1、Welding theory焊接理論焊接理論AreasAreas領域領域In this training we will cover the most general areas of:在這個訓練中,我們將介紹最通用的領域：Welding types 焊接類型Standards & Classes標準&級別Welding positions焊接位置Welding symbols焊接代號Calculations計算Quality Assurance質量保證Types of welding類型的焊接類型的焊接Fusion welding is a generic term for welding

2、processes熔焊焊接過程是一個通用的術語. that rely upon melting to join materials of similar類似的,依靠融化加入材料.compositions and melting points.成分和熔化點。Types of welding類型的焊接 Consumable electrode flux coated 自耗電極磁通涂MMA - Manual Metal Arc (stick welding) MMA -手動金屬電弧(粘焊) Carbon Dioxide (A mix between argon and carbon dioxide

3、is normal) 二氧化碳(氬氣和二氧化碳之間的混合是正常的)MAG - Metal Active Gas 雜志-金屬活性氣體 Argon, Helium 氬、氦MIG - Metal Inert Gas 米格-金屬惰性氣體 Argon, Helium 氬、氦TIG Tungsten Inert Gas TIG(鎢極惰性氣體 Standards 標準標準ISO 5817 Quality levels for imperfections 缺陷質量分級ISO 4063 Reference Numbers for Welding methods 焊接方法的參考數據ISO 3834-01 ,-02

4、, -03, -04 Quality requirements for fusion welding. 熔焊質量要求ISO 9606 Qualification test for welders 對焊工資格考試ISO 2553Welded, brazed and soldered joints 焊接,焊接和焊接接頭symbolic representation on drawings 符號表示，圖紙ISO 17635 Non-destructive testing of welds. General rules for 焊縫的無損檢驗，一般規則metallic materials 金屬材料 (

5、Acceptance levels cannot be a direct interpretation of the quality levels defined in ISO 5817 or ISO 10042. They are linked to the overall quality of the produced batch of welds.).and many more其他，更多Welding is controlled by a numbers of Standards. 焊接由數字控制的標準Standards標準標準Why do we need standards?為什么我們

6、需要標準Reduce Risk減小風險More sustainable更可持續Improving performance性能提升Welding classes焊 接 類General 一般一般Welding class as following: 焊接類如下SS-EN ISO 5817 for ferrite material and stainless steel. 對鐵氧體材料和不銹鋼SS-EN ISO 5817。SS-EN ISO 10042 for aluminium. 為鋁SS-EN ISO 10042。Acceptance boundary, discontinuities and

7、 form deviations,see SS-EN ISO 6520-1, 接受邊界、斷層和偏差,看到SS-EN ISO 6520 - 1,table 1.Welding class B 焊接類 BThe transition between the weld and the base material shall be even, and shall not焊接和基材之間的過渡應均勻,不得have any sharp notches. Craters shall be filled in and unevennesses shall be removed.有任何鋒利的等級。隕石坑應當填寫,

8、不應刪除The weld face and root face of butt joints shall have a plane or slightly convex form.對接接頭的焊縫表面和根面有一架飛機或略凸的形式Corner joints shall be convex on the outside and in the main concave or plane on the inside.角接頭應在主凹或凸在外面和飛機The weld face of T-joints shall preferably have a concave or plane form, but a s

9、lightly convex form is acceptable.丁字接頭的焊接面最好是有一個凹形或平面形式,但略凸形式是可以接受的The homogeneity of the weld shall in the main meet the requirements of X-ray class焊縫應均勻性的主要滿足x射線類的要求4 (blue). However, internal pores and discrete inclusions (slag, heavy metals,oxides and shrinkage cavities) meeting the requirements

10、 of X-ray class 3 (green) are acceptable.藍色)。然而,內部孔隙和離散夾雜物(礦渣、重金屬、氧化物和收縮蛀牙)會議的要求x射線3班(綠色)是可以接受的。For fillet welds the throat thickness a shall not be less than that stated.填角焊的焊接厚度不得少于規定。Welding class C焊接類 CHigh welding reinforcement, high root reinforcement, visible root defects and sharpnotches are

11、 not permitted.焊接加固高、根鋼筋,可見根缺陷和鋒利的等級是不允許的.T-joints and corner joints welded from one side (root side inaccessible) may,however, have a moderate notch on the root side.從一側丁字接頭和角接頭焊接(根端訪問),然而,有一個溫和的切口在根端.The homogeneity of weld shall in the main meet the requirements of X-ray class 3(green) according

