焊接工藝培訓(xùn)

1、焊接工藝培訓(xùn),碳鋼藥皮焊條（AWS A5.1/ASME SFA5.1）,焊條型號列表,補充符號,低合金鋼藥皮焊條（AWS A5.5/ASME SFA5.5）,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)測試位置,1G, 3G, 6G, 2F, 5F, 等式規(guī)范制定的測試用焊接位置. They are properly referred to as Test Positions. 相似的描述見ISO 6947 定義PA, PC, PG, 等.,1G/PA,15,焊縫水平軸,板水平擺放,5,2G/PC,板豎置,焊縫水平軸,15,5,3F/PF or PG,5,6G,455,Fla

2、t Positions Axis Inclination,15,Start at Nominal Flat Position,焊縫表面向上,WWW.SPERKOENGINEERING.COM,平焊位置上傾角限制,15,Weld may incline upward to a limit of 15,WWW.SPERKOENGINEERING.COM,Flat Upward Inclined Limit,15,But the welder could be traveling down the incline. . .,WWW.SPERKOENGINEERING.COM,Flat Downwar

3、d Limit Is Implied,15,Welding Positions,Tabulation of Positions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 HorizontaB0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15 to 8080 to 280 E80 to 900 to 360 How this table and

4、 the diagram on the previous page work are shown in the following diagrams,Flat Position -Rotation About Axis,WWW.SPERKOENGINEERING.COM,Flat Rolled Limit Clockwise,210,180,30,Flat Rolled Limit Clockwise,210,180,30,Equivalent to rotating The plate 30,WWW.SPERKOENGINEERING.COM,Flat Rolled Limit Counte

5、rclockwise,30,150,180,Flat Rotated Limits Not Considering Inclination,60,Welding Positions,Tabulation of Positions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 HorizontaB0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15

6、to 8080 to 280 E80 to 900 to 360 How this table and the diagram on the previous page work are shown in the following diagrams,Flat Uphill Limit Rotated,15,60,Flat Downhill Limit Rotated,15,Composite Flat Position Ranges,30,60,Compare this range to 1G/PA. . .,15/FLAT,Testing Position 1G/PA,15/PA,Weld

7、 Axis Horizontal,Plate Horizontal,5/PA,30/FLAT,Flat 1G !,Welding Positions,Tabulation of Positions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 Horizontal B0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15 to 8080 to 280

8、 E80 to 900 to 360 How this table and the diagram on the previous page work are shown in the following diagrams,Horizontal Position Axis Inclined,15,Basic Horizontal Position,Horizontal Position Uphill Inclined Limit,15,Horizontal Position Downhill Inclined Limit,15,Welding Positions,Tabulation of P

9、ositions of Groove Welds PositionDiagram ReferenceInclination of AxisRotation of Face FlatA0 to 15150 to 210 Horizontal B0 to 1580 to 150 210 to 280 OverheadC0 to 800 to 80 210 to 360 VerticalD15 to 8080 to 280 E80 to 900 to 360 How this table and the diagram on the previous page work are shown in t

10、he following diagrams,Horizontal Position Rotated,210,Start at the Flat Rolled Limits,180,30,Lets go to an end view. . . .,Horizontal End View,30,Horizontal starts where Flat ends. . . .,210,WWW.SPERKOENGINEERING.COM,Horizontal Rotates to where the plate is perpendicular to the ground,30,Horizontal

11、rotates clockwise . .,WWW.SPERKOENGINEERING.COM,Horizontal Position Rotated Limit,30,Horizontal ends here. . . .,10,90,280,70,Non-inclined Horizontal Position Limits,Starts with plate Rotated 30,70,Non-inclined Horizontal Position Limits,Finishes with plate Rotated 10 beyond perpendicular,Composite

12、Horizontal Position Limits,Compare Horizontal to 2G/PC,Test Position 2G/PC,Plates Vertical,Weld Axis Horizontal,15/PC,15/H,5/PC,-60+10/H,Horizontal 2G/PC !,80,280,Overhead Position,160 range,Basic Overhead,Face of weld is overhead!,0,Basic Overhead End View,Face of weld is overhead,0,Overhead Partia

13、l Rotation End View,Face of weld is overhead,0,Overhead Maximum Rotation End View,0,280,Face of weld on This side,Overhead Maximum Opposite Rotation End View,0,280,80,Face of weld on This side,Same Rotation in Isometric View,Basic Overhead,Face of weld is overhead,0,Face of weld is overhead,Overhead

14、 Partial Rotation Isometric View,0,Overhead Maximum Rotation Isometric View,0,280,Face of weld On this side,WWW.SPERKOENGINEERING.COM,Overhead Maximum Opposite Rotation Isometric View,0,280,80,Face of weld is on this side,Overhead PositionAxis Inclination,Basic Overhead for Inclined Axis,Face of wel

15、d is overhead,0, Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,Overhead Inclined Axis Rotation,0,0, Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,Overhead Inclined Axis Limit,0,80,Overhead Inclined Axis Limit,0,80,Weld can rotate 360 about vertical axis while inclined 10 forward tilt.,Overhe

16、ad Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead I

17、nclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld can rotate about The vertical axis,10,Overhead Inclined Axis Limit,0,Weld ends up back Where it started!,10,仰焊位置,280,80,0,0,80,360,10, Sperko Engineering 2005,WWW.SPERKOENGINEERING.COM,仰焊4G,Vertical P

18、osition Part 1,65 Range of Inclination From 15 to 80. Face of weld is up,15,80,Vertical Position Part 1,Range of inclination Starts at 15 Face of weld is up,15,Vertical Position Part 1,Range of inclination continues upward. . .,Greater than 15,Vertical Position Part 1,Until reaching 80,80,Vertical P

