WPS焊接工艺规程(AWS版)课件

Weldingprocedurespecification(WPS)焊接工艺规范KevinMoWeldingprocedurespecificatioWhatisaWPS?

什么是焊接工艺规范(WPS)?焊接工艺规范是为了制造符合规范要求的焊缝而提供指导的、经过评定合格的焊接工艺文件。它或其它文件可用于对焊工或焊机操作工提供指导,以保证符合规范要求。

AWPSisawrittenqualifiedweldingprocedurepreparedtoprovidedirectionformakingproductionweldstoCoderequirements.TheWPSorotherdocumentsmaybeusedtoprovidedirectiontothewelderorweldingoperatortoassurecompliancewiththeCoderequirements.WhatisaWPS?

什么是焊接工艺规范(WPS)?WhatisincludedbyaWPS?

WPS的内容一份完整的WPS应当包含在WPS中所采用的、对每一种焊接方法而言的所有重要变素、非重要变素和当需要时的附加重要变素。样表见图1。焊接工艺规范其实就是规定某一焊接工艺的各种焊接变素。ThecompletedWPSshalldescribealloftheessential,nonessential,and,whenrequired,supplementaryessentialvariablesforeachweldingprocessusedintheWPS.Forthesample,plsseethefigure1.WhatisincludedbyaWPS?

WPSWhotakechargeofcompilingWPS?

WPS应该由谁制定?每个制造者或承包者应按照焊接规范的规定编写合理的WPS.具体的说WPS是由代表厂家的焊接工程师编写的。EachmanufacturerandcontractorshallpreparewrittenWeldingProcedureSpecificationswhicharedefinedincorrespondingweldingcode.WhotakechargeofcompilingWAvailabilityoftheWPS

WPS的可得性用于产品焊接的WPS,应当在制造现场便于获得，以供查考，并供授权检验师(AI)检查。AWPSusedforCodeproductionweldingshallbeavailableforreferenceandreviewbytheAuthorizedInspector(AI)atthefabricationsite.AvailabilityoftheWPS

WPS的可AuthorizedbyAI授权检验师检查conductedbywelder焊工或焊接操作工根据WPS进行生产compiledbyweldingengineeraccordingtoqualifiedPQR焊接工程师根据评定合格的工艺评定记录（PQR)制定恰当的焊接工艺规范（WPS）supervisedbyAI授权检验师检查SimpleconnectiondiagramWPS关系简图Remarks:PQRisthequalifiedweldingprocedureprocedureandtestresultsrecord.备注：PQR是经过评定合格的焊接工艺数据及相关试验结果记录AuthorizedbyAIconductedbyw+FCAW药芯焊丝保护焊SAW埋弧焊GMAW气保焊SMAW焊条电弧焊GTAW钨极氩弧焊+HowisaWPScreated?

如何创建一个WPS?接头形式

jointtype焊接方法

weldingprocess建造规范

construction

specification+FCAW药芯焊丝保护焊+HowisaWPScrea选择资源成本实际约束浏览规范，列出可行焊接方法主要约束修订可行焊接方法评估生产成本选择规范选择资源成本实际约束浏览规范，列出可行焊接方法主要约束修订可WeldProcessSelection

焊接工艺选择The“ideal”weldingprocessisthatwhichachievestheminimumspecificationrequirementsattheminimumcost...完美的焊接工艺是那种以最小成本获得规范要求的最低水平……ThePracticalWeldingEngineerWeldProcessSelection

焊接工艺选择TVariables焊接变素重要变素essentialvariables

影响接头弯曲和拉伸性能的因素Affectthebendabilityandtensionabilityofjoint非重要变素nonessentialvariables

对弯曲和拉伸不能产生明显影响的因素Can’tproducevisibleaffectiononbendabilityandtensionabilityofjoint附加重要变素supplementalessentialvariables

