焊接材料的选用及消耗定额.doc

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1、【精品文档】如有侵权，请联系网站删除，仅供学习与交流焊接材料的选用及消耗定额.精品文档.焊接材料的选用及消耗定额1、本标准适用于锅炉、压力容器焊材定额的制定和选用2、引用标准GB324-88焊缝符号表示法GB985-88气焊、手工电弧焊及气体保护焊焊缝坡口的基本形式与尺寸GB986-88埋弧焊焊缝坡口的基本形式和尺寸3、焊接材料的选择3.1.焊条的选择原则3.1.1考虑母材的机械性能和化学成分（常见化学成分和焊缝金属机械参见表）1、普通结构钢的焊接，通常要求焊缝金属与母材等强度，应选用抗拉强度等于或稍高于母材的焊条2、对于合金结构钢，通常要求焊缝金属的主要成分与母材金属相同或者相近。3、当母材

2、中C及S、P等元素含量偏高时，焊缝金属容易产生裂纹，应选用抗裂性能好的低氢型焊材。低碳钢或低合金高强钢的焊接应根据钢材的抗拉强度来选择等强或稍高强度的焊材。耐热钢或不锈钢的焊接，应选用熔敷金属化学成分与母材相同或相近的焊条异种钢焊接材料的选择比较复杂，选择时应遵循以下一般原则：组织基本类似，强度等级不同的钢之间的焊接，最好选用抗拉强度介于被焊材料之间的折中焊条。碳钢、低碳钢、耐热钢与奥氏体钢焊接，如果产品工作温度较低，选用Cr25Ni13型不锈钢填充金属。碳钢与耐热钢焊接时应选用E5015型焊条。3.1.2考虑焊件的结构复杂程度和刚性形状复杂、结构刚性大以及厚度大的焊件必须采用抗裂性能较好的低

3、氢焊条考虑焊件的工作条件，包括载荷、介质和温度等，选用相应的能满足使用要求的焊条，如高温条件下工作的焊件应选择耐热钢焊条，接触腐蚀介质的焊条应选择不锈钢焊条，承受动载或冲击载荷的焊件应选择强度较高、塑性和韧性较高的低氢型焊条。在没有规定的情况下，一般受压件选择碱性焊条，结构件选择酸性焊条，对于同一强度级别或同一化学成分的焊条，碱性焊条可代替酸性焊条，强度略低的焊条，但不得反代。3.1.4考虑改善焊工劳动条件，提高劳动生产率，经济合理性等方面在酸性焊条和碱性焊条都可满足性能的要求时，应尽量采用酸性焊条，在使用性能相同的基础上选择价格较低的焊条。3.2埋弧焊、电渣焊用焊丝的选择原则3.2.1埋弧焊

4、、电渣焊用焊丝应根据所焊钢材的类别几对接接头性能的要求加以选择，并与适当的焊剂配合使用。3.2.2低碳钢和低合金钢高强钢焊接应选择与钢材强度相匹配的焊丝。3.2.3 耐热钢和不锈钢的焊接应选择与钢材成分相近的焊丝。3.3气焊及气体保护焊焊丝的选择原则3.3.1气焊及气体保护焊焊丝的选择应选择与母材化学成分相一致、并含有一定量的脱氧元素，如锰硅等，使焊缝具有一定的机械性能，同时应考虑焊丝在焊接时不应强烈的飞溅和蒸发。3.4 常用的焊丝的化学成分参见表三3.5焊剂的选择3.5.1低碳钢的焊剂可选用高锰高硅型焊剂。3.5.2低合金高强度钢的焊接可选用中锰中硅或低锰中硅型焊剂。3.5.3对于耐热钢、不