12、to the IIW X-ray atlas.焊縫應均勻性的x射線的主要滿足要求3班(綠色)根據IIW x射線地圖集。For fillet welds the throat thickness a shall not be less than that stated.填角焊的焊接厚度不得少于規定。Welding class D 焊接類 DThe surface of the weld shall be free from significant surface cavities, externalpores, penetrations and overlapped welds. Visible

13、 cracks and similar defects arenot permitted.焊縫表面應無明顯表面蛀牙,外部毛孔,穿透及重疊焊?？梢娏芽p和類似的缺陷是不允許的。For fillet welds the throat thickness a shall not be less than that stated.填角焊的焊接厚度不得少于規定。Welding classes焊接類v Class C is the default class if a drawing is missing weld class information! C類是默認焊接信息。Reference Numbers

14、 for Welding methods焊接方法的參考數據焊接方法的參考數據111Manual metal arc welding 手動金屬電弧焊114Self-shielded tubular - cored arc welding 管狀空心電弧焊121Submerged arc welding with solid wire electrode (partly mechanised) 與固體電極絲埋弧焊(部分機械化)125Submerged arc welding with tubular cored electrode (partly mechanised) 埋弧焊用管狀空心電極(部分機

15、械化)131MIG welding with solid wire electrode MIG焊接與固體電極絲135MAG welding with solid wire electrode MAG焊接與固體電極絲136MAG welding with flux cored electrodes MAG焊接通量空心電極138MAG welding with metal cored electrode MAG焊接用金屬空心電極141TIG welding with solid filler material 鎢極惰性氣體保護電弧焊與固體填充材料142Autogenous TIG welding

16、自鎢極惰性氣體保護電弧焊143TIG welding with tubular cored filler material 鎢極惰性氣體保護電弧焊與管狀空心填充材料145TIG welding using reducing gas and solid filler material (wire/rod) 鎢極惰性氣體保護電弧焊用減少氣體和固體填充材料(鋼絲/桿)15Plasma arc welding 等離子弧焊；等離子電弧焊接311Oxy - acetylene welding 氧-乙炔焊*NOTE The principles of this standard may be applied

17、 to other fusion welding processes. 注意這個標準的原則可能適用于其他熔焊過程。This standard covers the following manual or partly mechanized welding processes (reference numbers ofwelding processes for symbolic representations are listed in ISO 4063):這個標準涵蓋以下手冊或部分機械化焊接過程焊接過程(參考數字符號表示ISO 4063中列出):Visa pistolpositionerWel

18、d Gun Positions焊接槍位置焊接槍位置Example 1:例子 1：Weld Gun Positions焊接槍位置焊接槍位置Example 2:例子2：q A falling weld shall be avoided as far as possible!q 焊縫應盡可能避免下跌!q The weld gun should be slightly pointed towards the thickest material. This prevents undercuts.q 焊接槍應該稍微指向最厚的材料。這可以防止削弱。 q A gun that is pointed away

19、from the weld will make the protective gas to flow away from the weld-pool.q 一把槍,指著離焊縫將使保護氣體流向焊池。Weld Gun Positions焊接槍位置Symbols符號1.Weld method: 141 = TIG with solid filer material. 焊接方法:141 = TIG固體產品材料。2.Weld class = Class C 焊接類= C類3.Design Throat thickness = weld measurement 2mm. 設計焊接厚度=焊縫測量2毫米。4.F

20、illet weld 角焊縫5. Welded all around 沿周邊焊接的12345Symbols符號Symbols符號Symbols符號支撐桿參考線指定一個角焊縫箭頭的一面A tringle on the reference line: Specifies a fillet weld on the arrow side of the joint 支撐桿參考線指定一個角焊縫接頭的另一邊A tringle on the reference line: Specifies a fillet weld on the other side ofThe joint 4.7.3 Multiple

21、reference lines多個參考線Two or more reference line closest to indicate a series of operations.The operation shallbe specified on the reference line closest to the arrowhead.Subsequent operations shall be specified sequentially on the other reference lines(seeFigure6) 兩個或兩個以上的參考線接近顯示一系列的操作。在指定的操作應當參考線箭頭。

