濟(jì)南型鋼焊接從材料預(yù)處理到焊后檢驗(yàn)，每個(gè)環(huán)節(jié)都需嚴(yán)格遵循技術(shù)規(guī)范。本文將從實(shí)踐角度出發(fā)，系統(tǒng)梳理型鋼焊接過(guò)程中需重點(diǎn)關(guān)注的技術(shù)要點(diǎn)。

　　From material pretreatment to post weld inspection, every step of Jinan section steel welding must strictly follow technical specifications. This article will systematically sort out the technical points that need to be focused on in the welding process of section steel from a practical perspective.

　　一、焊接前材料準(zhǔn)備與檢驗(yàn)

　　1、 Preparation and Inspection of Materials Before Welding

　　材料驗(yàn)收標(biāo)準(zhǔn)

　　Material acceptance criteria

　　需核對(duì)材質(zhì)證明書(shū)與實(shí)物標(biāo)識(shí)的一致性，某鋼鐵企業(yè)的質(zhì)檢流程顯示，Q355B型鋼的化學(xué)成分偏差需控制在GB/T 1591標(biāo)準(zhǔn)范圍內(nèi)。對(duì)于進(jìn)口材料，需進(jìn)行-20℃低溫沖擊試驗(yàn)，確保韌性指標(biāo)達(dá)標(biāo)。

　　It is necessary to verify the consistency between the material certificate and the physical identification. The quality inspection process of a certain steel enterprise shows that the chemical composition deviation of Q355B steel needs to be controlled within the range of GB/T 1591 standard. For imported materials, a -20 ℃ low-temperature impact test is required to ensure that the toughness index meets the standard.

　　坡口加工規(guī)范

　　Specification for groove processing

　　采用機(jī)械加工或等離子切割制備坡口，某機(jī)械加工廠(chǎng)的工藝參數(shù)表明，U型坡口較V型坡口可減少填充量。坡口表面需用角磨機(jī)打磨至露出金屬光澤，某檢測(cè)標(biāo)準(zhǔn)的粗糙度要求為Ra6.3。

　　The groove is prepared by mechanical processing or plasma cutting. The process parameters of a certain mechanical processing plant indicate that U-shaped grooves can reduce the filling amount compared to V-shaped grooves. The surface of the groove needs to be polished with an angle grinder until the metallic luster is exposed. The roughness requirement of a certain testing standard is Ra6.3.

　　預(yù)處理工藝

　　Pre treatment process

　　焊接前需進(jìn)行預(yù)熱處理，某焊接研究所的推薦方案顯示，當(dāng)環(huán)境溫度低于5℃或板厚超過(guò)30mm時(shí)，Q345R鋼需預(yù)熱至100-150℃。預(yù)熱范圍應(yīng)達(dá)到板厚的3倍，且不小于100mm。

　　Preheating treatment is required before welding. The recommended solution from a welding research institute shows that when the ambient temperature is below 5 ℃ or the plate thickness exceeds 30mm, Q345R steel needs to be preheated to 100-150 ℃. The preheating range should reach 3 times the thickness of the plate and not be less than 100mm.

　　二、焊接工藝參數(shù)控制

　　2、 Welding process parameter control

　　方法選用原則

　　Principles for Method Selection

　　手工電弧焊：適用于單件小批量生產(chǎn)，某船廠(chǎng)實(shí)踐表明，E5015焊條在立焊位置需采用短弧操作，擺動(dòng)幅度不超過(guò)3倍焊條直徑。

　　Manual arc welding: suitable for single piece and small batch production. Practice at a shipyard has shown that the E5015 welding rod needs to be operated with a short arc at the vertical welding position, with a swing amplitude not exceeding 3 times the diameter of the welding rod.

　　氣體保護(hù)焊：CO?氣體流量需控制在15-25L/min，某汽車(chē)工廠(chǎng)的實(shí)測(cè)數(shù)據(jù)顯示，氣體純度低于99.5%會(huì)導(dǎo)致焊縫含氫量增加。

　　Gas shielded welding: The CO? Gas flow rate needs to be controlled at 15-25L/min. Actual measurement data from a certain automobile factory shows that gas purity below 99.5% will lead to an increase in hydrogen content in the weld seam.

