焊接工艺规范-en.docx

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1、焊接工艺规程1 .范围本规范适用于本公司集装箱生产焊接加工，焊接方法为半自动金属极活性气体 保护焊。2 .相关标准EN 25817钢焊接接头的缺陷EN ISO 13920焊接结构件允许的公差.焊工焊工必须经过考试并取操作资格证后，方可上岗,焊工考试按照EN287进行。3 .母材集装箱生产主要母材为:母材规格材质钢板t3 20Q235B,Q345B方管160*160*6.316Mn槽钢Q235B箱角ZG16Mn.焊丝3.1 焊丝选用ER50-6级别的焊丝,如G3Sil , ER70s6等等。3.2 焊丝必须通过GL船级社认证，目前选用我公司选用ESAB OK AristoRod 12.50, 1

2、.2。4 .焊机焊机选用GLC451-B, GLC451-C进行焊接作业.5 .保护气体焊接所使用的富氮混合气必须是检验合格的气体，氨气与CO2混合 比例为82： 180.焊前准备5.1 焊前应穿戴好劳保用品，并对焊机及附属设备进行检查，应 确保电路、水路、气路及机械装置的正常运行。5.2 焊接工作尽可能在室内进行，当工件外表潮湿或暴露于雨雪条件下，不得进行焊接作业。5.3 焊接部位必须进行焊前清理、去除铁锈、油污等杂质，重要部位还要求打磨 光洁。5.4 影响焊接质量的定位焊缝应该在焊接之前打磨掉.6 .焊接施工6.1 开始焊接前应明确图纸上对焊缝的要求，6.2 二氧化碳气体保护焊所用的气瓶应

3、配有预热器和流量计，气体纯度不得低于99.5 %,当压力低于LOMPa时，应停止使用。99.6 据各焊缝的接头类型，坡口形式，焊接位置，选用合理的焊接参数。对接焊缝焊接参数可参照下表选用:坡口形式焊接位置焊接层焊接电流焊接电压气体流量平焊PA打底110-13017-2012-2060* _-填充240-26024-2815-25盖面230-25023-2715-25立焊打底120-14017-2012-20 / /=X-4一 2-3PF填充130-15017-2012-20盖面120-14017-2012-20横焊PC打底140-16017-2012-20填充180-20019-2212-20

4、盖面170-19019-2212-20平焊PA打底110-13017-2012-20填充240-26024-2815-25 1 )1盖面230-25023-2715-25立焊PF打底120-14017-2012-20LP-3门仁J填充130-15017-2012-20盖面120-14017-2012-20横焊PC打底160-18018-2112-20填充230-26023-2815-25盖面19-21019-2215-25角焊缝焊接参数可参照下表选用:焊喉尺寸焊接位置焊接电流焊接电压气体流量3平角焊PB240-26024-2815-254平角焊PB250-27025-2915-255平角焊PB

5、250-27024-2815-256平角焊PB260-28025-2915-2599.7 接顺序应根据具体的结构条件合理确定.99.8 于重要焊缝，应注意防止在引弧处及收弧处产生焊接缺陷.99.9 氧化碳气体保护焊除根部和盖面层时，焊缝每层厚度为4-6mm,全部多道 焊缝应尽量采用错层焊工艺焊时，前一层焊道外表必须进行清理，检查、修整，如发现有影响焊接 质量的缺陷，必须修整清除后再焊10.焊后处理焊接结束，焊工应清理焊道外表的熔渣、飞溅物.10.1 对于焊缝超高或凸度过大等不合要求的焊缝，可用手砂轮机进行打磨，打磨时, 不允许损伤焊缝周围工件的外表,打磨后，焊缝外表应光滑平整.10.4 使用手

6、砂轮进行打磨作业时，手砂轮机不允许随意接触工件，以免划伤工件.10.5 焊接完成后,在主要焊缝旁边打上操作焊工工号钢印。主要焊缝为：（1）箱 角与方管、工字梁连接的部位；（2）波浪板之间焊缝，及波浪板与方管之间的焊 缝。10.6 焊后,焊工自己检查焊缝外形尺寸及外观质量，按照图纸及EN ISO 13920标 准检验各尺寸，按照EN25817标准检验焊缝外观质量。10.7 自检合格后报检，由检验员按照相关检验标准进行检验。10.8 焊缝缺陷超标允许返修，但返修次数不超过两次。10.9 焊缝出现裂纹时，焊工不得擅自处理，应及时的报告技术人员，查清原因， 订出修补措施方可处理。Welding Pro

