,喉为0,1毫米高。NOK！*hint: calculate ”backwards”提示:计算工式“由后向前计算”Imperfections不完整性CBD计算实例Please take notes and write down your answersand how you came to the specific conclusion. 请做笔记请做笔记, ,写下你的答案写下你的答案T

36、he answer is right infront of you你面前的答案是正确的 Save them for your own reference! 留作自己的参考!Calculate Imperfections计算的不完美计算的不完美Calculate Imperfections计算的不完美计算的不完美Example 1. 例子 1.perfect :Excess Weld metal完美的:焊缝余高Weld class: C焊缝级别： Cb measured to be 16 mmb测量 16毫米h measured to be3.1 mmh测量 3.1毫米Allowed exces

37、s weld h= 3,4 mm允许多余的焊接余高 = 3，4毫米APPROVED被认可的D DB BC CCalculate Imperfections计算的不完美计算的不完美D DC CB BExampIe 2. 例子 2.Imperfection (fault): Excessive throat thickness不完美的（缺陷）：角焊缝填充金属过厚Weld class: B 焊缝级别： B a measured to be 5 mm (a5 on drawing) a 测量是5毫米(a5图纸)h measured to be3 mm h 测量3毫米 total8 mm 总高8毫米Al

38、lowed throat thickness = 1,75 mm (total 6,75 mm) 1,25 mm over tolerance.允许焊接厚度（余高）= 1,75毫米(总6.75毫米) 1、25毫米公差。NOT APPROVED不被肯定Calculate Imperfections计算的不完美计算的不完美Exampel 3. 例子3.Imperfection (fault): Excessive asymmetry of fillet weld (uneven leg length)不完美（缺陷）：过度的不对称角焊缝(不等长)Weld class: B 焊接类: Ba measu

39、red to be 6 mm (a6 on drawing)a 一个测量6毫米(a6图纸)Z 2 measured to be 8,5 mm Z 2测量8、5毫米h measured to be2,5 mm h 测量是2、5毫米Allowed excess asymmetry h= 2,4 mm (total 8,4 mm) 0,1 mm over tolerance允许多余的不对称h = 2,4毫米(8,4毫米) 0,1毫米公差NOT APPROVED不被肯定D DC CB BValidation and Quality Assurance验证和质量保证验证和质量保证Validation and Quality Assurance验证和质量保证验证和质量保证Supplier recommendations/requirements: 供应商建议/要求:Right education Theory & Practical 正确的教育理论与实践oWhat training did the welder get? 焊机得到了什么培训？oWho approved it? 谁批准了吗?oWas it based on any ISO or similar standards?