5、锈钢、低温钢的焊接可选用中硅低碳硅型焊剂。3.5.4对于某写高合金钢的焊接，可选用碱度高的中硅、低硅焊剂或陶质型焊剂。从而降低合金元素的烧损或对焊缝进行掺合金。3.5.5常用焊剂组成成分参见表3.6根据上述原则，各类钢材焊接材料选用表（参见表一）作为我厂锅炉、 压力容器焊接材料选用的参考依据3.7受压元件焊接在选择焊材时应注意根据厂里目前的焊接工艺评定情况进行，对变换了焊材牌号应按照蒸汽锅炉安全技术监察规程等有关焊接工艺评定标准进行评定，评定合格方可选用。4焊材消耗定额制定方法4.1手工电弧焊：G条耗=2 G填充埋弧自动焊：G丝耗=1.18G填充 G剂耗=1.25G丝耗电渣焊：G丝耗=1.05

6、G填充 G剂耗=0.5Kg/m 钨极氩弧焊：G丝耗=1.25G填充 氧乙炔焊：G丝耗=1.1G填充熔化极气体保护焊： G丝耗=1.05G填充 4.2本定额标准指定的焊接方法，其定额有互换性。如因焊接方法改变，其定额可按下列公式换算： G条耗=1.7G丝耗4.3填充金属的计算方法如下： G填充=FLP10-6 式中 F：焊缝金属的横截面积L：焊缝实际长度P：焊材金属的比重 常见焊缝填充金属比重填充金属钢铸铁不锈钢紫铜比重7.856.6-7.77.758.965焊条规格的选择应根据焊件壁厚、结构、接头形式、焊缝尺寸以及性能要求加以选择5.1焊条规格的选择应根据焊件壁厚、结构、接头形式、焊缝尺寸以及

7、性能要求加以选择5.2对于焊件壁厚5MM和小管径钢管焊接时应尽量选择小于焊件厚度以及与焊缝尺寸相适应的规格焊条，对于壁厚5MM且焊缝尺寸大（角焊缝尺寸大于5）的焊件，在满足性能和操作的前提下应尽量选用规格大的焊条。5.3对于有焊缝根部质量要求的多层焊，打底层应选择小直径焊条焊接（2.5-3.2）中间层和盖面层根据破口宽度选择稍大规格的焊条（3.2-5）5.4对于无焊缝根部质量要求的受压件和非受压件,焊条的选择根据焊缝尺寸,并考虑生产效率可选择焊缝尺寸相适应规格的焊条6常用接头单位长度的焊材定额实例(以下实例中的接头形式应符合GB985和GB986标准.焊材消耗定额制定方法1各种焊接方法的焊材消

8、耗定额计算方法如下：手工电弧焊：G条耗=2G填充埋弧自动焊：G丝耗=1.18G填充 G剂耗=1.25G丝耗钨极氩弧焊：G丝耗=1.25G填充 熔化极气体保护焊：G丝耗=1.05G填充其中：G条耗=1.7G丝耗2常用接头单位长度的焊材定额实例：2.1筒体、集箱、管子对接焊缝焊缝形式焊缝截面计算公式坡口及焊缝尺寸焊缝截面积(mm2)焊材消耗定额（Kg/mm）Bpach焊条焊丝焊剂 F=4/3c?h+(-P)2?tg/2+?b+(p+1)26116010251.20.8048216012277.91.223102260142103.41.6231232601821512.37114326020321

9、4.83.372163260243264.74.156 F=2/3C?h+?b+(-P)2 ?tg/26305512252.70.827855016291.11.43010182121.11.901126202166.32.61114233221.43.47616273270.34.244 F=4/3C?h+?b+(/2)2611/143771.2090.7121.00082121831121.7581.0341.293101831271.9941.1731.466123122031642.5751.5181.893142231933.0301.7822.228162432243.5172.0

10、692.586 F=2/3(C1+C2)?h+?b+(-P)2 ?tg/2+(/2)2142.519170164 1843179.52.8181.6582.0721660164 204211.43.3191.9642.45518184 204277.64.3582.5793.22420204 204330.95.1953.0743.84322224 204391.56.1473.6374.54624244 204459.37.2114.2675.334焊缝形式焊缝截面计算公式坡口及焊缝尺寸焊缝截面积(mm2)焊材消耗定额（Kg/mm）bPa ch焊条焊丝焊剂单面焊双面成型F=2/3h?c+(-

