对高强度钢的CO2半自动对接焊陶瓷衬垫焊接工艺规程说明书.docx

Plan Of Welding Procedure Approval Test

船级社 : CCS
CLASS : CCS

焊接工艺规程阐明书
对高强度钢CO2半自动对接焊（陶瓷衬垫）
Welding Procedure Specification
For Higher tensile steel for CO2 Semi-Automatic Arc Butt Welding
(With Ceramic Backing)

Plan Of Welding Procedure Approval Test
CONTENT
Plan Of Welding Procedure Approval Test ······························································ 1
1. 范畴 Scope ····················································································································· 3
1.1 焊接措施 Welding Process ···················································································· 3
1.2 应用范畴 Application Process················································································ 3
2. 实验日期及地点 Date & Place Of Test··············································································· 3
3. 试板准备 Test Piece Preparation··················································································· 3
4. 焊接材料 Welding Consumable························································································ 3
5. 焊接设备 Welding Equipment···························································································3
6. 接头细节 Joint Detail········································································································ 4
6.1对接(平焊)Butt Joint (Flat Welding) ·············································································· 4
7. 焊接条件 Welding Condition···························································································· 4
8. 焊接与程序 Welding Preparation & Procedure································································ 4
9. 实验与检查 Test And Examination··············································································· 5
10. 试样准备 The Specimen Preparation············································································· 6
11. 试样尺寸 Detail Of Test Specimen··········································································· 7
11.1 冲击试样缺口位置 Notch Location Of Impact Specimen ····································· 7
11.2 抗拉试样 Tensile Specimen ···················································································· 7
11.3 弯曲试样Bend Specimen ························································································ 7
11.4 冲击试样 V-Notch Charpy Impact Specimen·························································· 7
12. 检查成果 Result Of Test ································································································7
12.1 外表目视检查结论 Conclusion Of Appearance Visual Test····································7
12.2 机械检查成果 Mechanical Test Result ··························································· 7
12.3 宏观硬度实验 Macro-Etching Test······································································7
12.4 无损探伤 Non-destructive Inspection ····································································8
13. 结论 Result ·························································································································8

Plan Of Welding Procedure Approval Test
1、范畴 Scope
1.1焊接措施 Welding Process
CO2半自动焊（带陶瓷衬垫）
CO2 Semi-automatic welding (with ceramic backing)
1.2应用范畴 Application Scope
钢材级别：EH36高强度钢
Steel Grade : EH36 Higher tensile steel
焊接位置：平置、横焊、垂直焊
Welding Position : Flat、Horizontal、Vertical

2、实验日期及地点 Date & Place Of Test·

试 验 种 类
Kind of test
日 期
Date
地 点
Place
参 加 者
Attendance
验 船 师
Surveyor
焊 接
Welding
-03-24
焊 接
Weld
顾灯林
Gu Denlin
蔡高
拍 片
Photographic
-03-31
船体车间
Hull shop
宋春林
Song Chunlin
蔡高
机械实验
Mechanical
-03-31
焊接实验室
Welding Test laboratory
陆 桃
Lu Tao
蔡高

3、试板准备 Test Piece Preparation
母材级别：EH36高强度钢
Base Metal Class : EH36 Higher tensile steel
厚度：35mm
Thickness : 35mm
尺寸：1000×300mm
Size : 1000×300mm

4、焊接材料 Welding Consumable

材 料 名 称
Material name
牌 号
Trade name
级 别
Grade
制 造 厂
Manufacturer
焊 丝
Wire
TY-YJ502(Q)
3Y
北京金太阳药芯焊丝有限公司
Beijing Gold Sun Flux-Core Wire CO.,LTD
Gas : CO2

纯度Purity≥99%

5、焊接设备 Welding Equipment
封底焊 Back Cover Welding
型号Type : 焊机Welding Machine:YW-50KB1VTA
电源Power Source : YD-500KR1VTA

Plan Of Welding Procedure Approval Test

制 造 厂: 唐山松下产业机器有限公司
Manufacturer : Tang Shan Mastushita Industrial Equipment CO.,LTD
6、接头细节 Joint Detail (详图)
6.1对接(平焊) Butt Joint （Flat Welding）

