1、Welding procedure specification (WPS)焊接工艺规范Kevin Mo,What is a WPS? 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。A WPS is a written qualified welding procedure prepared to provide direction for making production welds to Code requirements. The WPS or other
2、 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。The completed WPS shall describe all of the ess
3、ential, 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。Each manufacturer and contractor shall prepare w
4、ritten Welding Procedure Specifications which are defined in corresponding welding code.,Availability of the WPS WPS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。A WPS used for Code production welding shall be available for reference and review by the Authorized Inspector (AI) at the fabrication si
5、te.,Authorized by AI 授权检验师检查,conducted by welder 焊工或焊接操作工 根据WPS进行生产,compiled by welding engineer according to qualified PQR 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）,supervised by AI 授权检验师检查,Simple connection diagramWPS关系简图,Remarks: PQR is the qualified welding procedure procedure and test results re
6、cord. 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,+,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,+,How is a WPS created? 如何创建一个WPS?,接头形式 joint type,焊接方法 welding process,建造规范 construction specification,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,Weld Process Selection 焊接工艺选择,The “ideal” welding proces
7、s is that which achieves the minimum specification requirements at the minimum cost. 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,The Practical Welding Engineer,Variables 焊接变素,重要变素essential variables影响接头弯曲和拉伸性能的因素Affect the bend ability and tension ability of joint非重要变素non essential variables对弯曲和拉伸不能产生明显影响的因素Cant pro
8、duce visible affection on bend ability and tension ability of joint附加重要变素supplemental essential variables 影响接头冲击性能的因素Affect the toughness of joint,Essentials listed in AWS D1.1 AWS 对各种焊接方法重要变素的规定,Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS),Filler 填充材料 Increase in filler metal classification
9、strength增加填料的强度 Change from one electrode classification to any other electrode classification，limited to FCAW从一种焊丝型号改变到另一种焊丝型号（只限药芯焊丝） Change to an electrode classification not covered in AWS A5.18,A5.20,A5.28,A5.29.焊丝变为在AWS中没有的型号Electrode焊丝 Change in nominal electrode diameter :焊丝直径变化（实芯焊丝），焊丝直径增加
10、（药芯焊丝）,Electrical parameters焊接参数 A change in the amperage for each diameter每种焊丝直径的电流变化超过10 A change in type of current (ac or dc) or polarity and mode of transfer (GMAW only)电流极性变化或GMAW过渡模式变化 A change in the voltage for each diameter，surpass 7%电压改变超过7 An increase or decrease in the wire feed speed f
11、or each electrode diameter surpass 10%送丝速度改变超过10,Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS),A change in the travel speed surpass 25%焊接速度改变超过25 An increase in heat input surpass 10%热输入增加超过10 Shielding gas保护气A change in shielding gas from a single gas to any other single gas or mixture of gas
12、, or in the specified nominal percentage composition of a gas mixture, or to no gas保护气从单种气体变为其它单种气体或混合气体,Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS),A change in total gas flow rate气体流量增加大于50或减小超过20 A change to a shielding gas not covered in。改变为不包含在AWS A5.18,5.28,A5.20,A5.29中的保护气。General 一般条件
13、For the PQR groove area, an increase or decrease 25% in the number of passes 对于与PQR坡口面积相同的，焊道数改变超过25A change in position not qualified焊接位置改变为未经评定的位置。,Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS),A change in diameter, or thickness, or both, not qualified by Table 2工件直径或厚度未在评定范围之外。 A change in
14、base metal or combination of base metals not listed on the PQR 母材未经评定Vertical Welding: For any pass from uphill to downhill or vice versa立焊：任何焊道从上到下焊接或相反 A change in groove type (e.g., single-V to double-V), 坡口形式变化（例如，单V到双V),Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS),A change in the type of
15、 groove to a square groove and vice versa从任何坡口形式改变为直边或相反 A change exceeding the tolerances, including decreasing of groove angle, decreasing of root opening, increasing of root face.坡口角度减小，坡口间隙减小以及钝边增加超过公差范围 The omission, but not inclusion, of backing or back gouging取消衬垫或清根 Decrease from preheat tem
16、perature6 by 15 Celsius degree预热温度降低超过15度,Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS),Figure 1. WPS sample 图1.样表,Welding Procedure Specification (WPS) 焊接工艺规范样表,Type of qualification test WPS评定试验项目及试样数量、类型,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: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) Visual Inspection 外观检验(2) NDT无损检验，含RT,MT,UT,PT
18、等(3) Face, root and side bend面弯，背弯及侧弯(4) Reduced Section缩截面焊缝拉伸(5) All-Weld-Metal Tension全熔敷金属拉伸(6) Macroetch 宏观浸蚀,Number and type of test specimens and range of thickness qualified-CJP 评定焊缝的厚度和试验数量及类型(全焊透接头）,Number and type of test specimens and range of thickness qualified-PJP 评定焊缝的厚度和试验数量及类型(部分焊透
19、接头）,Number and type of test specimens and range of thickness qualified-Fillet joint 评定焊缝的厚度和试验数量及类型(角接头）,Classification of base metal 母材分类,Classification of base metal 母材分类,Classification of base metal 母材分类,Square 直边,Single-V 单V坡口(带衬垫),Double-V 双V形坡口 (X形坡口),Groove Weld Types坡口形式,Welding variables焊接因
20、素,Single-bevel 单边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 单面U形坡口,Double-U 双面U形坡口,Groove Weld Types坡口形式,Welding variables焊接因素,Single-J 单面J形坡口,Double-J 双面J形坡口,Groove Weld Types坡口形式,Welding variables焊接因素,Flare-bevel 卷边接头,Flare-V V形卷边接头,Groove Weld Types坡口形式,Welding va
21、riables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,坡口焊缝板焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position坡口焊缝管焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position坡口焊缝管焊接位置,Welding Posi
22、tions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position坡口焊缝管焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Groove weld pipe welding position坡口焊缝管焊接位置,Welding Positions 焊接位置,Welding variables焊接因素,Positions of Plate fillet welds 板角焊缝位置,Welding Positions 焊接位置,Welding variables焊接因素,Positio
23、ns of test piping or tubing for fillet welds管管、管板角焊缝位置,Welding Positions 焊接位置,Welding variables焊接因素,Heat Input热输入,U = arc voltage电弧电压 I = current焊接电流 V = travel speed (mm/s)焊接速度 E = heat input (kJ/mm.) 热输入,E=UI/V,Welding variables焊接因素,Gauging 清根 To make sure that get a complete penetration and good
24、fusion at root, grinding 1st pass and welding from another side.为确保根部焊透及熔合良好，打磨根部焊道后从另一面再焊一道。,Welding variables焊接因素,Welding Codes 焊接法规,American Welding Society (AWS) - Governing body of the welding industry 美国焊接学会（AWS）- 焊接行业的权威机构 Structural Welding Code (AWS D1.1) 结构焊接规范（AWS D 1.1） Bridge Welding Code (AWS D1.5) 桥梁焊接规范 (AWS D 1.5) Pressure Vessel Code (ASME section 9) 压力容器规范(ASME 第九部分) Shipbuilding Code (ABS) 造船规范(ABS) Contract file. 承包商技术规范,