11、P)2 ?tg/2+?b+(b+1)?h31.50.5.5608223.40.367.2023.5280.439.274430.90.485.3034.52110357.20.898.561561.20.964.60361274.81.174785.31.339814100.91.5841016131.72.0681218167.12.6231523232.93.6571625257.84.0482032366.95.7602540527.88.286F=2/3(C1+C2) ?h+?b+(-H-P)2 ?tg/2+(H+P)2?tg/2282.51P=41H=101=601=80304 32

12、43515.68.0954.7905.98730354 334569.38.9385.2896.61132374 344621.59.7585.7747.21734394 344676.410.6206.2847.85536414 354737.911.5856.8558.56938424 35480012.5607.4329.29040444 354868.813.6408.07110.0942464 354942.114.7918.75210.9446504 3641084.717.09410.0612.8448524 3641191.918.71311.0713.8450544 3741

13、269.719.93411.7314.93F=2/3(C1+C2) ?h+?b+?R2/2+H2tg/2F?(H-P-R)?2R+1/4(-b)2tg250?282.51P=41H=121R=10=60=80264 3643623.69.7915.7937.24230264 374635.69.9795.9057.38132264 384692.110.8666.4308.03734264 394753.111.8246.9968.74536264 404815.512.8037.5769.47038264 414879.313.8058.16910.2140284 424948.614.89

14、38.81211.0242284 4341015.215.9399.43111.7944284 4441055.316.5689.80412.8446304 4541156.718.16111.0713.8448304 4641227.619.27311.7314.9350304 4741299.820.1072管接头、吊耳、钢架等结构角焊缝焊缝形式焊缝截面计算公式坡口及焊缝尺寸焊缝截面积(mm2)焊材消耗定额（Kg/mm）Bpk、k1焊条 ?8时F=1/2?（k+1）2当k?8时F=1/2k20.5-1280.126312.50.1964180.283524.50.3856320.50274

15、0.50.6368500.7859500.7851060.50.95011721.1301284.51.32713981.53914112.51.766 F=1/2k?k1+?b+1/22?tg50?51-20-27 645.90.72168 761.50.96679 873.21.149810 999.11.5561012 10139.62.1921214 101782.7951416 10224.83.5291517 10249.13.9111618 10274.54.3101820 10329.15.1672022 10388.46.9802224 10452.47.1032426 10

16、521.28.1832628 10594.89.3382830 10673.210.5693032 10726.311.4033234 12846.213.2853436 12938.814.7393638 121035.316.2703840 141138.417.8734042 141287.420.2124244 141401.121.9974446 141519.623.854648 141632.825.7924850 141770.927.8035052 14190329.888焊缝形式焊缝截面计算公式坡口及焊缝尺寸焊缝截面积(mm2)焊材消耗定额（Kg/mm）bpk、k1焊条 F

17、=k?k1+?b+1/4(-p)2?tg50?10226 675.111.179127 7102.81.614148 8134.92.118169 9171.42.6912012 10256.54.0272817 10427.46.7103220 10532.18.3542.3 热交换器、空气预热器管子与管板对接焊缝焊缝形式焊缝截面计算公式坡口及焊缝尺寸焊缝截面积(mm2)焊材消耗定额（Kg/mm）dbch焊条 F=2/3h?c+b?1140-15.51.35.80.006165.55.80.006195.55.80.0062261.46.60.0072566.60.0083266.60.01

18、03866.60.0124266.60.0145161.570.01857670.02060670.02170670.02476670.026 角焊缝焊材计算系数Kg/m2 =0.0314 8 =0.5024 15 =1.76633 =0.0707 9 =0.6359 16 =2.00964 =0.1256 10 =0.758 17 =2.26864.5 =0.1503 11 =0.9485 18 =2.54345 =0.1963 12 =1.1304 19 =6 =0.2826 13 =1.3267 20 =3.147 =0.3847 14 =1.5386各种焊接材料互换系数G焊条2G填充1