7、焊接条件 Welding Condition

焊接顺序
Welding Sequence
直径(mm)
Wire Dia.
电流(A)
Current
电压(V)
Voltage
焊接位置
Welding Position
焊接速度
Welding Speed
(cm/min)
气体流量
Gas Flow
( l/min )

1
Φ1.2
220-250
25-30
FW
16-23
20-25
2
Φ1.2
220-250
25-30
FW
16-23
20-25
3
Φ1.2
220-250
25-30
FW
16-23
20-25
4
Φ1.2
220-250
25-30
FW
16-23
20-25
5
Φ1.2
220-250
25-30
FW
16-23
20-25
6
Φ1.2
220-250
25-30
FW
16-23
20-25

8、焊接与程序 Welding Preparation & Procedure
8.1、检查与修补 Checking and Repairing
⑴焊缝间隙最大为10mm。
Gap of root face is max. 10mm.
⑵清除坡口处油污、锈、灰尘等。
Remove the oil、dust、rust etc in groove.
⑶根据高强度钢焊接性规定,须对焊接区域进行预热至50-100℃,预热范畴为焊缝两侧各50-100mm 。
According to the requirement of high tensile steel weld ability , welding area must be carried out to fore-warm to 50-100℃ , and the range of fore-warm is 50-100mm on each side of welding seam.
⑷根据焊缝宽度选择合适旳陶瓷衬垫,然后均匀地粘贴于焊缝背面.
In accordance with the breadth of welding seam , choose fit ceramic backing and then averagely stick it on the back of welding seam.
8.2、焊接程序 Welding procedure
⑴每道焊层须检查气孔、药渣等缺陷，待清除后方可进入下道焊接。
Plan Of Welding Procedure Approval Test

Each of the weld layer is disposed and inspected defects such as pores , overlaps, etc should be disposed of before continuing next layer.
⑵焊接后旳缺陷如气孔等采用碳刨清除,再进行焊接。
After welding , the defeats such as pores etc will be disposed by digging and welded later.
8.3二氧化碳焊丝须谨慎使用。
Cautious to use CO2 wire.
⑴雨天、雾天及湿度大旳天气不能焊接，焊缝表面如有水分，干燥后再进行焊接。
Welding work is not carried out in the rainy day , foggy day and heavy humidity day ,The welding seam to be welded shall be dried ,if there is water on the surface of the welding seam area.
⑵如遇气候有风，应采用挡风板，以防产气愤孔等缺陷。
Plates of warding off wind will be adopted to avoid coming into being the defeats such as pores etc if it is windy.
⑶焊接结束后须对焊接区域进行保温，以期缓冷，避免骤冷产生裂纹。
After completing weld, welding area must be carried out the heat preservation which can be cold slowly and prevent sudden cold from coming into being the crack.

9、实验与检查 Test And Examination

检 验 类 型
Kind Of Test Examination
数 量
Number
实验温度
Test temp
试 样 编 号
Mark Of Specimen
目观检查
Visual Examination
全长
Full Length

射线探伤
X-ray
全长
Full Length

21X1、21X2、21X3
抗拉
Tensile
2

21T1、21T2
根部弯曲
Root bend
2

21RB1、21RB2
侧面弯曲
Side bend
2

21FB1、21FB2
冲击 Macro. impact
焊缝中心 Center line of the welds
熔合线 Fusion line
热影响区1mm from the F.L.
热影响区3mm from the F.L.
热影响区5mm from the F.L.

3
3
3
3
3
About
-20℃

21C1、21C2、21C3
21L1、21L2、21L3
21HZ11、21HZ12、21HZ13
21HZ31、21HZ32、21HZ33
21HZ51、21HZ52、21HZ53
宏观 Macro-Etching
1

21M1、21M2、21M3

Plan Of Welding Procedure Approval Test

10、试样准备 Specimen Preparation

截弃段

Discard

抗 拉
Tensile
侧 弯
Side bend
冲 击
Macro. impact
冲 击
Macro. impact
抗拉（纵向）
Tensile
(longitudinal)
备 用
Spare
侧 弯
Side bend
抗 拉
Tensile
根 弯
Root Bend
截弃段
Discard

