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1、1Welding procedure specification (WPS)焊接工艺规范Kevin Mo2What is a WPS?什么是焊接工艺规范什么是焊接工艺规范(WPS)?t焊接工艺规范是为了制造符合焊接工艺规范是为了制造符合规范规范要求的焊缝而提供指导的、经过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工提供指导,以保证符合规范要求。以保证符合规范要求。 A WPS is a written qualified welding procedure prepared to p
2、rovide 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.3What is included by a WPS?WPS 的内容的内容t一份完整的一份完整的WPS 应当包含在应当包含在WPS中所采用的、对每中所采用的、对每一种焊接方法而言的所
3、有一种焊接方法而言的所有重要变素重要变素、非重要变素非重要变素和当和当需要时的需要时的附加重要变素附加重要变素。样表见样表见图图1。焊接工艺规范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。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,
4、pls see the figure 1.4Who take charge of compiling WPS?WPS应该由谁制定应该由谁制定?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的可得性的可得性t用于产
5、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.6Authorized by AIAuthorized by AI授权检验师检查授权检验师检查conducted by welder conducted by welder 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
6、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 diagram WPS关系简图Remarks:PQR is the qualified wel
7、ding 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?How is a WPS created?如何创建一个如何创建一个如何创建一个如何创建一个WPS?WPS?接头形式接头形式接头形式接头形式joint typejoint type焊接方法焊接方法焊接方法焊接方法welding w
8、elding processprocess建造规范建造规范建造规范建造规范constructionconstructionspecificationspecification8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
9、最低水平The Practical Welding EngineerThe Practical Welding Engineer10Variables 焊接变素焊接变素t重要变素重要变素essential variables 影响接头弯曲和拉伸性能的因素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对弯曲和拉伸不能产生明显影响的因素Cant produce visible affection on bend
10、 ability and tension ability of jointt附加重要变素附加重要变素supplemental essential variables 影响接头冲击性能的因素影响接头冲击性能的因素Affect the toughness of joint11AWS 对各种焊接方法重要变素的规定对各种焊接方法重要变素的规定12 Essentials in GMAW or FCAWGMAW and FCAW中的重要变素中的重要变素(AWS)tFiller 填充材料填充材料tIncrease in filler metal classification strength增加填料的强度t
11、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）tChange 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tElectrode焊丝焊丝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）13tElec
12、trical parameters焊接参数焊接参数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 transfer (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
13、 electrode diameter surpass 10%送丝速度改变超过10 Essentials in GMAW or FCAW Essentials in GMAW or FCAWGMAW and FCAWGMAW and FCAW中的重要变素中的重要变素中的重要变素中的重要变素(AWS)(AWS)14tA change in the travel speed surpass 25%焊接速度改变超过25tAn increase in heat input surpass 10%热输入增加超过10 tShielding gas保护气保护气tA change in shielding g
14、as 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 FCAW Essentials in GMAW or FCAWGMAW and FCAWGMAW and FCAW中的重要变素中的重要变素中的重要变素中的重要变素(AWS)(AWS)15tA change in total
15、 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。改变为不包含在中的保护气。tGeneral 一般条件一般条件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。 Essentials in GMAW or FCAW Essentials in GM
16、AW or FCAWGMAW and FCAWGMAW and FCAW中的重要变素中的重要变素中的重要变素中的重要变素(AWS)(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 FCAW Essentials in GMAW or FCAWGMAW and FCAWGMAW and FCAW中的重要变素中的重要变素中的重要变素中的重要变素