19、.25G焊丝1.7Gco21.75G焊剂焊材转换系数焊条：埋弧焊丝：焊剂1：0.6：0.9氩弧焊打底的角焊缝焊材（焊丝）定额（Kg/m）焊角坡口为50(1.2为马鞍形坡口系数)20.0186*1.2=0.02256 2.50.03045*1.2=0.03654 30.0421*1.2=0.05052 3.50.0585*1.2 =0.070240.0749*1.2=0.0899 50.11694*1.2=0.1407360.16839*1.2=0.2021 70.2292*1.2=0.2751 80.29936*1.2=0.3593氩弧焊打底的对接焊缝焊材定额（Kg/m）焊角坡口为60本定额计

20、算公式：7.85（2 tg30?）20.01813*1.2=0.02176 2.50.02946*1.2=0.035352 30.04079*1.2=0.04895 40.07252*1.2=0.08742 4.50.09291*1.2=0.11149 50.1133*1.2=0.13597 60.16316*1.2=0.1958 70.2220*1.2=0.2665蛇形管对接自动线不开坡口焊材定额（Kg/个）焊丝直径132*3=0.00254 本定额计算公式：32*3=0.05052*0.0322=0.0025432*3.5=0.00353 32*3.5=0.0702*0.0322=0.00

21、353 32*4=0.00452 32*4=0.0899*0.0322=0.00452管子对接开坡口为60的焊丝定额（Kg/m）32*3=0.00411 32*3.5=0.005697 32*4=0.007291 32*5=0.0064538*3.5=0.00645 38*4=0.008658 38*5=0.0135342*3.5=0.00749 42*4=0.00957 42*4.5=0.01226 42*5=0.014949651*4=0.01162 51*5=0.0181657*3=0.007345 57*4=0.012987 57*5=0.0202960*3=0.007689 60*4

22、=0.01367 60*5=0.0213676*6=0.0434全焊透骑座式管头焊材定额（焊条）（kg/个） 本定额计算公式：=7.85（k2+d2?tg50?） 323842515760768910813315921924527332530.0330.03920.04340.05260.05880.06190.078440.05190.06080.06720.08160.09120.0960.12160.14240.17280.21280.254450.07350.08130.09470.11720.1310.13790.17460.20450.24810.39450.471660.1312

23、0.15930.17810.18740.23740.2780.33730.41540.49660.6840.76520.852670.17130.2080.23250.24470.30990.39930.47610.58630.64850.89310.99921.113380.30980.39240.45950.55750.68660.82081.13051.26471.4092100.4520.57240.67050.81361.00191.19781.64981.84562.05652.4482121.16491.43451.71492.3622.64252.94453.5053131.6

24、643142.28493.14713.35213.92314.0704152.60063.5824.00724.46525.3157162.97534.0984.58455.10846.0814183.07075.05585.65616.30257.5029206.17956.91317.70329.1704227.4168.29649.24511.0054248.76469.805210.925713.00682610.227511.44112.749415.17782811.802613.203814.712817.51533013.490515.092216.81720.02023215

25、.292817.108419.063622.69483419.249721.49725.53533621.51623.974928.54153823.909626.642131.71684026.428229.448635.05784229.074032.39738.56784431.847635.487342.46754634.745938.716946.09154837.769242.085750.1025040.199644.793953.326板材对接焊材定额（Kg/m） 坡口形式吊耳定额计算 焊条焊丝焊丝(埋弧焊) 焊条289.7915.7937.242101.179309.9795

26、.9657.381121.643210.8666.438.037142.1183612.8037.5769.47162.6913813.8058.16910.21204.0274014.8938.81211.02286.714215.9399.43211.79328.3544618.16811.0713.844819.27311.7314.935020.10712.55516.632100 25.21100 24.381 插入式管头焊材定额及封板定额（Kg/个）规格管头焊材定额封板焊材定额（更改）E5015D*3.2455MPa7MPa8MPa10MPa16MPa32*30.0450.0132

