51000DWT鑄鋼件焊接工藝規(guī)程說明書.doc

Welding Procedure Specification for Steel CastingJJS/WPS-2001-01鑄鋼件的CO2半自動氣體保護焊/手工電弧焊焊接工藝規(guī)程說明書Welding Procedure SpecificationforCO2 Semi-Automatic Arc Welding / Manual Metal Arc Weldingfor Steel Casting Compiled by: 郭建華Checked by:Verified by:靖江造船廠Jingjiang Shipyard18 March, 20011范圍 Scope11 焊接方法 Welding Process CO2半自動氣體保護焊 / 手工電弧焊CO2 Semi-Automatic Arc Welding / Manual Metal Arc Welding12 應用范圍 Application Range本說明書適用于船體鑄鋼件的CO2半自動氣體保護焊或手工電弧焊。This Welding Procedure Specification Is Apply to the Purpose of CO2 Semi-Automatic Arc Welding or Manual Metal Arc Welding for Steel Casting.2焊接材料 Welding Consumable焊接方法welding process材料名稱Material牌號Trade Name尺寸Size(mm)級別Grade制造廠ManufacturerCO2半自動氣體保護焊CO2 Semi-Automatic Arc Welding藥芯焊絲Flux-Cored WireSQJ501Ni1.23YSAH10天津三英焊業(yè)有限公司Tianjing Sainteagle Welding Co., LtdTWE-7111.23SAHH3YSA天泰焊材工業(yè)股份有限公司Tientai Electrode Co., Ltd氣體Gas: CO2純度Purity99%手工電弧焊Manual Metal Arc Welding焊條ElectrodeJH.E50153.2, 4.0, 5.03YH10江陰東青焊接材料有限公司Jiangyin Dongqing Welding Material Co., Ltd4接頭細節(jié) Joint Detail5焊接順序 Welding Sequence6焊接條件 Welding Condition焊接方法Welding Procedure直徑（mm）Dia of wire電流（A）Current電壓（V）Voltage焊接位置Welding Position焊接速度Speed氣體流量Gas flowCO2 半自動氣體保護焊CO2 Semi-Automatic Arc Welding1.21402001520All1015cm/min2025l/min手工電弧焊Manual Metal Arc Welding61 焊接要求 Welding Requirement1. 焊接之前必須除去預加工邊的銹蝕，油污，灰塵，潮濕等。Welding should be done after removing the rust, oil, dust, moisture etc.2. 每道焊層必須用鋼絲刷清理打磨干凈。Each layer should be removed slag by wire brush and grinding.3. 如果坡口用碳弧氣刨開設，坡口處的碳跡必須打磨干凈。If groove is air-arc gouged, grind surface of groove to smooth and to remove all trace of carbon.4. 電焊條須經烘干處理（詳見6.5），未經烘干的焊條不得使用。Electrode should be dried as per section 6.5 and should not be used without drying.5. 手工焊時焊條的擺動幅度應小于所用焊條直徑的3倍。Wide of weaving to be limited to less than three times of used electrode diameter.62 預熱 Preheating1. 焊縫預熱溫度為125200（預熱范圍距焊縫中心為75mm），用電加熱器或火焰進行加熱并覆蓋以絕緣毛毯，預熱時必須緩慢且均勻，以避免出現裂紋和變形（每小時約60100）。Weld joint to be preheated of 125200 (measured 75mm from edge of weld groove), apply heat slowly and evenly by using electrical heating equipment and torch, then wrapped with insulation blanket (about 60 to 100 per hour max).2. 焊縫清根后必須打磨干凈去除掉所有的碳化物，并按照上述工藝重新預熱。After back gouging the weld joint should be grind smooth, removed all carbon and repreheated according to the above procedure.63 層間溫度控制 Interpass Temperature Control較合適的層間溫度為125250，其溫度下限用以保證在多層焊中后道焊縫有起碼的預熱條件，其溫度上限以避免出現熱應力裂紋。通過補充加熱或緩慢焊接來控制層間溫度。Interpass temperature to be controlled of 125250, the lower limitation ensures at least preheat conditions during subsequent passes, the maximum limit of temperature to be absolutely controlled to avoid thermal stress cracks. Control interpass temperature by supplementary heat as per above preheat procedure or welding slowly.64 焊后熱處理 Postweld Heat Treatment1. 對于大型鑄鋼件(如掛舵臂、艉框架、墊塊、舵桿等)，可將焊縫區(qū)域用電加熱設備或火焰加熱到200250，保溫1.5小時并覆蓋以絕緣毛毯，然后使其緩慢冷卻。As regards large castings such as rudder horns, stern frames, shoe pieces and rudder stocks etc, the temperature of the welding area should be heated to 200250 by electrical heating equipment and torch, then wrapped with insulation blanket, and keep the temperature for approximately 1.5 hours then allow to cool down slowly.2. 對于小型精加工鑄鋼件，可將焊縫區(qū)域用電加熱設備或火焰加熱到600650，保溫1.5小時并覆蓋以絕緣毛毯，然后使其緩慢冷卻。As regards small castings for fine machining purpose, the temperature of the welding area should be heated to 600650 by electrical heating equipment and torch, then wrapped with insulation blanket, and keep the temperature for approximately 1.5 hours then allow to cool down slowly.65 焊接材料的管理 Control Of Welding Materials焊接結束，焊絲焊條必須返還到儲藏室去。Wire should be returned to the stored house after finish welding.焊條干燥狀態(tài)如下 condition for drying electrodes is as follows:焊接材料welding material標號brand烘干溫度drying temp.保溫conditioned temp.低氫型low hydrogenJH.E501530035080120最長使用時間 used max. Time1). 室外工作出4小時以內。Below 4hr in outdoor working.2). 室內工作出5小時以內。Below 5hr in indoor working.3). 超過以上時間焊條必須送回烘干室烘干。Over time electrode should be returned to drying room.焊接方法welding process焊接位置welding position直徑(mm)dia. of wire / electrode電流(A)current電壓(V)voltage焊接速度(cm/min)speed氣體流量(l/min)gas flow接頭細節(jié)joint detailsCO2 半自動氣體保護焊CO2 Semi-Automatic Arc Welding平焊flat1.2140160253010152025橫焊horizontal1.2140200152010152025立焊vertical1.21402