WPS焊接工艺规程.pdf
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1、Welding pr ocedur e specification(WPS)焊接工艺规范Kevin MoLINCOLNELECTRICWhat is a WPS?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 工提供指导似保证符合规范要求。A WPS is a w r itten qualified w elding pr ocedur e pr epar ed to pr ovide dir ection for making pr oduction w elds to Code r equ
2、ir ements.The WPS or other documents may be used to pr ovide dir ection to the w elder or w elding oper ator to assur e compliance w ith the Code r equir ements.LINCOLN1h ELECTRIC2What is incl uded by a WPS?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
3、接变素。The completed WPS shall descr ibe all of the essential,nonessential,and,w hen r equir ed,supplementar y essential var iables for each w elding pr ocess used in the WPS.For the sample,pls see the fiaur e 1.LINCOLN1h ELECTRIC3Who take charge of compil ing WPS?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
4、.具体的说WPS是由代表厂家的焊接工程 师编写的。Each manufactur er and contr actor shall pr epar e w r itten Welding Pr ocedur e Specifications w hich ar e defined in cor r esponding w elding code.LINCOLNSb ELECTRIC4Availability of the WPSWPS的可得性川于产品焊接的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。A WPS used for Code pr oduction w e
5、lding shall be available for r efer ence and r eview by the Author ized Inspector(Al)at the fabr ication site.LINCOLNSb ELECTRIC5Simple connection diagramWPS关系简图compiled by w elding engineer accor ding to qualified PQR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)Author ized by AI授权检验师检查Remarks:PQR is the
6、 qualified welding procedure procedure and test results record.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conducted by w elder焊工或焊接操作工 根据WPS进行生产super vised by AI授权检验师检1LINCOLN6ELECTRICHow is a WPS created?如何创建一个WPS?接头形式j oint typeFCAW药芯焊丝保护 焊SAW埋弧焊GMAW气保焊 SMAW焊条电弧焊 GTAW铝极氨弧焊焊接方法 wel ding process+Str uctur al Wel
7、ding Code-SteelANSVAWS D1.1-96 An American Nstional Standard建造规范 construction specificationLINCOLN1h ELECTRIC7浏览规范,列出可行焊接方法主要约束FUNCTIONAL CONSTRAINTS :一:.:.:.:.:;:.;.:%:.:2:,:.=.:.rEquipimnt,Personnel Services,Space:.:簿:”二演,霸 诚.:.二n嚏患;.嚏皿年约束修订可行焊接方法J REVISED UST OF ACCEPTABLE PROCESSES评估生产成本EVALUATE
8、 PRODUCTION COSTTS(IMal Costs;Not Just Wel d Costs)、,、“,、.A J:”,、了.小毋.点八“选择Wel d Process Sel ection焊接工艺选择Th e“ideal welding process is th at wh ich ach ieves th e minimum specif ication requirements at th e minimum cost.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Th e Practical Welding EngineerLINCOLNSb ELECTRIC9Var
9、iabl es焊接变素 重要变素essential variables影响接头弯曲和拉伸性能的因素Affect the bend ability and tension ability of joint 非重要变素non essential variables对弯曲和拉伸不能产生明显影响的因素CaNt produce visible affection on bend ability and tension ability of joint 附力口重要变素supplemental essential variables影响接头冲击性能的因素Affect the toughness of joi
10、nt10ELECTRICEssential s l isted in AWS D1.1AWS对各种焊接方法重要变号Tabl e Changes Requiring WPS Requal ification for GMAW.FCAW,and GTAWEl ectrodeEssential Varubl e Chants to PQR Requtnug RequahficabonProcecSMAWSAWGMAWFCAWGTAWFil l er MetalI)Incre-ase in fil l er metal cl arification stxe.thXXX2)Change frccn l
11、 ow hydrogen to noo-l g-bydrce n SNfAW el ectrodeX3)Change from one el ectrode or fl ux-el ectrode ck MfkaboD to any otbe r el ectrode or fl uxl ectxode cl assification1XXX4)Change to an el ectrode or fl ux-ekctrode cl n&ifkatioD7 not covered in:AWSA5.1 or A55AWSAS.17crAS.23AWS A5.i&or A5.28AWSA5.20
12、cr A5.29AWS A5.l 8or A52S5)Addition or del etion of fil l er metdX6)CKan郡 from col d wire fired to bot wire feed or vice ersaX7)Addition or del etion of suppl emental pc*deced or granul ar fil l er metal cr cut wireX8)辰reeein the amount of wppknrnul pc*de i/32in.(O.fc mm increaseAny increo*e Any inc
13、rease or decreaseAny increase 1716 in.1 j6 mm increase or decreasei I)Chan 邵 in number of el ectrode*XXX12)Change in tungsten el ectrode type a*shown in AWS A5.12XEssential s in GMAW or FCAW GMAW and FC AW中的重要变素(AWS).Filler填充材料 Incr ease in filler metal classification str ength增加填料的强度 Change fr om o