　　埋弧焊：適用于長(zhǎng)直焊縫，某鋼結(jié)構(gòu)公司的工藝規(guī)范要求，焊絲伸出長(zhǎng)度應(yīng)控制在30-40mm，過(guò)短易產(chǎn)生夾渣。

　　Submerged arc welding: suitable for long straight welds. According to the process specifications of a certain steel structure company, the extension length of the welding wire should be controlled within 30-40mm. If it is too short, slag inclusion may occur.

　　層間溫度管理

　　Interlayer temperature management

　　多層多道焊時(shí)，需用紅外測(cè)溫儀監(jiān)控層間溫度，某壓力容器制造標(biāo)準(zhǔn)規(guī)定，Q345R鋼層間溫度不得超過(guò)230℃。道間溫度低于規(guī)定值時(shí)，需重新預(yù)熱。

　　During multi-layer and multi pass welding, an infrared thermometer is required to monitor the interlayer temperature. According to the manufacturing standard of a certain pressure vessel, the interlayer temperature of Q345R steel shall not exceed 230 ℃. When the inter passage temperature is lower than the specified value, it needs to be preheated again.

　　變形控制技術(shù)

　　Deformation control technology

　　剛性固定法：在H型鋼組立時(shí)，需設(shè)置胎架間距，某橋梁項(xiàng)目的實(shí)踐表明，此法可使焊接變形量降低。

　　Rigid fixation method: When assembling H-beams, it is necessary to set the spacing between the tire frames. The practice of a certain bridge project has shown that this method can reduce welding deformation.

　　反變形法：根據(jù)板厚預(yù)設(shè)反變形量，某重工企業(yè)的經(jīng)驗(yàn)公式顯示，12mm厚鋼板對(duì)接焊反變形角需預(yù)設(shè)3°。

　　Anti deformation method: Based on the preset anti deformation amount of the plate thickness, the empirical formula of a certain heavy industry enterprise shows that the anti deformation angle of 12mm thick steel plate butt welding needs to be preset at 3 °.

　　三、焊接過(guò)程質(zhì)量監(jiān)控

　　3、 Quality monitoring of welding process

　　操作規(guī)范執(zhí)行

　　Execution of operational standards

　　焊工需持證上崗，某質(zhì)量監(jiān)督機(jī)構(gòu)的檢查數(shù)據(jù)顯示，無(wú)證作業(yè)導(dǎo)致的焊接缺陷率高達(dá)15%。引弧板需與母材同質(zhì)，長(zhǎng)度不小于50mm，引弧點(diǎn)距焊縫端部距離需大于20mm。

　　Welders need to hold certificates to work, and inspection data from a quality supervision agency shows that the welding defect rate caused by unlicensed operations is as high as 15%. The arc starting plate should be of the same quality as the base material, with a length of not less than 50mm, and the distance between the arc starting point and the end of the weld seam should be greater than 20mm.

　　參數(shù)實(shí)時(shí)調(diào)整

　　Real time parameter adjustment

　　焊接電流需根據(jù)焊縫位置動(dòng)態(tài)調(diào)整，某機(jī)器人焊接系統(tǒng)的算法顯示，平焊位置電流可比立焊位置提高。對(duì)于角焊縫，需采用月牙形運(yùn)條方式，確保兩側(cè)熔合良好。

　　The welding current needs to be dynamically adjusted according to the position of the weld seam. The algorithm of a certain robot welding system shows that the current in the flat welding position can be higher than that in the vertical welding position. For fillet welds, a crescent shaped strip running method should be used to ensure good fusion on both sides.

　　環(huán)境條件保障

　　Environmental condition guarantee

　　焊接環(huán)境濕度需低于90%，某檢測(cè)中心的試驗(yàn)表明，高濕環(huán)境會(huì)導(dǎo)致焊縫含氫量增加。在露天作業(yè)時(shí)，需設(shè)置防風(fēng)棚，某風(fēng)電塔筒項(xiàng)目的實(shí)踐顯示，風(fēng)速超過(guò)2m/s時(shí)需停止焊接。

　　The humidity in the welding environment should be below 90%. A test conducted by a certain testing center has shown that high humidity environments can lead to an increase in hydrogen content in the weld seam. When working outdoors, windproof shelters need to be set up. The practice of a wind turbine tower project shows that welding needs to be stopped when the wind speed exceeds 2m/s.