22、后續操作順序應當指定其他參考線(參見圖6)NOTE For joints requiring more than one weld type,combined symbols may also be used (see Table2)注意關節需要不止一個焊縫類型,結合符號也可以使用(見表二)a)System A-A rrow side (symbol on solid component of reference line)b)方法A-A箭頭(符號參考線）C)System B-Arrow side (symbol below reference line)C) 方法 B-A箭頭(符號下面的參考

23、線)b) System A-other side (symbol on dashed component of reference line)b) 方法A-O箭頭(符號參考線）B) System B-other side (symbol above reference line)B) 方法B-O箭頭(符號參考線）e)Same weld produced using four options a) to d) e)相同的焊接生產使用四個選項)d)Terminology術語術語WELD DRA WING TERMlNOLOGY:焊縫半徑標注 Weld leg 焊腳 Weld face 焊縫表面 W

24、eld throat 焊縫厚度 Weld groove radius 焊縫坡口半徑 Root opening （groove weld) 根部間隙(坡口焊) Weld root face 焊根的臉 Weld groove angle 焊縫坡口角度(A) FILLET WELDS 角角焊縫焊縫(B) GROOVE WELDS 坡口坡口焊縫焊縫THROAT焊高LEG SIZE 焊腳尺寸FACE 斜面BEVEL ANGLE邊緣斜截角GROOVE ANGLEV 坡口角度LEG SIZE 焊腳尺寸GROOVE RADIUS根部半徑ROOT OPENING根部間隙ROOT FACE根面THICKNESS厚

25、度a nominal throat thickness of the fillet weld (see also ISO 2553) 角焊縫的焊縫名義厚度(參見ISO 2553)A area surrounding the gas pores 周圍氣體毛孔B width of weld reinforcement 焊縫補強的寬度d diameter of gas pore 氣體孔隙直徑dA diameter of area surrounding the gas pores 直徑周圍氣體的毛孔h height or width of imperfection 缺陷的高度或寬度l length

26、of imperfection in longitudinal direction of the weld 焊縫缺陷在縱向方向上的長度lp length of projected or cross-sectional area 投影長度和橫截面積s nominal butt weld thickness (see also ISO 2553) 名義上的對接焊縫厚度(見ISO 2553)t wall or plate thickness (nominal size) 墻或板厚度(公稱尺寸)wp width of the weld or width or height of the cross-

27、sectional area 焊縫的寬度或寬度或高度的橫截面積z leg length of a fillet weld (see also ISO 2553) 角焊縫的焊腳長度(參見ISO 2553) angle of weld toe 角焊縫趾 angle of angular misalignment 角的角位移i penetration in fillet welds 滲透在填角焊r radius of weld toe 焊趾半徑Terminology術語Symbols in ISO5817符號ISO5817Edge preparation坡口準備坡口準備TYPES OF BUTTWE

28、LDS SYMBOLIZATION類型的對接焊縫編號The common types of edge prepartion associated with a butt weld are indicated as follows:常見的邊緣制作與對接焊縫表示如下:Square edge preparation直角邊緣準備Single v preparation單邊（v型）的準備Double v preparation雙邊（v型）的準備Single U preparation單邊（U型）的準備Double U preparation雙邊（U型）的準備In some cases of joint

29、preparation,only one part is prepared,e.g.single bevel butt or single j butt ln these cases,the arrow points at the edge to be prepared.The vertical upright of the symbol is always to the left on the reference line.在某些情況下共同準備,只有一個部分是準備,如單斜對接或單j對接這些情況下,箭頭指向邊緣做好準備。垂直直立的符號總是左參考線。Edge preparation坡口準備Int

30、rusion熔深Dimensions and Calculation尺寸計算尺寸計算DIMENSIONING OF FILLET WELDS尺寸標注的填角焊EN 22553 requirementsEN 22553的需求a = design throat thicknessa = 設計厚度規則:設計焊接厚度(a)=腿長度x0.7(“z”)。Z = leg lengthZ = 腳高長度S = actual throat thicknessS =實際焊接熔深The leg length of a fillet weld is locaed to the left of the weld symbo

31、l (triangle).The dimension is in millimeters preceded with the letter “z”.lf no letter is shown on a drawing,then assume the dimension is leg length.角焊縫的焊腳長度是軌跡焊接符號的左邊(三角形)。前面尺寸在毫米以字母“z”。如果沒有顯示在繪圖的信,然后假設維度是腿的長度。The European system uses mainly the “a”value,while the American one uses the “z”value.歐洲主

