WPS焊接工艺规程(AWS版)

1Weldingprocedurespecification(WPS)焊接工艺规范KevinMo2WhatisaWPS?什么是焊接工艺规范(WPS)?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工提供指导,以保证符合规范要求。AWPSisawrittenqualifiedweldingprocedurepreparedtoprovidedirectionformakingproductionweldstoCoderequirements.TheWPSorotherdocumentsmaybeusedtoprovidedirectiontothewelderorweldingoperatortoassurecompliancewiththeCoderequirements.3WhatisincludedbyaWPS?WPS的内容一份完整的WPS应当包含在WPS中所采用的、对每一种焊接方法而言的所有重要变素、非重要变素和当需要时的附加重要变素。样表见图1。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。ThecompletedWPSshalldescribealloftheessential,nonessential,and,whenrequired,supplementaryessentialvariablesforeachweldingprocessusedintheWPS.Forthesample,plsseethefigure1.4WhotakechargeofcompilingWPS?WPS应该由谁制定?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。EachmanufacturerandcontractorshallpreparewrittenWeldingProcedureSpecificationswhicharedefinedincorrespondingweldingcode.5AvailabilityoftheWPSWPS的可得性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。AWPSusedforCodeproductionweldingshallbeavailableforreferenceandreviewbytheAuthorizedInspector(AI)atthefabricationsite.6AuthorizedbyAI授权检验师检查conductedbywelder焊工或焊接操作工根据WPS进行生产compiledbyweldingengineeraccordingtoqualifiedPQR焊接工程师根据评定合格的工艺评定记录（PQR)制定恰当的焊接工艺规范（WPS）supervisedbyAI授权检验师检查SimpleconnectiondiagramWPS关系简图Remarks:PQRisthequalifiedweldingprocedureprocedureandtestresultsrecord.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+FCAW药芯焊丝保护焊SAW埋弧焊GMAW气保焊SMAW焊条电弧焊GTAW钨极氩弧焊+HowisaWPScreated?如何创建一个WPS?接头形式jointtype焊接方法weldingprocess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9WeldProcessSelection焊接工艺选择The“ideal”weldingprocessisthatwhichachievestheminimumspecificationrequirementsattheminimumcost...完美的焊接工艺是那种以最小成本获得规范要求的最低水平……ThePracticalWeldingEngineer10Variables焊接变素重要变素essentialvariables影响接头弯曲和拉伸性能的因素Affectthebendabilityandtensionabilityofjoint非重要变素nonessentialvariables对弯曲和拉伸不能产生明显影响的因素Can’tproducevisibleaffectiononbendabilityandtensionabilityofjoint附加重要变素supplementalessentialvariables影响接头冲击性能的因素Affectthetoughnessofjoint11EssentialslistedinAWSD1.1AWS对各种焊接方法重要变素的规定12EssentialsinGMAWorFCAWGMAWandFCAW中的重要变素(AWS)Filler填充材料Increaseinfillermetalclassificationstrength增加填料的强度Changefromoneelectrodeclassificationtoanyotherelectrodeclassification，limitedtoFCAW从一种焊丝型号改变到另一种焊丝型号（只限药芯焊丝）ChangetoanelectrodeclassificationnotcoveredinAWSA5.18,A5.20,A5.28,A5.29.焊丝变为在AWS中没有的型号Electrode焊丝Changeinnominalelectrodediameter:焊丝直径变化（实芯焊丝），焊丝直径增加（药芯焊丝）13Electricalparameters焊接参数Achangeintheamperageforeachdiameter每种焊丝直径的电流变化超过10％Achangeintypeofcurrent(acordc)orpolarityandmodeoftransfer(GMAWonly)电流极性变化或GMAW过渡模式变化Achangeinthevoltageforeachdiameter，surpass7%电压改变超过7％Anincreaseordecreaseinthewirefeedspeedforeachelectrodediametersurpass10%送丝速度改变超过10％EssentialsinGMAWorFCAWGMAWandFCAW中的重要变素(AWS)14Achangeinthetravelspeedsurpass25%焊接速度改变超过25％Anincreaseinheatinputsurpass10%热输入增加超过10％Shieldinggas保护气Achangeinshieldinggasfromasinglegastoanyothersinglegasormixtureofgas,orinthespecifiednominalpercentagecompositionofagasmixture,ortonogas保护气从单种气体变为其它单种气体或混合气体EssentialsinGMAWorFCAWGMAWandFCAW中的重要变素(AWS)15Achangeintotalgasflowrate气体流量增加大于50％或减小超过20％Achangetoashieldinggasnotcoveredin。改变为不包含在AWSA5.18,5.28,A5.20,A5.29中的保护气。General一般条件ForthePQRgroovearea,anincreaseordecrease25%inthenumberofpasses对于与PQR坡口面积相同的，焊道数改变超过25％Achangeinpositionnotqualified焊接位置改变为未经评定的位置。EssentialsinGMAWorFCAWGMAWandFCAW中的重要变素(AWS)16Achangeindiameter,orthickness,orboth,notqualifiedbyTable2工件直径或厚度未在评定范围之外。AchangeinbasemetalorcombinationofbasemetalsnotlistedonthePQR母材未经评定VerticalWelding:Foranypassfromuphilltodownhillorviceversa立焊：任何焊道从上到下焊接或相反Achangeingroovetype(e.g.,single-Vtodouble-V),坡口形式变化（例如，单V到双V)EssentialsinGMAWorFCAWGMAWandFCAW中的重要变素(AWS)17Achangeinthetypeofgroovetoasquaregrooveandviceversa从任何坡口形式改变为直边或相反Achangeexceedingthetolerances,includingdecreasingofgrooveangle,decreasingofrootopening,increasingofrootface.坡口角度减小，坡口间隙减小以及钝边增加超过公差范围Theomission,butnotinclusion,ofbackingorbackgouging取消衬垫或清根Decreasefrompreheattemperature6by15Celsiusdegree预热温度降低超过15度EssentialsinGMAWorFCAWGMAWandFCAW中的重要变素(AWS)18Figure1.WPSsample图1.样表WeldingProcedureSpecification(WPS)焊接工艺规范样表19TypeofqualificationtestWPS评定试验项目及试样数量、类型ThetypeandnumberofqualificationtestsrequiredtoqualifyaWPSforagiventhickness,diameter,orboth,shallconformtoTable2(CJP),Table3(PJP)orTable4(fillet).DetailsontheindividualNDTandmechanicaltestrequirementsarefoundinthefollowingsubsections:评定WPS试验的项目及数量应遵照表2(全焊透接头），表3（部分焊透接头）或表4（角接头）。主要有以下几种试验项目。(1)VisualInspection外观检验(2)NDT无损检验，含RT,MT,UT,PT等(3)Face,rootandsidebend面弯，背弯及侧弯(4)ReducedSection缩截面焊缝拉伸(5)All-Weld-MetalTension全熔敷金属拉伸(6)Macro－etch宏观浸蚀20Numberandtypeoftestspecimensandrangeofthicknessqualified-CJP评定焊缝的厚度和试验数量及类型(全焊透接头）21Numberandtypeoftestspecimensandrangeofthicknessqualified-PJP评定焊缝的厚度和试验数量及类型(部分焊透接头）22Numberandtypeoftestspecimensandrangeofthicknessqualified-Filletjoint评定焊缝的厚度和试验数量及类型(角接头）23Classificationofbasemetal母材分类24Classificationofbasemetal母材分类25Classificationofbasemetal母材分类26Square直边Single-V单V坡口(带衬垫)Double