WPS焊接工艺规程课件

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1、12What is a WPS?什么是焊接工艺规范什么是焊接工艺规范(WPS)?t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工提供指导,以保证符合规范要求。以保证符合规范要求。A WPS is a written qualified welding procedure prepared to provide direction for making production welds to Code

2、 requirements.The WPS or other documents may be used to provide direction to the welder or welding operator to assure compliance with the Code requirements.3What is included by a WPS?WPS 的内容的内容t一份完整的一份完整的WPS 应当包含在应当包含在WPS中所采用的、对每中所采用的、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。需要时的附加

3、重要变素。样表见图样表见图1。焊接工艺规范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。其实就是规定某一焊接工艺的各种焊接变素。The completed WPS shall describe all of the essential,nonessential,and,when required,supplementary essential variables for each welding process used in the WPS.For the sample,pls see the figure 1.4Who take charge of compiling WPS?WPS

4、应该由谁制定应该由谁制定?t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。Each manufacturer and contractor shall prepare written Welding Procedure Specifications which are defined in corresponding welding code.5Availability of the WPS WPS的可得性的可得性t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。A WPS used for Code

5、production welding shall be available for reference and review by the Authorized Inspector(AI)at the fabrication site.6Remarks:PQR is the 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7+How is a WPS created?如何创建一个如何创建一个WPS?接头形式接头形式joint type焊接方法焊接方法weldin

6、g process建造规范建造规范constructionspecification8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9Weld Process Selection焊接工艺选择焊接工艺选择10Variables 焊接变素焊接变素t重要变素重要变素essential variables 影响接头弯曲和拉伸性能的因素影响接头弯曲和拉伸性能的因素Affect the bend ability and tension ability of jointt非重要变素非重要变素non essential variables 对弯曲和拉伸不能产生明显影

7、响的因素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 jointt附加重要变素附加重要变素supplemental essential variables 影响接头冲击性能的因素影响接头冲击性能的因素Affect the toughness of joint11Essentials listed in AWS D1.1AWS 对各种焊接方法重要变素的规定对各种焊接方法重要变素的规定12 Essentials in GMAW or FCAWGMAW and FCAW中的

8、重要变素中的重要变素(AWS)tFiller 填充材料填充材料tIncrease in filler metal classification strength增加填料的强度tChange from one electrode classification to any other electrode 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）tChange to an electrode classification not covered in AWS A5.18,A5.20,A5.28,A5.29.焊丝变为在AWS中没有

9、的型号tElectrode焊丝焊丝tChange in nominal electrode diameter:焊丝直径变化（实芯焊丝），焊丝直径增加（药芯焊丝）13tElectrical parameters焊接参数焊接参数tA change in the amperage for each diameter每种焊丝直径的电流变化超过10tA change in type of current(ac or dc)or polarity and mode of transfer(GMAW only)电流极性变化或GMAW过渡模式变化tA change in the voltage for eac

10、h diameter，surpass 7%电压改变超过7tAn increase or decrease in the wire feed speed for each electrode diameter surpass 10%送丝速度改变超过10 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素中的重要变素(AWS)14tA change in the travel speed surpass 25%焊接速度改变超过25tAn increase in heat input surpass 10%热输入增加超过10 tShielding gas保护气

11、保护气tA change in shielding gas from a single gas to any other single gas or mixture of gas,or in the specified nominal percentage composition of a gas mixture,or to no gas保护气从单种气体变为其它单种气体或混合气体 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素中的重要变素(AWS)15tA change in total gas flow rate气体流量增加大于50或减小超过20t

12、A change to a shielding gas not covered in。改变为不包含在AWS A5.18,5.28,A5.20,A5.29中的保护气。tGeneral 一般条件一般条件tFor the PQR groove area,an increase or decrease 25%in the number of passes 对于与PQR坡口面积相同的，焊道数改变超过25tA change in position not qualified焊接位置改变为未经评定的位置。Essentials in GMAW or FCAWGMAW and FCAW中的重要变素中的重要变素(

13、AWS)16tA change in diameter,or thickness,or both,not qualified by Table 2工件直径或厚度未在评定范围之外。tA change in base metal or combination of base metals not listed on the PQR 母材未经评定tVertical Welding:For any pass from uphill to downhill or vice versa立焊：任何焊道从上到下焊接或相反tA change in groove type(e.g.,single-V to dou