影响接头冲击性能的因素AffectthetoughnessofjointVariables焊接变素重要变素essentialvaEssentialslistedinAWSD1.1AWS对各种焊接方法重要变素的规定EssentialslistedinAWSD1.1EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)Filler填充材料Increaseinfillermetalclassificationstrength增加填料的强度Changefromoneelectrodeclassificationtoanyotherelectrodeclassification，limitedtoFCAW从一种焊丝型号改变到另一种焊丝型号（只限药芯焊丝）ChangetoanelectrodeclassificationnotcoveredinAWSA5.18,A5.20,A5.28,A5.29.焊丝变为在AWS中没有的型号Electrode焊丝Changeinnominalelectrodediameter:焊丝直径变化（实芯焊丝），焊丝直径增加（药芯焊丝）EssentialsinGMAWorFCElectricalparameters焊接参数Achangeintheamperageforeachdiameter每种焊丝直径的电流变化超过10％Achangeintypeofcurrent(acordc)orpolarityandmodeoftransfer(GMAWonly)电流极性变化或GMAW过渡模式变化Achangeinthevoltageforeachdiameter，surpass7%电压改变超过7％Anincreaseordecreaseinthewirefeedspeedforeachelectrodediametersurpass10%送丝速度改变超过10％EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)Electricalparameters焊接参数Achangeinthetravelspeedsurpass25%焊接速度改变超过25％Anincreaseinheatinputsurpass10%热输入增加超过10％Shieldinggas保护气Achangeinshieldinggasfromasinglegastoanyothersinglegasormixtureofgas,orinthespecifiednominalpercentagecompositionofagasmixture,ortonogas保护气从单种气体变为其它单种气体或混合气体EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)AchangeinthetravelspeedsAchangeintotalgasflowrate气体流量增加大于50％或减小超过20％Achangetoashieldinggasnotcoveredin。改变为不包含在AWSA5.18,5.28,A5.20,A5.29中的保护气。General一般条件ForthePQRgroovearea,anincreaseordecrease>25%inthenumberofpasses对于与PQR坡口面积相同的，焊道数改变超过25％Achangeinpositionnotqualified焊接位置改变为未经评定的位置。EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)AchangeintotalgasflowratAchangeindiameter,orthickness,orboth,notqualifiedbyTable2工件直径或厚度未在评定范围之外。AchangeinbasemetalorcombinationofbasemetalsnotlistedonthePQR母材未经评定VerticalWelding:Foranypassfromuphilltodownhillorviceversa立焊：任何焊道从上到下焊接或相反Achangeingroovetype(e.g.,single-Vtodouble-V),坡口形式变化（例如，单V到双V)EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)Achangeindiameter,orthickAchangeinthetypeofgroovetoasquaregrooveandviceversa从任何坡口形式改变为直边或相反Achangeexceedingthetolerances,includingdecreasingofgrooveangle,decreasingofrootopening,increasingofrootface.坡口角度减小，坡口间隙减小以及钝边增加超过公差范围Theomission,butnotinclusion,ofbackingorbackgouging取消衬垫或清根Decreasefrompreheattemperature6by15Celsiusdegree预热温度降低超过15度EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)AchangeinthetypeofgrooveFigure1.WPSsample

图1.样表WeldingProcedureSpecification(WPS)

焊接工艺规范样表

Figure1.WPSsample图Typeofqualificationtest

WPS评定试验项目及试样数量、类型Thetypeandnumberofqualificationtestsrequiredto

qualifyaWPSforagiventhickness,diameter,orboth,

shallconformtoTable2(CJP),Table3(PJP)or

Table4(fillet).DetailsontheindividualNDTandmechanical

testrequirementsarefoundinthefollowing

subsections:

评定WPS试验的项目及数量应遵照表2(全焊透接头），表3（部分焊透接头）或表4（角接头）。主要有以下几种试验项目。

(1)VisualInspection外观检验

(2)NDT无损检验，含RT,MT,UT,PT等

(3)Face,rootandsidebend面弯，背弯及侧弯

(4)ReducedSection缩截面焊缝拉伸

(5)All-Weld-MetalTension全熔敷金属拉伸

(6)Macro－etch

宏观浸蚀Typeofqualificationtest

WPSNumberandtypeoftestspecimensandrangeofthicknessqualified-CJP评定焊缝的厚度和试验数量及类型(全焊透接头）NumberandtypeoftestspecimNumberandtypeoftestspecimensandrangeofthicknessqualified-PJP评定焊缝的厚度和试验数量及类型(部分焊透接头）NumberandtypeoftestspecimNumberandtypeoftestspecimensandrangeofthicknessqualified-Filletjoint评定焊缝的厚度和试验数量及类型(角接头）NumberandtypeoftestspecimClassificationofbasemetal

