1、1Welding procedure specificationWelding procedure specification (WPS)(WPS)焊接工艺规范焊接工艺规范Kevin MoKevin Mo2What is a WPS?什么是焊接工艺规范(WPS)?t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 prod
2、uction 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.3What is included by a WPS?WPS 的内容t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
3、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 1.4Who take charge of compiling WPS?WPS应该由谁制定?t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
4、的。 Each manufacturer and contractor shall prepare written Welding Procedure Specifications which are defined in corresponding welding code.5Availability of the WPS WPS的可得性t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
5、 the Authorized Inspector (AI) at the fabrication site.6Authorized by AIAuthorized by AI授权检验师检查授权检验师检查conducted by wconducted by welderelder 焊工或焊接操作工焊工或焊接操作工 根据根据WPSWPS进行生产进行生产compiled by welding engineer compiled by welding engineer according to qualified PQRaccording to qualified PQR焊接工程师根据评定合格的工艺
6、评定焊接工程师根据评定合格的工艺评定记录（记录（PQR)PQR)制定恰当的焊接工艺规范制定恰当的焊接工艺规范 （WPSWPS）supervised by AIsupervised by AI授权检验师检查授权检验师检查Simple connection diagramSimple connection diagram WPS WPS关系简图关系简图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7+FCAWFCAW药芯焊丝保
7、护药芯焊丝保护焊焊SAWSAW埋弧焊埋弧焊GMAWGMAW气保焊气保焊SMAWSMAW焊条电弧焊焊条电弧焊GTAWGTAW钨极氩弧焊钨极氩弧焊+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9Weld Process Selection焊接工艺选择The “ideal” welding process is that which The “ideal” weldin
8、g process is that which achieves the minimum specification achieves the minimum specification requirements at the minimum cost.requirements at the minimum cost.完美的焊接工艺是那种以最小成本获得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规范要求的最低水平The Practical Welding EngineerThe Practical Welding Engineer10Variables 焊接变素t重要变素essenti
9、al variables 影响接头弯曲和拉伸性能的因素Affect the bend ability and tension ability of jointt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 produce visible affection on bend ability and tension ability of jointt附加重要变素supplemental essential variables 影响接头冲击性能的因素Affect the toughness of joint11Essentials listed
10、 in AWS D1.1AWS 对各种焊接方法重要变素的规定12 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)tFiller 填充材料tIncrease in filler metal classification strength增加填料的强度tChange 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）tChange to an electrode class
11、ification not covered in AWS A5.18,A5.20,A5.28,A5.29.焊丝变为在AWS中没有的型号tElectrode焊丝tChange in nominal electrode diameter :焊丝直径变化（实芯焊丝），焊丝直径增加（药芯焊丝）13tElectrical parameters焊接参数tA change in the amperage for each diameter每种焊丝直径的电流变化超过10tA change in type of current (ac or dc) or polarity and mode of transfe
12、r (GMAW only)电流极性变化或GMAW过渡模式变化tA change in the voltage for each diameter，surpass 7%电压改变超过7tAn increase or decrease in the wire feed speed for each electrode diameter surpass 10%送丝速度改变超过10 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)14tA change in the travel speed surpass 25%焊接速度改变超过25tAn incre
13、ase in heat input surpass 10%热输入增加超过10 tShielding gas保护气tA 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 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)15t
14、A change in total gas flow rate气体流量增加大于50或减小超过20tA 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。tGeneral 一般条件tFor 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25tA change in position not qualified焊接位置改变为未经评定的位置。 Esse
15、ntials in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)16tA 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。tA change in base metal or combination of base metals not listed on the PQR 母材未经评定tVertical 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
16、反tA 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 FCAWGMAW and FCAW中的重要变素(AWS)17tA 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tA change exceeding the tolerances, including decreasing of groove angle, decreasing of root op
17、ening, 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tThe omission, but not inclusion, of backing or back gouging取消衬垫或清根tDecrease from preheat temperature6 by 15 Celsius degree预热温度降低超过15度 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素(AWS)18Figure 1. WPS sample 图1.样表Welding Procedure Specification
18、 (WPS)焊接工艺规范样表19Type of qualification testWPS评定试验项目及试样数量、类型tThe 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
19、 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) Macroetch 宏观浸蚀20Number and type of test specim
20、ens 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）21Number 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(部分焊透接头）22Number 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）23Classification of base metal 母材分类24Class
21、ification of base metal 母材分类25Classification of base metal 母材分类26SquareSquare直边直边Single-VSingle-V单单V V坡口坡口( (带衬垫带衬垫) )Double-VDouble-V双双V V形坡口形坡口(X(X形坡口形坡口) )Groove Weld Types坡口形式Welding variables焊接因素27Single-bevelSingle-bevel单边单边V V形坡口形坡口Double-bevelDouble-bevelK K形坡口形坡口Groove Weld Types坡口形式Welding
22、 variables焊接因素28Single-USingle-U单面单面U U形坡口形坡口Double-UDouble-U双面双面U U形坡口形坡口Groove Weld Types坡口形式Welding variables焊接因素29Single-JSingle-J单面单面J J形坡口形坡口Double-JDouble-J双面双面J J形坡口形坡口Groove Weld Types坡口形式Welding variables焊接因素30Flare-bevelFlare-bevel卷边接头卷边接头Flare-VFlare-VV V形卷边接头形卷边接头Groove Weld Types坡口形式We
23、lding variables焊接因素31Welding Positions 焊接位置 Welding variables焊接因素32Welding Positions 焊接位置 Welding variables焊接因素坡口焊缝板焊接位置33Welding 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34Welding 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35
24、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36Welding 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37Welding Positions 焊接位置 Welding variables焊接因素Positions of Plate fillet welds 板角焊缝位置38Welding Positions 焊接位置 Welding variabl
25、es焊接因素Positions of test piping or tubing for fillet welds 管管、管板角焊缝位置39Welding Positions 焊接位置 Welding variables焊接因素40Heat Input热输入U = arc voltageU = arc voltage电弧电压电弧电压I = currentI = current焊接电流焊接电流V V = travel speed ( = travel speed (mm/smm/s) )焊接速度焊接速度E E = heat input (kJ/ = heat input (kJ/mmmm.) .
26、) 热输入热输入E=UI/VWelding variables焊接因素41tGauging 清根tTo make sure that get a complete penetration and good 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42Welding 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 tStructural Welding Code (AWS D1.1)t结构焊接规范（AWS D 1.1）tBridge Welding Code (AWS D1.5)t桥梁焊接规范 (AWS D 1.5)tPressure Vessel Code (ASME section 9)t压力容器规范(ASME 第九部分)tShipbuilding Code (ABS)t造船规范(ABS) tContract file.t承包商技术规范