14、ble-V),坡口形式变化（例如，单V到双V)Essentials in GMAW or FCAWGMAW and FCAW中的重要变素中的重要变素(AWS)17tA change in the type of groove to a square groove and vice versa从任何坡口形式改变为直边或相反tA change exceeding the tolerances,including decreasing of groove angle,decreasing of root opening,increasing of root face.坡口角度减小，坡口间隙减小以及钝

15、边增加超过公差范围tThe omission,but not inclusion,of backing or back gouging取消衬垫或清根tDecrease from preheat temperature6 by 15 Celsius degree预热温度降低超过15度 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素中的重要变素(AWS)18Figure 1.WPS sample 图1.样表Welding Procedure Specification(WPS)焊接工艺规范样表焊接工艺规范样表19Type of qualification

16、 testWPS评定试验项目及试样数量、类型评定试验项目及试样数量、类型tThe type and number of qualification tests required to qualify a WPS for a given thickness,diameter,or both,shall conform to Table 2(CJP),Table 3(PJP)or Table 4(fillet).Details on the individual NDT and mechanical test requirements are found in the following subs

17、ections:评定评定WPS试验的项目及数量应遵照表试验的项目及数量应遵照表2(全焊透接头），表全焊透接头），表3（部（部分焊透接头）或表分焊透接头）或表4（角接头）。主要有以下几种试验项目。（角接头）。主要有以下几种试验项目。(1)Visual Inspection 外观检验 (2)NDT无损检验，含RT,MT,UT,PT等 (3)Face,root and side bend面弯，背弯及侧弯 (4)Reduced Section缩截面焊缝拉伸 (5)All-Weld-Metal Tension全熔敷金属拉伸 (6)Macroetch 宏观浸蚀20Number and type of te

18、st specimens and range of thickness qualified-CJP评定焊缝的厚度和试验数量及类型评定焊缝的厚度和试验数量及类型(全焊透接头）全焊透接头）21Number and type of test specimens and range of thickness qualified-PJP评定焊缝的厚度和试验数量及类型评定焊缝的厚度和试验数量及类型(部分焊透接头）部分焊透接头）22Number and type of test specimens and range of thickness qualified-Fillet joint评定焊缝的厚度和试验

19、数量及类型评定焊缝的厚度和试验数量及类型(角接头）角接头）23Classification of base metal 母材分类母材分类24Classification of base metal 母材分类母材分类25Classification of base metal 母材分类母材分类26Groove Weld Types坡口形式坡口形式Welding variables焊接因素焊接因素27Groove Weld Types坡口形式坡口形式Welding variables焊接因素焊接因素28Groove Weld Types坡口形式坡口形式Welding variables焊接因素焊接

20、因素29Groove Weld Types坡口形式坡口形式Welding variables焊接因素焊接因素30Groove Weld Types坡口形式坡口形式Welding variables焊接因素焊接因素31Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素32Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素坡口焊缝板焊接位置33Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素Groove weld pipe weldin

21、g position 坡口焊缝管焊接位置34Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素Groove weld pipe welding position 坡口焊缝管焊接位置35Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素Groove weld pipe welding position 坡口焊缝管焊接位置36Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素Groove weld pipe welding positio

22、n 坡口焊缝管焊接位置37Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素Positions of Plate fillet welds 板角焊缝位置38Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素Positions of test piping or tubing for fillet welds 管管、管板角焊缝位置39Welding Positions 焊接位置焊接位置 Welding variables焊接因素焊接因素40Heat Input热输入热输入E=UI/VWel

23、ding variables焊接因素焊接因素41tGauging 清根清根tTo make sure that get a complete penetration and good fusion at root,grinding 1st pass and welding from another side.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。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。Welding variables焊接因素焊接因素42Welding Codes 焊接法规焊接法规 American Welding Society(AWS)-Governi

24、ng body of the welding industry美国焊接学会（美国焊接学会（AWS）-焊接行业的权威机构焊接行业的权威机构 tStructural Welding Code(AWS D1.1)t结构焊接规范（结构焊接规范（AWS D 1.1）tBridge Welding Code(AWS D1.5)t桥梁焊接规范桥梁焊接规范(AWS D 1.5)tPressure Vessel Code(ASME section 9)t压力容器规范压力容器规范(ASME 第九部分第九部分)tShipbuilding Code(ABS)t造船规范造船规范(ABS)tContract file.t承包商技术规范承包商技术规范