母材分类Classificationofbasemetal

Classificationofbasemetal

母材分类Classificationofbasemetal

Classificationofbasemetal

母材分类Classificationofbasemetal

Square直边Single-V单V坡口(带衬垫)Double-V双V形坡口(X形坡口)GrooveWeldTypes坡口形式Weldingvariables焊接因素SquareSingle-VDouble-VGrooveWSingle-bevel单边V形坡口Double-bevelK形坡口GrooveWeldTypes坡口形式Weldingvariables焊接因素Single-bevelDouble-bevelGrooveSingle-U单面U形坡口Double-U双面U形坡口GrooveWeldTypes坡口形式Weldingvariables焊接因素Single-UDouble-UGrooveWeldTySingle-J单面J形坡口Double-J双面J形坡口GrooveWeldTypes坡口形式Weldingvariables焊接因素Single-JDouble-JGrooveWeldTyFlare-bevel卷边接头Flare-VV形卷边接头GrooveWeldTypes坡口形式Weldingvariables焊接因素Flare-bevelFlare-VGrooveWeldWeldingPositions焊接位置

Weldingvariables焊接因素WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素坡口焊缝板焊接位置WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素Grooveweldpipeweldingposition坡口焊缝管焊接位置WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素Grooveweldpipeweldingposition坡口焊缝管焊接位置WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素Grooveweldpipeweldingposition坡口焊缝管焊接位置WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素Grooveweldpipeweldingposition坡口焊缝管焊接位置WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素PositionsofPlatefilletwelds板角焊缝位置WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素Positionsoftestpipingortubingforfilletwelds管管、管板角焊缝位置WeldingPositions焊接位置WeldingWeldingPositions焊接位置Weldingvariables焊接因素WeldingPositions焊接位置WeldingHeatInput热输入U=arcvoltage电弧电压I=current焊接电流V=travelspeed(mm/s)焊接速度E=heatinput(kJ/mm.)热输入E=UI/VWeldingvariables焊接因素HeatInput热输入U=arcvoltage电Gauging清根Tomakesurethatgetacompletepenetrationandgoodfusionatroot,grinding1stpassandweldingfromanotherside.为确保根部焊透及熔合良好，打磨根部焊道后从另一面再焊一道。Weldingvariables焊接因素Gauging清根Weldingvariables焊接WeldingCodes焊接法规

AmericanWeldingSociety(AWS)-Governingbodyoftheweldingindustry美国焊接学会（AWS）-焊接行业的权威机构StructuralWeldingCode(AWSD1.1)结构焊接规范（AWSD1.1）BridgeWeldingCode(AWSD1.5)桥梁焊接规范(AWSD1.5)PressureVesselCode(ASMEsection9)压力容器规范(ASME第九部分)ShipbuildingCode(ABS)造船规范(ABS)Contractfile.承包商技术规范WeldingCodes焊接法规Weldingprocedurespecification(WPS)焊接工艺规范KevinMoWeldingprocedurespecificatioWhatisaWPS?

什么是焊接工艺规范(WPS)?焊接工艺规范是为了制造符合规范要求的焊缝而提供指导的、经过评定合格的焊接工艺文件。它或其它文件可用于对焊工或焊机操作工提供指导,以保证符合规范要求。

AWPSisawrittenqualifiedweldingprocedurepreparedtoprovidedirectionformakingproductionweldstoCoderequirements.TheWPSorotherdocumentsmaybeusedtoprovidedirectiontothewelderorweldingoperatortoassurecompliancewiththeCoderequirements.WhatisaWPS?

什么是焊接工艺规范(WPS)?WhatisincludedbyaWPS?

WPS的内容一份完整的WPS应当包含在WPS中所采用的、对每一种焊接方法而言的所有重要变素、非重要变素和当需要时的附加重要变素。样表见图1。焊接工艺规范其实就是规定某一焊接工艺的各种焊接变素。ThecompletedWPSshalldescribealloftheessential,nonessential,and,whenrequired,supplementaryessentialvariablesforeachweldingprocessusedintheWPS.Forthesample,plsseethefigure1.WhatisincludedbyaWPS?