7、cedure Regulations1. ScopeThis applies for welding and production of container in our company. Welding method is semiautomatic and metal electrode activated gas shielded arc welding.2. Relevant StandardEN 25817 defect of welded jointEN ISO 13920 permissible tolerance of welding partsWelderWelders mu

8、st pass the exams and acquire operation certificates, and then they are qualified to do their work. Welding examinations can be carried out according to EN287.3. Original materialsOriginal materials for producing containers:Original materialspecificationmaterialSteel platet3 20Q235B,Q345BSquare pipe

9、s160*160*6316MnChannel steelQ235BCorner fittingZG16MnWelding wire3.1 choose ER50-6 grade welding wires such as G3Sil , ER70S6 and so on.3.2 The weling wires must be authorized by GL.At present, our company has adopttedESAB OK AristoRod 12.50, 1.2。4. Welding machineChoose GLC451-B, GLC451 -C welding

10、machines for welding tasks.5. Protective gasThe mixed argon and carbon gas must be qualified and the mixed ration between argon and CO2 is 82： 12.6. Preparations before weldingBefore welding,please wear protective clothing, gloves,footware and eye protection and also chech the welding machine and an

11、cillary equipment. Make sure the normal running of electricity, water, gas and machinery equipment.6.1 The welding work shall be better done in doors. No welding when the parts surface is humid or the work is done in exposed rainy and snowy day.6.2 For the welding parts, work such as cleaning, remov

12、ing rust and oil stain shall be done before welding.The important parts are required to polish.6.3 The tack weld which affects the welding quality shall be polished.7. .Welding workBefore welding, all the requirements in the drawings for the welding lines shall be confirmed clearly.7.1 The air bottl

13、e which used in carbon dioxide gas shielded arc welding shall be equipped with warm-up machine and flow meter. The gas purity shall not be less than99.5%. Stop using when pressure is less than 1 .OMPa.7.2 According to all sorts of welding seam joints, beveled edges and welding positions, appropriate

14、 parameters shall be chosen.For welding parameter of butt welding seam please refer to:Beveled edgeswelding positionWeld layerWelding currentWeldingvoltageGas flow60*PARoot weld110-13017-2012-20fillingcover240-260230-25024-2823-2715-2515-25APFRoot weld120-14017-2012-20afilling130-15017-2012-20v -41-

15、cover120-14017-2012-20PCRoot weld140-16017-2012-20filling180-20019-2212-20cover170-19019-2212-20PARoot weld110-13017-2012-20A z 2-3filling240-26024-2815-25cover230-25023-2715-251PFRoot weld120-14017-2012-20filling130-15017-2012-20cover120-14017-2012-20PCRoot weld160-18018-2112-20filling230-26023-281

16、5-25cover19-21019-2215-25For welding parameter of fillet weld please refer to:ThroatsizeWelding positionsWeldingelectrical currentWelding voltageGas flow3PB240-26024-2815-254PB250-27025-2915-255PB250-27024-2815-256PB260-28025-2915-25Welding orders shall be confirmed reasonably according to the exact

17、 welding parts conditions7.3 For some important weld, welding defects which caused at striking arc and ending arc shall be avoided.7.4 When use carbon dioxide shielded welding disposing root and covering the surface, the thickness of every layer weld is 4 to 6mm. For all multi-welds, staggered weld

18、shall be better adopted.7.5 For the multi-layers welding, the surface of prior pass must be cleaned, checked and trimmed. If any defects which affects welding quality, welding can be done again after cleaning and trimming.8. Post-welding processWelders should clean slag and spatter on the surface of

19、 pass.8.1 For the unqualified weld such super high and protruding excessively, manual grinding wheel can be used for polishing. When polishing, the surface around weld parts is not allowed to damage. After polishing, the surface of weld shall be smooth.10.4 When polish using grinding wheel, the grin

20、ding wheel machines is not allowed to touch working parts randomly, which prevents from scratching the parts.10.5 After welding, the welders steel seal shall be stamped beside the main seam. The main seams include(l)corner fittings and squared pipes, the connection parts of I-shape beam (2) the weld

21、 seam between wave plate and the line between wave plate and squared pipes.10.6 After welding, welders check the exterior dimensions and quality. Dimensions can be checked according the drawings and EN ISO 13920 standard; the exterior quality of weld seam according to EN25817 standard.1.1.1 Apply fo

22、r inspection after self-checking. Inspectors shall test according to the relevant checking standards.1.1.2 Return reparation is allowed if weld seams defects exceed the stipulate standards, while the returning times cant exceed 2 times.1.1.3 When cracks appear on weld seam, welder cant dispose them casually and should report to technicians immediately. Reasons shall be made out and make the corresponding solving methods as soon as possible.