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1、船用铸钢件与船用高强度钢气体保护焊/手工电弧焊 焊接工艺规程WPS of Ship Casting Steel to High Strength Steel Gas Shielded Welding /SMAW 船检意见：1. 焊工必须持经过船级社认可的焊工证2. 焊接材料必须符合焊接工艺标准经DNV认可3. 预先进行焊接试验，样板须经过NDT检测并合格再上船安装之前4. 焊接过程和焊接参数进行控制并记录5. 船上焊接焊缝需经过NDT检测合格 船东意见1. 焊工名单人员须经DNV认可资质2. 焊接材料需提供证书3. 焊接结束需通过UT和MT检测提供报告4. 焊接过程中船厂必须对温度（层间温度）
2、控制 5.船厂必须对预热及焊后热处理进行控制，焊接报告必须提交至DNV及船东办公室。编制AUTHORIZE校对APPROVE审核CHECK船检CLASS船东OWNER注：此工艺文件经船东船检认可签字后下发生产部，后期博特宁(ZC3001 / ZC3002/ZC3009/ZC3010)所有船只艉部节能罩均按照此工艺规程施工，原件由品质部存档。Notice: This technology process to be delivered to production dept. after approving by owner and class, and Bertling (ZC3001 / ZC
3、3002/ ZC3009/ZC3010) vessel stern duct welding to be carried out according to it, the technology process to be kept by QC dept. 1. 范围: Scope:1.1 焊接方法Welding process 手工电弧焊 SMAW1.2 应用范围Applied range本工艺规程适用于船用铸钢件与船用钢板焊接This technology process is applied for ship steel casting to steel welding 2. 母材Moth
4、er Plate 铸钢件材质为DNV410W，船用钢为DNVA36 Steel-casting class DNV410W, steel grade is DNVA363.焊接接头方式及坡口形式Welding joint and bevel DNV410W30mm0-3mm45CDNV410W30mm30mmDNVA3663-5mm(1)(2)0-3mm45C30mmDNVA3660-3mm 4焊接要求 Welding Requirement1. 焊接之前必须除去预加工边的锈蚀，油污，灰尘，潮湿等。Welding should be done after removing the rust,
5、oil, dust, moisture etc.2. 每道焊层必须用钢丝刷清理打磨干净。Each layer should be removed slag by wire brush and grinding.3. 如果坡口用碳弧气刨开设，坡口处的碳迹必须打磨干净。If groove is air-arc gouged, grind surface of groove to smooth and to remove all trace of carbon.4. 电焊条须经烘干处理（详见8.3），未经烘干的焊条不得使用。Electrode should be dried as per secti
6、on 6.5 and should not be used without drying.5. 手工焊时焊条的摆动幅度应小于所用焊条直径的3倍。Wide of weaving to be limited to less than three times of used electrode diameter.6. 焊接采用退焊法，焊接应用小电流多层多道焊，每道焊层不能过大，每层焊道应用手锤锤击焊缝以减少焊缝应力，各焊道接头应错开50mm。 Carry out back ward and multi-pass, multi-layer welding with low current and th
7、in layer, harming each pass to reduce concentrated strength, joints of each pass shall be 50mm off set.7. 每道焊缝应连续施焊，以确保合适的层间温度。Continue welding every pass to keep properly layer temp. 5预热 Preheating1. 焊缝预热温度为60100（预热范围距焊缝中心为75mm），用电加热器或火焰进行加热并覆盖以绝缘毛毯，预热时必须缓慢且均匀，以避免出现裂纹和变形（每小时约60100）。Weld joint to be
8、 preheated of 60100 (measured 75mm from edge of weld groove), apply heat slowly and evenly by using electrical heating equipment and torch, then wrapped with insulation blanket (about 60 to 100 per hour max).2. 焊缝清根后必须打磨干净去除掉所有的碳化物，并按照上述工艺重新预热。After back gouging the weld joint should be grinded smoo
9、th, removed all carbon and repreheated according to the above procedure.6层间温度控制 Interpass Temperature Control较合适的层间温度为125160，其温度下限用以保证在多层焊中后道焊缝有起码的预热条件，其温度上限以避免出现热应力裂纹。通过补充加热或缓慢焊接来控制层间温度。Interpass temperature to be controlled of 125160, the lower limitation ensures at least preheat conditions during
10、 subsequent passes, the maximum limit of temperature to be absolutely controlled to avoid thermal stress cracks. Control interpass temperature by supplementary heat as per above preheat procedure or welding slowly.7后热处理 Postweld Heat Treatment对于大型铸钢件，可将焊缝区域用电加热设备或火焰加热到120，保温1.5小时并覆盖以绝缘毛毯，然后使其缓慢冷却。As
11、 regards large castings such the temperature of the welding area should be heated to 120 by electrical heating equipment and flame, then wrapped with insulation blanket, and keep the temperature for approximately 1.5 hours then allow to cool down slowly.8焊接材料的管理 Control Of Welding Materials焊接结束，焊条必须
12、返还到储藏室去。Rest Electrodes should be returned to the stored house after finish welding.焊条干燥状态如下 condition for drying electrodes is as follows:焊接材料welding material标号brand烘干温度drying temp.保温conditioned temp.低氢型low hydrogenJH.E501530035080120最长使用时间 used max. Time1). 室外工作出4小时以内。Within 4hr in outdoor working
13、.2). 室内工作出5小时以内。Within 5hr in indoor working.3). 超过以上时间焊条必须送回烘干室烘干。Over above mentioned time electrode should be returned to drying room.焊接方法welding process焊接位置welding position直径(mm)dia. of wire / electrode电源极性Power polarity电流(A)current电压(V)voltage焊接速度(cm/min)speed接头细节joint details手工电弧焊Manual Metal
14、Arc Welding平焊flat3.24.0直流反接Direct current902402530520电极立焊vertical3.24.0直流反接Direct current9020025304109.焊接注意事项Notice during welding1）焊接过程引弧应有焊缝中心引燃，避免伤母材引起应力集中造成表面裂纹。Run in welding from welds bevel center to prevent mother plate damage and stress concentrated crack.2）焊接过程严格控制层间温度，随时监控检测靠近环氧区域温度严格控制低于
15、100C，施行间歇烧焊。Layer temp. must be controlled during welding, and monitoring epoxy surrounded area to be kept lower than 100C timely.3).焊接过程严格做好焊接记录焊接参数、焊工名、焊工证、预热温度、层间温度、焊后加热温度、保持时间、焊道数量等，见附表。Must be take record during welding process-welding parameter/welder/welder certificate/preheating temp./layer temp/after heating temp./keep temp. time/layer amount and others see attached form。 6