WPSWhotakechargeofcompilingWPS?

WPS应该由谁制定?每个制造者或承包者应按照焊接规范的规定编写合理的WPS.具体的说WPS是由代表厂家的焊接工程师编写的。EachmanufacturerandcontractorshallpreparewrittenWeldingProcedureSpecificationswhicharedefinedincorrespondingweldingcode.WhotakechargeofcompilingWAvailabilityoftheWPS

WPS的可得性用于产品焊接的WPS,应当在制造现场便于获得，以供查考，并供授权检验师(AI)检查。AWPSusedforCodeproductionweldingshallbeavailableforreferenceandreviewbytheAuthorizedInspector(AI)atthefabricationsite.AvailabilityoftheWPS

WPS的可AuthorizedbyAI授权检验师检查conductedbywelder焊工或焊接操作工根据WPS进行生产compiledbyweldingengineeraccordingtoqualifiedPQR焊接工程师根据评定合格的工艺评定记录（PQR)制定恰当的焊接工艺规范（WPS）supervisedbyAI授权检验师检查SimpleconnectiondiagramWPS关系简图Remarks:PQRisthequalifiedweldingprocedureprocedureandtestresultsrecord.备注：PQR是经过评定合格的焊接工艺数据及相关试验结果记录AuthorizedbyAIconductedbyw+FCAW药芯焊丝保护焊SAW埋弧焊GMAW气保焊SMAW焊条电弧焊GTAW钨极氩弧焊+HowisaWPScreated?

如何创建一个WPS?接头形式

jointtype焊接方法

weldingprocess建造规范

construction

specification+FCAW药芯焊丝保护焊+HowisaWPScrea选择资源成本实际约束浏览规范，列出可行焊接方法主要约束修订可行焊接方法评估生产成本选择规范选择资源成本实际约束浏览规范，列出可行焊接方法主要约束修订可WeldProcessSelection

焊接工艺选择The“ideal”weldingprocessisthatwhichachievestheminimumspecificationrequirementsattheminimumcost...完美的焊接工艺是那种以最小成本获得规范要求的最低水平……ThePracticalWeldingEngineerWeldProcessSelection

焊接工艺选择TVariables焊接变素重要变素essentialvariables

影响接头弯曲和拉伸性能的因素Affectthebendabilityandtensionabilityofjoint非重要变素nonessentialvariables

对弯曲和拉伸不能产生明显影响的因素Can’tproducevisibleaffectiononbendabilityandtensionabilityofjoint附加重要变素supplementalessentialvariables

影响接头冲击性能的因素AffectthetoughnessofjointVariables焊接变素重要变素essentialvaEssentialslistedinAWSD1.1AWS对各种焊接方法重要变素的规定EssentialslistedinAWSD1.1EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)Filler填充材料Increaseinfillermetalclassificationstrength增加填料的强度Changefromoneelectrodeclassificationtoanyotherelectrodeclassification，limitedtoFCAW从一种焊丝型号改变到另一种焊丝型号（只限药芯焊丝）ChangetoanelectrodeclassificationnotcoveredinAWSA5.18,A5.20,A5.28,A5.29.焊丝变为在AWS中没有的型号Electrode焊丝Changeinnominalelectrodediameter:焊丝直径变化（实芯焊丝），焊丝直径增加（药芯焊丝）EssentialsinGMAWorFCElectricalparameters焊接参数Achangeintheamperageforeachdiameter每种焊丝直径的电流变化超过10％Achangeintypeofcurrent(acordc)orpolarityandmodeoftransfer(GMAWonly)电流极性变化或GMAW过渡模式变化Achangeinthevoltageforeachdiameter，surpass7%电压改变超过7％Anincreaseordecreaseinthewirefeedspeedforeachelectrodediametersurpass10%送丝速度改变超过10％EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)Electricalparameters焊接参数Achangeinthetravelspeedsurpass25%焊接速度改变超过25％Anincreaseinheatinputsurpass10%热输入增加超过10％Shieldinggas保护气Achangeinshieldinggasfromasinglegastoanyothersinglegasormixtureofgas,orinthespecifiednominalpercentagecompositionofagasmixture,ortonogas保护气从单种气体变为其它单种气体或混合气体EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)AchangeinthetravelspeedsAchangeintotalgasflowrate气体流量增加大于50％或减小超过20％Achangetoashieldinggasnotcoveredin。改变为不包含在AWSA5.18,5.28,A5.20,A5.29中的保护气。General一般条件ForthePQRgroovearea,anincreaseordecrease>25%inthenumberofpasses对于与PQR坡口面积相同的，焊道数改变超过25％Achangeinpositionnotqualified焊接位置改变为未经评定的位置。EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)AchangeintotalgasflowratAchangeindiameter,orthickness,orboth,notqualifiedbyTable2工件直径或厚度未在评定范围之外。AchangeinbasemetalorcombinationofbasemetalsnotlistedonthePQR母材未经评定VerticalWelding:Foranypassfromuphilltodownhillorviceversa立焊：任何焊道从上到下焊接或相反Achangeingroovetype(e.g.,single-Vtodouble-V),坡口形式变化（例如，单V到双V)EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)Achangeindiameter,orthickAchangeinthetypeofgroovetoasquaregrooveandviceversa从任何坡口形式改变为直边或相反Achangeexceedingthetolerances,includingdecreasingofgrooveangle,decreasingofrootopening,increasingofrootface.坡口角度减小，坡口间隙减小以及钝边增加超过公差范围Theomission,butnotinclusion,ofbackingorbackgouging取消衬垫或清根Decreasefrompreheattemperature6by15Celsiusdegree预热温度降低超过15度EssentialsinGMAWorFCAW