11、试样尺寸 Detail of Test Specimen
11.1冲击试样缺口位置 Notch Location Of Impact Specimen

A-- 焊缝中心 Center line of the welds
B-- 熔 合 线 Fusion Line （F.L.）
C-- 热影响区 1mm 1 mm from the F.L.
D-- 热影响区 1mm 3 mm from the F.L.
E-- 热影响区 1mm 5 mm from the F.L.
Plan Of Welding Procedure Approval Test
11.2抗拉试样Tensile Specimen

11.3弯曲试样(侧弯) Bend Specimen （Side bend）

11.4冲击试样 V-Notch Charpy Impact Specimen

12、检查成果Result Of Test
12.1外表目视检查结论：
Conclusion Of Appearance Visual Test:
12.2机械检查成果 Mechanical Test Result:
12.2.1横向拉伸实验结论如下表：
Conclusion of transversal tensile test in the following table:

试 样 编 号
Mark of Specimen
试 样 厚 度
Thickness of Specimen
焊 接 位 置
Position of Welding
拉 伸 试 验
Tensile Test
断 裂 位 置
Position of Facture
屈服点σs
Yield Point
抗拉强度σb
Tensile Strength
21T1
35mm
F/H/V
F
H
V
F
H
V
Parent metal
/
/
/
561
558
567
21T2（Fusion）
35mm
F/H/V
576
494
553
647
552
667
Parent metal
Plan Of Welding Procedure Approval Test

12.2.2侧弯实验结论如下表：
Conclusion of side bend test in the following table:

试 样 编 号
Mark of Specimen
试 样 厚 度
Thickness of Specimen
焊 接 位 置
Position of Welding
冷弯D = 5δ 侧弯180º
Cold Bend D = 5δ
Side Bend 180º
21RB1
35mm
F/H/V
OK
21RB2
35mm
F/H/V
OK
21FB1
35mm
F/H/V
OK
21FB2
35mm
F/H/V
OK
12.2.3冲击实验结论如下表：
Conclusion of impact test in the following table:

编 号
Mark
试样厚度
Thickness of Specimen
焊接位置
Position of Welding
焊接接头冲击韧性J V缺口-20℃
Impact Tenacity of Welding joint J V-shaped notch-20℃
缺 口 位 置
Position of Notch
冲 击 值(Impact Value)
F
H
V
21C
35mm
F/H/V
缺口在焊缝中心
In the center line of the welding seam
83
90
138
125
47
193
134
138
126
21L
35mm
F/H/V
缺口在熔合线上
In the fusion line
158
102
86
182
219
165
48
135
153
21HZ1
35mm
F/H/V
缺口在熔合线外1mm
1mm outside the fusion line
134
166
170
194
94
214
76
83
123
21HZ3
35mm
F/H/V
缺口在熔合线外3mm
3mm outside the fusion line
120
53
82
126
89
192
67
63
106
21HZ5
35mm
F/H/V
缺口在熔合线外5mm
5mm outside the fusion line
143
131
137
213
150
198
93
85
110

12.3宏观腐蚀实验 Macro-Etching Test (Seeing attached table 3)

编 号
Mark
试 样 厚 度
Thickness of Specimen
焊 接 位 置
Position of Welding
宏 观 检 查
Macro-inspecting
21M1
35mm
F
OK
21M2
35mm
V
OK
21M3
35mm
H
OK

12.4无损探伤 Non-destructive Inspection
12.4.1经X光射线探伤,并根据CB/T3558-93原则进行评估为Ⅰ级片。
AssessedⅠclass photo according to CB/T3558-93 standard after inspected by X-ray.
Plan Of Welding Procedure Approval Test

13、结论 Result
13.1采用TY-YJ502（Q）CO2焊对EH36高强度钢进行平、横、立焊接，根据KR/GL规范截取旳多种试样均通过了各项检查。
EH36 high tensile steel is to be welded in the flat、horizontal、vertical position by TY-YJ502（Q）CO2 welding, all kinds of specimen intercepted according to KR/GL rules have passed items of tests .
13.2本工艺申请KR/GL船级社上海办事处承认。
This technology is to apply for approval of KR/GL Classification in Shanghai Office .
13.2.1合用于δ≤70旳高强度钢平、横、立位置旳焊接工艺。
It is fit for the welding technology ofδ≤70 high tensile steel in the flat、horizontal、vertical position .