海工产品检验员手册

海工产品检验员手册（焊接）一、Welder position qualification and range 焊工位置评定及范围Qualification评定Range qualified评定范围1F 2F 3F 4F 5F 1G 2G 3G 4G 5G 6G 6GR3F ＊＊＊4F ＊＊＊3G ＊＊＊＊＊＊4G ＊＊＊＊＊5G ＊＊＊＊＊＊＊＊＊6G ＊＊＊＊＊＊＊＊＊＊＊6GR ＊＊＊＊＊＊＊＊＊＊＊＊Welding positions—groove(plate)焊接位置—坡口（板）1G 2G3G4GWelding positions—fillet(plate)焊接位置—角焊缝（板）1F(FLAT平焊) 2F(HORIZONTAL横焊) 3F(VERTICAL立焊) 4F(OVERHEAD仰焊)Welding positions –pipe焊接位置—管1G ROTATED旋转2GWelding positions –pipe (continued)焊接位置—管5G6G 6GR; T.K.Y 连接二、AWS Specifications for electrodesAWS焊条规范三、Electrode deposition efficiency and stub loss factors焊条的熔敷效率和损耗系数CLASS AVERAGE EFFICIENCY * STUB LOSS **等级平均熔敷效率端头损耗E6010 63.8% STUB（残余长度）5/32E6010 14inE6011 68.5% LENGTH %DEPOSIT（沉淀物）%LOSSE6012 66.9% 2in 63.8 36.2E6013 66.8% 3in 58.5 41.5E7014 64.6% 4in 53.2 46.8E7016 62.8% 5in 47.9 52.1E7018 69.5% 6in 42.6 57.4E6020 65.2% WEIGHT OF WELD METAL(焊接金属重量) E7024 66.8% EFFICIENCY熔敷效率＝WEIGHT OF ELECTRODE USED INCLUDING STUB（使用焊条的重量，包括残余部分）E7027 68.3%* INCLUDES 2 in STUB LOSS包括残余部分的2in** E6010 IS 71.57% EFFICIENCY ,LOSS DUE TO SLAG , SPATTER AND SMOKE E6010熔敷效率只有71。

57% ，由于焊渣、飞溅和烟的损失四、Typical shielded metal arc electrode orientation and weldingtechnique for carbon steel electrodes 碳钢手工电弧焊条操作的典型方位与技能* Travel angle may be 10to30for electrodes with heavy iron powder coatings.对于重铁粉药皮的焊条运条角度可以成10-30度的角五、Suggested amperage range for carbon steel and low-alloysteel electrodes碳钢和低合金钢焊条的推荐电流范围六、Troubleshooting mechanical problems encountered GMAWand FCAW-GGMAW 和FCAW-G 焊接中存在的机械问题与修复七、Troubleshooting electrical problems encountered in GMAWand FCAW-G GMAW and FCAW-G 焊接中电气问题的修复八、Cracks 裂纹A crack is defined as “A fracture type discontinuity characterized by a sharp tip and a high ratio of length and width to opening displacement.”Cracks are usually considered the most severe discontinuity because of their tendency to propagate under stress. Cracks are usually furtherdescribed by their location geometry ,time of occurrence ,or common usage terms ; see figure below for AWS crack terminology .裂纹被定义为: “断裂形不连续,表现为端部尖锐的长宽比很高的位移开裂.”裂纹通常被认为是严重的不连续,因为在应力的作用下将会延裂纹方向延伸.通常根据裂纹出现的位置和出现的时间或者常用的使用术语进行描述；见下面的插图：AWS裂纹术语学.(A) (B)LEGEND:1. CRATER CRACK弧坑裂纹2.FACE CRACK表面裂纹3.HEAT-AFFECTEDZONE CRACK热影响区裂纹MELLAR TEAR层状撕裂5.LONGITUOINAL CRACK纵向裂纹6.ROOT CRACK根部裂纹7.ROOT SURFACE CRACK根部表面裂纹8.THROA T CARCK焊喉裂纹9.TOE CRACK焊趾裂纹10.TRANSVERSE CRACK横向裂纹11.UNDERBEAD CRACK母才内部裂纹12.WELD INTERFACE CRACK焊接熔合面裂纹13.WELD METAL CRACK 焊缝裂纹九、Inclusions夹渣Inclusions are defined as ‘entrapped foreign solid material , such as slag , flux , tungsten , or oxide .” The inclusions may be found as single particles , aligned particles . Slag inclusions are frequently found on the weld surfaces , or along the toes of the weld due to improper cleaning techniques . Tungsten inclusions are usually subsurface . Examples of inclusions are shown below . Inclusions on the surface can be detected by VT ; subsurface inclusions require UT or RT.Slag inclusions (darkened areas)内部夹渣（发暗的区域）Repairs of inclusions on the surface require removal by gouging or grinding ,welding if required and reinspection by appropriate NDT method .subsurface inclusions require removal by gouging or grinding .followed by weld repair and reinspection .夹渣被定义为: “陷在焊缝中的外界固体物质,比如焊渣,焊剂,钨,或氧化物. 夹渣可能以单个颗粒或线形颗粒出现. 由于清理方法的不正确夹渣经常出现在焊缝表面或焊趾处。

夹钨出现在焊缝内部。

在表面的夹渣可以通过目视检查来发现；内部夹渣需要通过超声波或者X射线来检查发现。

表面的夹渣返修可以通过气刨或者打磨去除，修补处如果需要可以使用适当的NDT方法来重新检验。

焊缝内部夹渣需要通过气刨或打磨来去除，焊接修补并且重新检验。

十、Incomplete fusion未熔合Incomplete fusion is defined as”A weld discontinuity in which fusion did not occur between weld and fusion faces or adjoining weld beads .”incomplete fusion (1F)can occur on both groove welds and fillet welds where the weld does not extend to the joint root . see the figure below.未熔合被定义为：焊缝和坡口面或者相邻焊缝面未发生熔合的焊接不连续。

未熔合（1F）出现在坡口焊和填角焊中的接头根部。

见下图：(A)（B）（C）Detection of incomplete fusion using VT is possible if the discontinuity location is visible on the surface ; oblique angle lighting and 10 magnification aid the inspector . Generally ,1F subsurface and is found using UT or RT methods.如果未熔合明显的在表面可以通过目视检验发现；从斜角方向用光照射或10倍放大镜可以帮助检验。

通常在表面以下的未熔合需要通过UT和RT 来发现。

Repairs of incomplete fusion require removal of the discontinuity by gouging or grinding , followed by weld repair and final inspection.返修未熔合需要气刨或者打磨来去除缺陷，焊接返修并且做最终检验。

十一、Incomplete joint penetration未熔透Incomplete joint penetration is defined as “A joint condition in a groove weld in which weld metal does not extend through the joint thickness .”Note that it applies to groove welds only ,not filled welds . Examples of incomplete joint penetration(IJP)are shown in the following figures .未熔透被定义为：在坡口焊中焊接金属没有完全穿透坡口的接头厚度。