GMAWandFCAW中的重要变素(AWS)AchangeinthetypeofgrooveFigure1.WPSsample

图1.样表WeldingProcedureSpecification(WPS)

焊接工艺规范样表

Figure1.WPSsample图Typeofqualificationtest

WPS评定试验项目及试样数量、类型Thetypeandnumberofqualificationtestsrequiredto

qualifyaWPSforagiventhickness,diameter,orboth,

shallconformtoTable2(CJP),Table3(PJP)or

Table4(fillet).DetailsontheindividualNDTandmechanical

testrequirementsarefoundinthefollowing

subsections:

评定WPS试验的项目及数量应遵照表2(全焊透接头），表3（部分焊透接头）或表4（角接头）。主要有以下几种试验项目。

(1)VisualInspection外观检验

(2)NDT无损检验，含RT,MT,UT,PT等

(3)Face,rootandsidebend面弯，背弯及侧弯

(4)ReducedSection缩截面焊缝拉伸

(5)All-Weld-MetalTension全熔敷金属拉伸

(6)Macro－etch

宏观浸蚀Typeofqualificationtest

WPSNumberandtypeoftestspecimensandrangeofthicknessqualified-CJP评定焊缝的厚度和试验数量及类型(全焊透接头）NumberandtypeoftestspecimNumberandtypeoftestspecimensandrangeofthicknessqualified-PJP评定焊缝的厚度和试验数量及类型(部分焊透接头）NumberandtypeoftestspecimNumberandtypeoftestspecimensandrangeofthicknessqualified-Filletjoint评定焊缝的厚度和试验数量及类型(角接头）NumberandtypeoftestspecimClassificationofbasemetal

母材分类Classificationofbasemetal

Classificationofbasemetal

母材分类Classificationofbasemetal

Classificationofbasemetal

母材分类Classificationofbasemetal

Square直边Single-V单V坡口(带衬垫)Double-V双V形坡口(X形坡口)GrooveWeldTypes坡口形式Weldingvariables焊接因素SquareSingle-VDouble-VGrooveWSingle-bevel单边V形坡口Double-bevelK形坡口GrooveWeldTypes坡口形式Weldingvariables焊接因素Single-bevelDouble-bevelGrooveSingle-U单面U形坡口Double-U双面U形坡口GrooveWeldTypes坡口形式Weldingvariables焊接因素Single-UDouble-UGrooveWeldTySingle-J单面J形坡口Double-J双面J形坡口GrooveWeldTypes坡口形式Weldingvariables焊接因素Single-JDouble-JGrooveWeldTyFlare-bevel卷边接头Flare-VV形卷边接头GrooveWeldTypes坡口形式Weldingvariables焊接因素Flare-bevelFlare-VGrooveWeldWeldi