WPS焊接工艺规程

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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。
焊接方法 welding process
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浏览规范，列出可行焊接方法
规范
主要约束
实际约束 资源
修订可行焊接方法
评估生产成本
成本
选择
选择
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Weld Process Selection 焊接工艺选择 The “ideal” welding process 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……
Welding procedure specification (WPS) 焊接工艺规范
Kevin Mo
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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。
Shielding gas保护气
A change in shielding gas from a single gas to any other single gas or mixture of gas, 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
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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 written Welding Procedure Specifications which are defined in corresponding welding code.
对弯曲和拉伸不能产生明显影响的因素Can’t produce 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
supervised by AI 授权检验师检查
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How is a WPS created? 如何创建一个WPS?
FCAW药芯焊丝保护 焊
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接头形式 joint type
SAW埋弧焊 GMAW气保焊 SMAW焊条电弧焊 GTAW钨极氩弧焊
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建造规范 construction specification
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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 essential, nonessential, and, when required, supplementary essential variables for each welding process used in the WPS. For the sample, pls see the figure 1.
Remarks: PQR is the qualified welding procedure procedure and test results record.
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
conducted by welder 焊工或焊接操作工 根据WPS进行生产
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Welding Procedure Specification (WPS) 焊接工艺规范样表
Figure 1. WPS sample
图1Βιβλιοθήκη Baidu样表
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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 thickness, 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) Macro－etch 宏观浸蚀
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Essentials listed in AWS D1.1 AWS 对各种焊接方法重要变素的规定
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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 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
General 一般条件
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 25％ A change in position not qualified焊接位置改变为未经评定的位置 。
A WPS is a written qualified welding procedure prepared to provide direction for making production welds to Code requirements. The WPS or other documents may be used to provide direction to the welder or welding operator to assure compliance with the Code requirements.
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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％
Electrode焊丝
Change in nominal electrode diameter :焊丝直径变化（实芯焊 丝），焊丝直径增加（药芯焊丝）
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Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS)
Electrical parameters焊接参数
The Practical Welding Engineer
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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
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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 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 doubleV), 坡口形式变化（例如，单V到双V)
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Essentials in GMAW or FCAW GMAW and FCAW中的重要变素(AWS)
A change in the type of 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 temperature6 by 15 Celsius degree预热温度降低超过15度
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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 site.
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Simple connection diagram WPS关系简图
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）
Authorized by AI 授权检验师检查
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 for each electrode diameter surpass 10%送丝速度改变超 过10％