WPS焊接工藝規(guī)程(AWS版).ppt

1、Welding procedure specification (WPS) 焊接工藝規(guī)范 Kevin Mo,What is a WPS?什么是焊接工藝規(guī)范(WPS)?,焊接工藝規(guī)范是為了制造符合規(guī)范要求的焊縫而提供指導(dǎo)的、經(jīng)過(guò)評(píng)定合格的焊接工藝文件。它或其它文件可用于對(duì)焊工或焊機(jī)操作工提供指導(dǎo),以保證符合規(guī)范要求。 A WPS is a written qualified welding procedure prepared to provide direction for making production welds to Code requirements. The WPS or oth

2、er documents may be used to provide direction to the welder or welding operator to assure compliance with the Code requirements.,What is included by a WPS?WPS 的內(nèi)容,一份完整的WPS 應(yīng)當(dāng)包含在WPS中所采用的、對(duì)每一種焊接方法而言的所有重要變素、非重要變素和當(dāng)需要時(shí)的附加重要變素。樣表見(jiàn)圖1。焊接工藝規(guī)范其實(shí)就是規(guī)定某一焊接工藝的各種焊接變素。 The completed WPS shall describe all of the e

3、ssential, nonessential, and, when required, supplementary essential variables for each welding process used in the WPS. For the sample, pls see the figure 1.,Who take charge of compiling WPS?WPS應(yīng)該由誰(shuí)制定?,每個(gè)制造者或承包者應(yīng)按照焊接規(guī)范的規(guī)定編寫合理的WPS.具體的說(shuō)WPS是由代表廠家的焊接工程師編寫的。 Each manufacturer and contractor shall prepare

4、 written Welding Procedure Specifications which are defined in corresponding welding code.,Availability of the WPS WPS的可得性,用于產(chǎn)品焊接的WPS,應(yīng)當(dāng)在制造現(xiàn)場(chǎng)便于獲得，以供查考，并供授權(quán)檢驗(yàn)師(AI)檢查。 A WPS used for Code production welding shall be available for reference and review by the Authorized Inspector (AI) at the fabrication

5、 site.,Authorized by AI 授權(quán)檢驗(yàn)師檢查,conducted by welder 焊工或焊接操作工 根據(jù)WPS進(jìn)行生產(chǎn),compiled by welding engineer according to qualified PQR 焊接工程師根據(jù)評(píng)定合格的工藝評(píng)定記錄（PQR)制定恰當(dāng)?shù)暮附庸に囈?guī)范 （WPS）,supervised by AI 授權(quán)檢驗(yàn)師檢查,Simple connection diagram WPS關(guān)系簡(jiǎn)圖,Remarks: PQR is the qualified welding procedure procedure and test result

6、s record. 備注：PQR是經(jīng)過(guò)評(píng)定合格的焊接工藝數(shù)據(jù)及相關(guān)試驗(yàn)結(jié)果記錄,+,FCAW藥芯焊絲保護(hù)焊 SAW埋弧焊 GMAW氣保焊 SMAW焊條電弧焊 GTAW鎢極氬弧焊,+,How is a WPS created?如何創(chuàng)建一個(gè)WPS?,接頭形式j(luò)oint type,焊接方法welding process,建造規(guī)范constructionspecification,選擇,資源,成本,實(shí)際約束,瀏覽規(guī)范，列出可行焊接方法,主要約束,修訂可行焊接方法,評(píng)估生產(chǎn)成本,選擇,規(guī)范,Weld Process Selection焊接工藝選擇,The “ideal” welding process

7、is that which achieves the minimum specification requirements at the minimum cost. 完美的焊接工藝是那種以最小成本獲得規(guī)范要求的最低水平,The Practical Welding Engineer,Variables 焊接變素,重要變素essential variables 影響接頭彎曲和拉伸性能的因素Affect the bend ability and tension ability of joint 非重要變素non essential variables 對(duì)彎曲和拉伸不能產(chǎn)生明顯影響的因素Cant pr

8、oduce visible affection on bend ability and tension ability of joint 附加重要變素supplemental essential variables 影響接頭沖擊性能的因素Affect the toughness of joint,Essentials listed in AWS D1.1 AWS 對(duì)各種焊接方法重要變素的規(guī)定,Essentials in GMAW or FCAWGMAW and FCAW中的重要變素(AWS),Filler 填充材料 Increase in filler metal classification

9、 strength增加填料的強(qiáng)度 Change from one electrode classification to any other electrode classification，limited to FCAW從一種焊絲型號(hào)改變到另一種焊絲型號(hào)（只限藥芯焊絲） Change to an electrode classification not covered in AWS A5.18,A5.20,A5.28,A5.29.焊絲變?yōu)樵贏WS中沒(méi)有的型號(hào) Electrode焊絲 Change in nominal electrode diameter :焊絲直徑變化（實(shí)芯焊絲），焊絲直徑

10、增加（藥芯焊絲）,Electrical parameters焊接參數(shù) A change in the amperage for each diameter每種焊絲直徑的電流變化超過(guò)10 A change in type of current (ac or dc) or polarity and mode of transfer (GMAW only)電流極性變化或GMAW過(guò)渡模式變化 A change in the voltage for each diameter，surpass 7%電壓改變超過(guò)7 An increase or decrease in the wire feed speed