27、*3.50.0450.0242*30.0450.02242*40.0450.02542*50.0450.060.0351*3.50.0450.030.0451*40.0450.060.030.0451*50.0450.0710.030.0457*40.0450.060.030.0457*50.0450.0840.040.0460*30.0450.060.040.0560*40.0450.090.040.0560*50.0450.0910.040.0560*70.060.1840.040.0576*50.060.1840.050.060.0876*60.060.1840.050.060.0876

28、*70.090.230.050.060.0876*80.090.260.050.060.0889*50.060.1840.050.070.090.1389*70.090.230.050.070.090.12108*60.090.250.0860.1190.1180.1570.199108*70.090.260.0880.1150.1160.1530.195108*80.090.270.0820.1130.191108*100.6980.080.1090.183133*60.310.1450.1910.2430.3133*80.5940.150.1970.2510.377133*100.860.

29、140.1840.2350.291133*121.130.1350.1770.280133*131.280.1320.1750.275159*60.370.240.3050.3780.87159*70.560.2370.3010.3730.446159*80.710.2270.2890.3570.428159*101.030.240.3050.3780.87159*121.350.220.280.3470.415159*142.1320.180.240.30.4159*162.560.150.20.2550.383219*101.32219*121.8610.5010.6070.7231.15

30、42.251219*142.37219*162.940.4810.5820.6931.1071.771219*183.570.3720.5570.6631.695219*204.0380.5020.6070.7221.1542.251规格管头焊材定额封板焊材定额（更改）E5015D*3.2455MPa7MPa8MPa10MPa16MPa219*224.1720.3630.450.5450.6491.33219*244.94219*255.770.3510.4350.5260.6261.28219*286.680.3380.4190.5081.238219*307.630.330.4090.49

31、50.941219*328.65245*163.29245*183.99245*204.395245*224.67245*245.53245*266.46245*287.47245*308.54245*329.68245*3410.9245*3612.2245*3813.56245*4015273*101.77273*122.33273*142.96273*163.66273*184.450.8781.4031.82.2454.489273*205.460.7261.3791.772.213.793273*220.7071.3442.153.7273*246.160.6951.322.1123

32、.63273*267.190.9381.9222.3962.925.516273*288.33273*309.51273*3210.790.5370.7751.2371.5882.887273*3412.15273*3613.580.5170.7451.192.32273*3815.10.5070.6140.731.1662.274273*4016.7273*4218.78273*4420.13273*4621.99273*4823.91273*5025.91325*102.11325*122.77325*143.52规格管头焊材定额封板焊材定额（更改）E5015D*3.2455MPa7MPa

33、8MPa10MPa16MPa325*164.56325*185.3325*206.20.7332.73.294.648.013325*226.7325*247.33325*268.561.632.6053.1743.7986.837325*289.91325*3011.32325*3212.85325*3414.47325*3616.18325*3817.890.9231.8922.3582.8745.429325*4019.9325*4221.9325*4423.99325*4626.20.7511.4271.8312.2834.565325*4828.49角焊缝焊材计算系数Kg/m焊角高度

34、焊条焊丝焊角高度焊条焊丝20.03140.019110.94850.5730.07070.043121.13040.9640.12560.076131.32671.12650.19630.12141.53861.30660.28260.17151.76631.49970.38470.24162.00961.70680.50240.302172.68861.92690.63590.39182.54342.159100.7580.46202.142.665对接板的焊材定额（kg/m）(焊条)（集箱管材板材拼接定额计算）板厚焊条焊丝板厚焊条焊丝20.036264820.8844单面坡口坡口角度60本定额计算公式:7.85（2 tg30?） 30.08165022.661140.1455224.510150.22665426.431860.32635527.419870.44425628.42680.58015830.492690.73426032.6318100.90646538.2791121.30537044.4156131.53197550.9872141.77668058.1216152.03958565.4903162.32059073.4