19、osition Part 2,When the “E” portion of the diagram is reached,80,Vertical Position Part 2,The “E” portion of the diagram - 360 Rotation About vertical axis,80,Vertical Position Part 2,The “E” portion of the diagram begins here. .,80,Vertical Position Part 2,Partial rotation about Vertical axis,Verti

20、cal Position Part 2,More rotation about Vertical axis,Vertical Position Part 2,Even more rotation about Vertical axis,Vertical Position Part 2,Rotated 180 about Vertical axis,Vertical Position Part 2,Continuing Rotation about Vertical axis,Vertical Position Part 2,Continuing Rotation about Vertical

21、axis,Vertical Position Part 2,Continuing Rotation about Vertical axis,Vertical Position Part 2,360 of Rotation about Vertical axis completed,Vertical Position Part 3,80,280,200 Range of Rotation,Vertical Position Part 3,Start here with inclination Uphill or Downhill 15 Face of weld upward,15,Vertica

22、l Position Part 3,Rotate face while holding Inclination constant,15,Vertical Position Part 3,Continue rotating with Inclination constant,15,Vertical Position Part 3,Rotated to vertical limit Inclination constant,15,280,Vertical Position Part 3,Return to starting position Uphill or Downhill 15 Face o

23、f weld upward,15,Vertical Position Part 3,Rotate face of weld Opposite direction Inclination Constant 15,15,Vertical Position Part 3,Continue rotating Opposite direction Inclination Constant 15,15,Vertical Position Part 3,Plate near vertical Inclination Constant 15,15,Vertical Position Part 3,Plate

24、at vertical limit of rotation. Inclination Constant 15,15,80,Vertical Position Part 3,80,280,200 Range of Rotation inclined Uphill or Downhill 15,15,Vertical Position Part 3,80,280,200 Range of Rotation Inclination angle Increases,Vertical Position Part 3,280,200 Range of Rotation Inclination angle

25、Increases more. . .,80,Vertical PositionComposite,80,280,160 range,65,200,360,Welding Positions for Fillet Welds,Flat Fillet Weld,Horizontal Fillet Weld,Welding Positions for Fillet Welds,Welding Positions for Fillet Welds,Tabulation of Positions of Fillet Welds PositionDiagram ReferenceInclination

26、of AxisRotation of Face FlatA0 to 15150 to 210 Horizontal B0 to 15125 t0 150 210 to 235 OverheadC0 to 800 to125 235 to 360 VerticalD15 to 80125 to 235 E80 to 900 to 360,Welding Positions for Fillet Welds,The Horizontal Range Is smaller for fillet welds Than it is for groove welds,Welding Positions f

27、or Groove Welds,焊縫坡口的清理 UW-32規(guī)定，坡口表面應(yīng)清潔，無銹皮、銹、油、油脂、等其它有害物。,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)外進行焊接。 UW-16.1,Section VIII Division 1的焊接要求,UW-20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)，強度焊接、半強度焊接、密封焊接。強度焊用來承受全部軸向載荷；密封焊僅用于作為脹接的補充焊接，以保證密封

28、；半強度焊是根據(jù)在實際設(shè)計條件下機械和熱膨脹載荷來確定其強度的。 焊前準(zhǔn)備 切割邊必須光滑、清潔。（UW-31） 點焊焊縫、無論是去除，還是保留，都必須使用評定過的焊接工藝。（UW-31） 保留于焊縫中的點焊焊縫應(yīng)由評定過的焊工施焊。（UW-31） 非受壓件跨過受壓焊縫與受壓件相焊時，非受壓件必須開槽以避讓焊縫、或?qū)⑹軌汉缚p磨平。（UG-82） 當(dāng)受壓件焊在受壓焊縫上時，焊縫必須磨平。（UG-82）,UW-27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

29、(e)電渣焊 UW-27(f)電氣焊,縱縫的排列 UW-9(d)對容器各筒節(jié)縱縫之間的排列規(guī)定了要求，即要求縱縫相互錯開，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）要求進行RT檢驗。 焊接限制 Section VIII中關(guān)于焊接的兩項限制是： 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焊接工藝評定 UW-28給出了對焊接工藝進行評定的要求： 使用的焊接工藝必須有記錄，也就是說必須有書面的焊接工藝。 當(dāng)焊接受壓/受力件、用手工或半自動焊方法焊接非受壓/非受力件時，使用的焊接工藝應(yīng)按Section IX進行評定。

30、當(dāng)用機械焊方法焊接非受壓/非承力件時，使用的焊接工藝可不按Section IX進行評定。 UW-29焊工技能評定 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進行技能評定?？梢圆捎檬状魏附拥漠a(chǎn)品焊縫來進行技能評定，但必須仔細(xì)閱讀規(guī)范，以確定是否有例外或限制。銷釘焊必須在每個班開始時對焊工進行技能評定，但當(dāng)采用自動焊方法焊接非受壓或非受力件時，可不必進行技能評定試驗。Section IX中的其它要求必須滿足。,制造廠在焊接工藝評定方面的責(zé)任 制造廠/ASME持證廠的責(zé)任： 編寫書面WPS； 焊接評定試板，編寫焊接工藝評定記錄；機械性能試驗可由另一試驗室進行； 列出焊接參數(shù)； 在PQR上記錄焊接參數(shù)和試驗結(jié)果； 制定QC體系以控制焊接評定； 對焊接質(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 UW-35討論了縱縫和環(huán)縫的外觀要求，其中提到角焊縫和坡口焊