32、要系統使用“a”值,雖然美國人使用“z”值.10mm leg length Fillet weld 10毫米腿角焊縫長度As rule:Design Throat Thickness(“a”)=Leg Length(“z”)x0.7.規則:設計焊接厚度(a)=腿高長度x0.7(“z”)。fillet weld with 7mm design throat thickness角焊縫和焊縫設計厚度7毫米Dimensions and Calculation尺寸計算尺寸計算“z” measurment = a x 1,4 “z”測量=a x 1,4“a” measurment = z x 0,7 “a

33、”測量 = z x 0、7Calulation of a (throat) can also be done with: 計算(喉嚨嚨)也可以用:z + z / 2 x 0.7 = a (throat)z + z / 20.7 = a(喉嚨嚨)Calculate imperfections: STD 5817-B 計算缺陷: ISO5817-BFormula: a x 0,15 + 1 = 1,9 公式: a x 0,15 + 1 = 1,9Calculation: 6 x 0,15 + 1 = 1,9 計算: 6 x 0,15 + 1 = 1,9Explanation: a is throa

34、t thickness e.g a6, the total throat thickness is 8mm. Thismeans that the deviation is (h)2 mm. But the STD allows some tolerance, which the calculationgives us, 1,9 mm.解釋:一個是焊接厚度e。g a6,焊縫的總厚度是8毫米。這意味著,偏差(h)2毫米,但允許一些放寬計算, 1.9毫米。 So the total throat thickness can be (a)6mm + (h)1,9mm = 7,9mm所以總焊接厚度可以

35、(a)6毫米+(h)1,9毫米= 7,9毫米But since the measurement is total 8 mm, the throat is 0,1mm to high. NOK!但由于測量總8毫米,喉為0,1毫米高。NOK！*hint: calculate ”backwards”提示:計算工式“由后向前計算”Imperfections不完整性CBD計算實例Please take notes and write down your answersand how you came to the specific conclusion. 請做筆記請做筆記, ,寫下你的答案寫下你的答案T

36、he answer is right infront of you你面前的答案是正確的 Save them for your own reference! 留作自己的參考!Calculate Imperfections計算的不完美計算的不完美Calculate Imperfections計算的不完美計算的不完美Example 1. 例子 1.perfect :Excess Weld metal完美的:焊縫余高Weld class: C焊縫級別： Cb measured to be 16 mmb測量 16毫米h measured to be3.1 mmh測量 3.1毫米Allowed exces

37、s weld h= 3,4 mm允許多余的焊接余高 = 3，4毫米APPROVED被認可的D DB BC CCalculate Imperfections計算的不完美計算的不完美D DC CB BExampIe 2. 例子 2.Imperfection (fault): Excessive throat thickness不完美的（缺陷）：角焊縫填充金屬過厚Weld class: B 焊縫級別： B a measured to be 5 mm (a5 on drawing) a 測量是5毫米(a5圖紙)h measured to be3 mm h 測量3毫米 total8 mm 總高8毫米Al

38、lowed throat thickness = 1,75 mm (total 6,75 mm) 1,25 mm over tolerance.允許焊接厚度（余高）= 1,75毫米(總6.75毫米) 1、25毫米公差。NOT APPROVED不被肯定Calculate Imperfections計算的不完美計算的不完美Exampel 3. 例子3.Imperfection (fault): Excessive asymmetry of fillet weld (uneven leg length)不完美（缺陷）：過度的不對稱角焊縫(不等長)Weld class: B 焊接類: Ba measu

39、red to be 6 mm (a6 on drawing)a 一個測量6毫米(a6圖紙)Z 2 measured to be 8,5 mm Z 2測量8、5毫米h measured to be2,5 mm h 測量是2、5毫米Allowed excess asymmetry h= 2,4 mm (total 8,4 mm) 0,1 mm over tolerance允許多余的不對稱h = 2,4毫米(8,4毫米) 0,1毫米公差NOT APPROVED不被肯定D DC CB BValidation and Quality Assurance驗證和質量保證驗證和質量保證Validation and Quality Assurance驗證和質量保證驗證和質量保證Supplier recommendations/requirements: 供應商建議/要求:Right education Theory & Practical 正確的教育理論與實踐oWhat training did the welder get? 焊機得到了什么培訓？oWho approved it? 誰批準了嗎?oWas it based on any ISO or similar standards?