14、ne electr ode classification to any other electr ode classification,limited to FCAW从一种焊丝型号改变 到另一种焊丝型号(只限药芯焊丝)Change to an electr ode classification not cover ed in AWS A5.18,A5.20,A5.28,A5.29 焊丝变为在AWS中没有的型号 Electrode焊丝 Change in nominal electr ode diameter:焊丝直径变化(实芯焊 丝),焊丝直径增加(药芯焊丝)LINCOLNSb ELECTRI
15、C12Essential s in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)Electrical parameters焊接参数 A change in the amper age for each diameter每种焊丝 直径的电流变化超过10%A change in type of cur r ent(ac or de)or polar ity and mode of tr ansfer(GMAW only)电流放性灰化或&MAW过 渡模式变化 A change in the voltage for each diameter,sur pass 7%电压改变
16、超过7%An incr ease or decr ease in the w ir e feed speed for each electr ode diameter sur pass 10%送丝速度改变超 过 10%_LINCOLN1h ELECTRIC13Essential s in GMAW or FCAWGM AW and FCAW中的重要变素(AWS)A change in the tr avel speed sur pass 25%焊接速度改变超过 25%An incr ease in heat input sur pass 10%热输入增加超过 10%Shielding gas
17、保护气 A change in shielding gas fr om a single gas to any other single gas or mixtur e of gas,or in the specified nominal per centage composition of a gas mixtur e,or to no gas保护气从单木中气体变 为其它单种气体虚混合气体LINCOLNELECTRIC14Essential s in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)A change in total gas flow r ate气体流
18、量增加大于50%或减小超过 20%A change to a shielding gas not cover ed in。改变为不包含在 AWS A5.18,5.28,A5.20,A5.29中的保护气。.General 一般条件 For the PQR gr oove ar ea,an incr ease or decr ease 25%in the number of passes对手与PQR坡口面积相同的,焊道数诙变超过 25%A change in position not quahfied焊接不 改变为未经评定的位置LINCOLN1h ELECTRIC15Essential s in
19、GMAW or FCAWGMAW and FCAW中的重要变素(AWS)A change in diameter,or thickness,or both,not qualified by Table 2工件宜.径或厚度未在评定范围之 外。A change in base metal or combination of base metals not listed on the PQR 母材未经评定 Ver tical Welding:For any pass fr om uphill to dow nhill or vice ver sa立原:任何焊道从上到下焊接 或相反 A change
20、in gr oove type(e.g,single-V to double-V),坡口形式变化(例如,单V到双V)LINCOLN!h ELECTRIC16Essential s in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)A change in the type of gr oove to a squar e gr oove and vice ver sa从住何坡口形式改变为直边或相反 A change exceeding the toler ances,including decr easing of gr oove angle,decr easing o
21、f r oot opening,incr easing of r oot face,坡 口角度减小,坡 口间隙减小以及钝边增加超过公差范围 The omission,but not inclusion,of backing or back gouging取消舄垫或清根 Decr ease fr om pr eheat temper atur es by 15 Celsius degr ee预热温度降低超过15度LINCOLN!h ELECTRIC17Wel ding Procedj ur年加区焊接工艺规范例舞D QUALIFIED BY TESTING DURE QUALIFICATION R
22、ECORDS(PQR)Iden tifioation*_Yes I IPQR 23工Company Nan=_RED 工 nu._Wekfng Procesaies)PCLXW_Supporting PQR No.(s)PQR 2 31R/ision 工 Oate 工 2-1-7Authonzed by b J onesTypeManualMachri&I 1By eT Lya_Date 工-1 0-33 S-emkAutomatic x|Autcmatic IZJJOIHT DESIGN USEDType:_But t_9ng-1Xj Oocibia We4d|_Becking:Yes|X
23、J No J_Backing Material:_ASTM A 1 31A_Root Opening 金 Root Face Dimension _G roove An/o:52-Radus(J U)_zz_Back Gouging:Yes|_|No 区Method _BASE METALSMaterial S|eo._ASTM A 1 31Tyr=AThidoiEBS:Groove 3/4工 1/2Diameter(Pipe)_二_.F _-FILLER METALSAWS Specification_A5-20_AWS Cl assification _.7 工T-工_SHIELDIMG
24、Fl ux_zz_ Gas _CO)_Competition 工。O%UOEl etro-Fl ux(Cl ass)_Fl ow Rate 45-55UPH_ Gas Cup Size _PREHEATPreheat Tecnp.,Min 600_Int&rrass Tennp.,Min 6 0 _Max 350POSITIONPosition of Groove:O R Fil l et:一Vertical Progression:Up J_|Down|_|ELECTRICAL CHAFLACTERISTIGSTransfer MRe(GMAW)Short-Circuiting|Gioij
25、l ar 区 Sprary 匚 Current AC J_|DCEP 区 DCEN_ Pul se-Jl _|Other _Tcnosten 曰ectrode fGTAWi Size:_ _Type:-TECHNIQUEStriroe-r or Weave Bead:S 七 h/ngeirMul tipass or Singl e Pass iper Number of El etrode _ _El ectrode Spacing Lcogitudinal _二_Lateral_=_Ape _ZZ_Contact 7ute to Work Distance _1/_Peening None_
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- 关 键 词:
- WPS 焊接 工艺 规程
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