11、 for each electrode diameter surpass 10%送絲速度改變超過(guò)10,Essentials in GMAW or FCAWGMAW and FCAW中的重要變素(AWS),A change in the travel speed surpass 25%焊接速度改變超過(guò)25 An increase in heat input surpass 10%熱輸入增加超過(guò)10 Shielding gas保護(hù)氣 A change in shielding gas from a single gas to any other single gas or mixture of g

12、as, or in the specified nominal percentage composition of a gas mixture, or to no gas保護(hù)氣從單種氣體變?yōu)槠渌鼏畏N氣體或混合氣體,Essentials in GMAW or FCAWGMAW and FCAW中的重要變素(AWS),A change in total gas flow rate氣體流量增加大于50或減小超過(guò)20 A change to a shielding gas not covered in。改變?yōu)椴话贏WS A5.18,5.28,A5.20,A5.29中的保護(hù)氣。 General 一般

13、條件 For the PQR groove area, an increase or decrease 25% in the number of passes 對(duì)于與PQR坡口面積相同的，焊道數(shù)改變超過(guò)25 A change in position not qualified焊接位置改變?yōu)槲唇?jīng)評(píng)定的位置。,Essentials in GMAW or FCAWGMAW and FCAW中的重要變素(AWS),A change in diameter, or thickness, or both, not qualified by Table 2工件直徑或厚度未在評(píng)定范圍之外。 A change

14、in base metal or combination of base metals not listed on the PQR 母材未經(jīng)評(píng)定 Vertical Welding: For any pass from uphill to downhill or vice versa立焊：任何焊道從上到下焊接或相反 A change in groove type (e.g., single-V to double-V), 坡口形式變化（例如，單V到雙V),Essentials in GMAW or FCAWGMAW and FCAW中的重要變素(AWS),A change in the type

15、 of groove to a square groove and vice versa從任何坡口形式改變?yōu)橹边吇蛳喾?A change exceeding the tolerances, including decreasing of groove angle, decreasing of root opening, increasing of root face.坡口角度減小，坡口間隙減小以及鈍邊增加超過(guò)公差范圍 The omission, but not inclusion, of backing or back gouging取消襯墊或清根 Decrease from preheat

16、temperature6 by 15 Celsius degree預(yù)熱溫度降低超過(guò)15度,Essentials in GMAW or FCAWGMAW and FCAW中的重要變素(AWS),Figure 1. WPS sample 圖1.樣表,Welding Procedure Specification (WPS)焊接工藝規(guī)范樣表,Type of qualification testWPS評(píng)定試驗(yàn)項(xiàng)目及試樣數(shù)量、類型,The type and number of qualification tests required to qualify a WPS for a given thickn

17、ess, 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 subsections: 評(píng)定WPS試驗(yàn)的項(xiàng)目及數(shù)量應(yīng)遵照表2(全焊透接頭），表3（部分焊透接頭）或表4（角接頭）。主要有以下幾種試驗(yàn)項(xiàng)目。 (1) Visual Inspection 外觀檢驗(yàn) (2) NDT無(wú)損檢驗(yàn)，含RT,MT,UT

18、,PT等 (3) Face, root and side bend面彎，背彎及側(cè)彎 (4) Reduced Section縮截面焊縫拉伸 (5) All-Weld-Metal Tension全熔敷金屬拉伸 (6) Macroetch 宏觀浸蝕,Number and type of test specimens and range of thickness qualified-CJP 評(píng)定焊縫的厚度和試驗(yàn)數(shù)量及類型(全焊透接頭）,Number and type of test specimens and range of thickness qualified-PJP 評(píng)定焊縫的厚度和試驗(yàn)數(shù)量及

19、類型(部分焊透接頭）,Number and type of test specimens and range of thickness qualified-Fillet joint 評(píng)定焊縫的厚度和試驗(yàn)數(shù)量及類型(角接頭）,Classification of base metal 母材分類,Classification of base metal 母材分類,Classification of base metal 母材分類,Square 直邊,Single-V 單V坡口(帶襯墊),Double-V 雙V形坡口 (X形坡口),Groove Weld Types坡口形式,Welding varia

20、bles焊接因素,Single-bevel 單邊V形坡口,Double-bevel K形坡口,Groove Weld Types坡口形式,Welding variables焊接因素,Single-U 單面U形坡口,Double-U 雙面U形坡口,Groove Weld Types坡口形式,Welding variables焊接因素,Single-J 單面J形坡口,Double-J 雙面J形坡口,Groove Weld Types坡口形式,Welding variables焊接因素,Flare-bevel 卷邊接頭,Flare-V V形卷邊接頭,Groove Weld Types坡口形式,Wel

21、ding variables焊接因素,Welding Positions 焊接位置,Welding variables焊接因素,Welding Positions 焊接位置,Welding variables焊接因素,坡口焊縫板焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position 坡口焊縫管焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position 坡口焊縫管焊接位置,Wel

22、ding Positions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position 坡口焊縫管焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position 坡口焊縫管焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Positions of Plate fillet welds 板角焊縫位置,Welding Positions 焊接位置,Welding variables焊接因素,Positions of test pi