　　四、焊后處理與檢驗(yàn)

　　4、 Post weld treatment and inspection

　　應(yīng)力消除措施

　　Stress relief measures

　　對(duì)于厚板焊接結(jié)構(gòu)，需進(jìn)行消除應(yīng)力熱處理，某石化設(shè)備的工藝規(guī)范要求，加熱速率不超過(guò)50℃/h，保溫溫度580-620℃。振動(dòng)時(shí)效處理可作為替代方案，某機(jī)床底座的殘余應(yīng)力消除率達(dá)60%。

　　For thick plate welded structures, stress relief heat treatment is required. The process specification of a certain petrochemical equipment requires a heating rate not exceeding 50 ℃/h and an insulation temperature of 580-620 ℃. Vibration aging treatment can be used as an alternative solution, with a residual stress relief rate of 60% for a certain machine tool base.

　　缺陷返修規(guī)范

　　Defect Repair Specification

　　需用碳弧氣刨清除缺陷，某焊接標(biāo)準(zhǔn)的操作要求，氣刨深度不超過(guò)板厚的2/3。返修焊縫需重新進(jìn)行外觀(guān)檢查和無(wú)損檢測(cè)，某核電設(shè)備的驗(yàn)收數(shù)據(jù)顯示，返修次數(shù)超過(guò)2次的焊縫需進(jìn)行斷裂試驗(yàn)。

　　Carbon arc gouging is required to remove defects. According to the operating requirements of a certain welding standard, the gouging depth should not exceed 2/3 of the plate thickness. The repaired welds need to undergo visual inspection and non-destructive testing again. The acceptance data of a certain nuclear power equipment shows that welds that have been repaired more than twice need to undergo fracture testing.

　　檢驗(yàn)標(biāo)準(zhǔn)執(zhí)行

　　Execution of inspection standards

　　外觀(guān)檢查：焊縫余高需控制在0-3mm，某建筑規(guī)范的允許偏差為±1.5mm。咬邊深度不得超過(guò)0.5mm，累計(jì)長(zhǎng)度不超過(guò)焊縫全長(zhǎng)的10%。

　　Appearance inspection: The excess height of the weld seam should be controlled within 0-3mm, and the allowable deviation of a certain building code is ± 1.5mm. The depth of undercutting should not exceed 0.5mm, and the cumulative length should not exceed 10% of the total length of the weld seam.

　　無(wú)損檢測(cè)：超聲波探傷需采用GB/T 11345標(biāo)準(zhǔn)，某壓力管道的檢測(cè)靈敏度設(shè)置需達(dá)到Φ2-18dB。對(duì)于T型接頭，需增加磁粉檢測(cè)，確保角焊縫質(zhì)量。

　　Non destructive testing: Ultrasonic testing shall adopt the GB/T 11345 standard, and the detection sensitivity setting of a certain pressure pipeline shall reach Φ 2-18dB. For T-joints, magnetic particle testing needs to be added to ensure the quality of fillet welds.

　　濟(jì)南型鋼焊接需建立全流程質(zhì)量控制體系，從材料準(zhǔn)備、工藝控制到質(zhì)量檢驗(yàn)，每個(gè)環(huán)節(jié)都需嚴(yán)格執(zhí)行技術(shù)規(guī)范。通過(guò)科學(xué)選用焊接方法、精準(zhǔn)控制工藝參數(shù)、系統(tǒng)實(shí)施質(zhì)量監(jiān)控，可確保焊接質(zhì)量滿(mǎn)足工程要求。隨著智能焊接技術(shù)的發(fā)展，如機(jī)器人焊接、在線(xiàn)監(jiān)測(cè)系統(tǒng)等新技術(shù)的應(yīng)用，型鋼焊接正向自動(dòng)化、智能化方向演進(jìn)，這對(duì)提升濟(jì)南地區(qū)制造業(yè)水平具有重要意義。

　　Jinan section steel welding requires the establishment of a full process quality control system, from material preparation, process control to quality inspection, and each link must strictly comply with technical specifications. By scientifically selecting welding methods, accurately controlling process parameters, and systematically implementing quality monitoring, the welding quality can be ensured to meet engineering requirements. With the development of intelligent welding technology, such as the application of new technologies such as robot welding and online monitoring systems, steel welding is evolving towards automation and intelligence, which is of great significance for improving the manufacturing level in Jinan area.

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