焊接工艺培训

1、最后最后一个一个字母字母0123456789电源(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药皮类型(b)有机物金红石*金红石*金红石*低氢低氢矿物质低氢金红石*电弧类型熔透(C)深适中浅浅适中适中适中适中适中药皮中的铁粉含量0%10%无0%10%0%10%30%50%无无50%30%50%0%10%备注: (a) E-6010是直流反接；E-6020是交流或直流 (b) E-6010是有机物药皮；E-6020是矿物质药皮 (c) E-6010是深熔焊条；E-6020是熔深适中的焊条* 硬质二氧化钛药皮E7018-XE焊条表示符号焊

2、条表示符号70焊缝金属的抗拉强度等级，度量衡单位：psi1焊接位置8药皮成分，熔透性，电流极性X补充要求焊接位置1平焊，横焊，立向上焊，仰焊2平焊，横焊4平焊，横焊，立向下焊，仰焊碳钢药皮焊条（AWS A5.1/ASME SFA5.1）等级等级焊条药皮成分焊条药皮成分熔深熔深电流极性电流极性EXXX0纤维素，硅深直流反接EXXX1纤维素，钾深交流，直流反接EXXX2金红石，硅一般交流，直流正接EXXX3金红石，钾浅交流，直流反接/直流正接EXXX4金红石，铁粉一般交流，直流反接/直流正接EXXX5低氢，硅一般直流反接EXXX6低氢，钾一般交流，直流反接EXXX7铁粉，氧化铁一般交流，直流正接E

3、XXX8低氢，铁粉一般交流，直流反接EXXX9氧化铁，金红石，钾一般交流，直流反接/直流正接焊条型号列表后缀后缀补充要求补充要求-1改进E7018焊条的冲击性能，也可用于表示改进E7024焊条的延展性。-M军用要求-好的韧性，暴漏在空气中时良好的防潮能力，熔敷金属中扩散氢含量低-HX用于表示熔敷金属中的最大扩散氢含量。列入-H4=4ml/100g补充符号低合金钢药皮焊条（AWS A5.5/ASME SFA5.5）E7018-XE焊条表示符号焊条表示符号70焊缝金属的抗拉强度等级，度量衡单位：psi1焊接位置8药皮成分，熔透性，电流极性X合金成分后缀符号列表后缀符号列表后缀合金成分后缀符号描述

4、-A1 碳-钼钢 含钼：0.40%0.65% -B1 铬-钼钢 含铬：0.40%0.65%，含钼：0.40%0.65% -B2 铬-钼钢 含铬：1.00%1.50%，含钼：0.40%0.65% -B2L 铬-钼钢 低碳(Wc0.05%)，含铬：1.00%1.50%，含钼：0.40%0.65% -B3 铬-钼钢 含铬：2.00%2.50%，含钼：0.90%1.20% -B3L 铬-钼钢 低碳(Wc0.05%)，含铬：2.00%2.50%，含钼： 0.90%1.20% -B4L 铬-钼钢 低碳(Wc0.05%)，含铬：1.75%2.25%，含钼：0.40%0.65% -B5 铬-钼钢 含铬：0.4

5、0%0.60%，含钼：1.00%1.25% -B6 含铬：4.60%6.00%，含钼：0.45%0.65% -B8 含铬：8.00%10.5%，含钼：0.80%1.20% -C1 镍钢 含镍：2.00%2.75% -C1L 镍钢 低碳(Wc0.05%)，含镍：2.00%2.75% -C2 镍钢 低碳(Wc0.05%)，含镍：3.00%3.75%后缀符号列表后缀符号列表后缀合金成分后缀符号描述 -C2L 含镍钢 低碳(Wc0.08%)，含镍：3.00%3.75% -C3 含镍钢 含镍：0.80%1.10% -NM 含镍钢 含镍：0.80%1.10%，含钼：0.40%0.65% -D1 含镍、钼

6、含锰：1.00%1.75%，含钼：0.25%0.45% -D2 含锰、钼 含锰：1.65%2.00%，含钼：0.25%0.45% -D3 含锰、钼 含锰：1.00%1.80%，含钼：0.40%0.65% -W 耐候钢 Ni, Cr, Mo, Cu -G 未定义化学成分 -M 军用等级 可能具有更多要求力学性能等级力学性能等级级别最小抗拉强度最小屈服强度 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)化学元素的作用化学元素的作用符号名称作用C碳 最有效的增加金属硬度的元素Mn锰 对于金属硬度的影响仅次于碳Si硅 还原剂，P磷 含量过高易导致裂纹S硫 含量过高易导致裂纹Cr铬 提升金属材

8、料耐腐蚀性Ni镍 提升金属材料的低温韧性Mo钼 提升金属材料的高温强度B硼 少量可提升金属材料硬度Cu铜 耐腐蚀型弱，裂纹敏感度高Al铝 还原剂，改进金属材料力学性能Ti钛 去除氧、硫、氮、碳N氮 改善金属材料强度，不易于金属材料的冲击韧性Cb钴 提升金属材料硬度，改善金属材料力学性能V矾 提升金属材料硬度，改善金属材料力学性能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 6

9、947 定义PA, PC, PG, 等.1G/PA15焊缝水平轴板水平摆放2G/PC板竖置焊缝水平轴153F/PF or PG56G455Flat Positions Axis Inclination15Start at Nominal Flat Position焊缝表面向上WWW.SPERKOENGINEERING.COM平焊位置上倾角限制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焊缝坡口的清理焊缝坡口的清理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-16.1Section VIII Divisio

34、n 1的焊接要求的焊接要求UW-20管子与管板的焊接管子与管板的焊接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；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

35、须磨平。（UG-82）UW-27焊接方法焊接方法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(e)电渣焊UW-27(f)电气焊纵缝的排列纵缝的排列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

36、艺评定焊接工艺评定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。 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在焊接工艺评定方面的责任制造厂制造厂/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焊缝咬边焊缝咬边UW