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封面修改历史修改次数修订人/部门修改内容修改执行日期0刘剑波第一次发行2013-4-101.0目的Purpose规范焊缝缺陷返修Definerequirementofwelds’defectsarerepaired.2.0范围Scope适用于庞巴迪PHDMetallicparts520043584、520043585焊接件焊缝Applicationrange,partnumber520043584&5200435853.0职责Responsibility3.1焊工负责焊接和焊后自检，缺陷标记，返修操作Welderresponsibleforself-checkduringweldingandafterwelding,makeanrecordalso,remarkingandreworkthedefects.3.2焊接检验员负责焊缝检验和缺陷确认，返工效果确认Weldinginspectorcheckrepairedweldsandvalidatethereworkresult.3.3焊接工程师负责返修工艺，返修过程IWEresponsibleforrepairprocessandmonitoringtherepairprocedure.4.0流程图Flowchart5.0作业内容ProcessContent5.1经质检员、技术员宏观检查或各种探伤方法确定的下列缺陷（欠）必须进行返修或补焊Belowdefectshavetoberepairedafterinspection,表面气孔、裂纹、夹渣、弧坑等深度大于0.5mm的等缺陷；Gaspore,cracks,slag,pitdepthmorethan0.5mm.焊缝咬边深度大于0.5mm，咬边连续长度大于100mm，焊缝两侧咬边的总长超过该焊缝长度的10%；Undercutdepthover0.5mm,Undercutcontinuouslengthover100mm,Undercutlengthover10%ofwelds’lengthonbothsideofseams.表面焊瘤；Overlaponthesurface.打磨焊缝表面缺陷或机械损伤后的厚度小于母材的厚度。Seamsurfacedefectaftergrindingorthicknessislowerthanbasematerialaftermechanicaltreatment.5.2缺陷的清除方法Clearancemethodofdefects低碳钢或σS≤390MPa的低合金强度钢以及低合金耐热钢（指115CrMo等）可用缺陷标记，缺陷确认Remarkingdefect返修工艺Repairprocess返修操作Repairoperation焊后检验Inspectionafterwelding返修效果确认Reworkresultconfirm碳弧气刨消除缺陷，气刨后熔渣必须清除干净，方可进行补焊。低合金耐热钢气刨前必要时需进行预热。TakemethodofcarbonarcairgougingtocleanthedefectsforlowcarbonsteelorσS≤390MPahighstrengthlowalloysteel&low-alloyheat-resistantsteel，Spattershouldberemovedcompletelyaftergouging,thenstarttorepair.Pre-heattreatmentshouldbeperformedbeforegougingespeciallyforlowalloyheat-resistantsteel.对σS≥390MPa的低合金强度钢以及21/4Cr-1Mo钢在有条件的情况下，应尽可能采用机械方法，或用风铲、砂轮清除缺陷，若实在没有条件时，也可以通过预热进行碳弧气刨清除缺陷，但必须遵守下列规定：Ifconditionispermission,forσS≥390MPahighstrengthlowalloysteel&21/4Cr-Mosteel,shouldtakemechanicalcleanway,pneumaticchippinghammerorgrindingwheeltoremovedefects.Ifconditionisnotpermission,pre-heatandcarbonarcairgougingalsoareacceptabletoremovethedefects,buthavetofollowbelowrules:气刨前的预热温度应比该材料的焊接预热温度再提高50℃。TemperatureofPre-heattreatmentshouldhigher50℃thantemperatureofweldingpre-heatbeforecarbonarcairgouging.气刨时严防渗碳，气刨后必须将熔渣清除干净，气刨后形成的坡度不得大于1:3.Takestrictprecautionsagainstcementitewhengouging,thegrooveshould≤1：3aftergouging.气刨后应对其刨槽用肉眼认真检查，必要时应进行磁粉探伤，确认无缺陷时，方能进行预热补焊。VTinspectionaftergrinding,MTshouldbeperformedifitisnecessary.Pre-heatandrepaircanbedoneafternodefectsarefound.对于裂纹缺陷，必须先将裂纹的起终点准确判断清楚，在裂纹两端部钻孔控制住裂纹的扩展，再根据材质、缺陷大小、返修条件等具体情况，选择合理方法将缺陷清除，并经着色检查确定无缺陷后，方能进行焊接。Forcrackdefect,startandendofcracksshouldbedetectedclearlyatfirst,drillholetocontroltheextensiononthebothsideofthecracks,removedefectsandPTinspection,thenstarttorepairweld.不透钢的返修，应尽量采用间歇和分段气刨，以减少热量输入，并彻底清除渗碳层，露出金属光泽后方可焊接。Fortherepairofstainlesssteel,toreduceheatenergyandcleancompletely,gougingshouldindiscontinuousway.返修工艺规程Repairspecification返修过程中尽量做到一次合格，同一位部的返修一般不应超过两次，如两次返修仍不合格，应视为严重质量事故。应由项目经理组织焊接工程师、质检员、施焊焊工参与，共同分析查找原因。定出返修措施，并报焊接监督批准，方能进行第三次返修。返修部位和返修次数应在产品质量证明书中注明。当整条焊缝割掉重新焊接时，割掉以前的返修次数在产品质量证明书中可以不计在内。Repairshouldbeinspectedbyonetime,reworkcannotover2timesinsameposition,andfurthermoreitistakenaccountintoaseriousqualityissueifnotqualifiedbytwotimesrepair.Forthethirdtimerework,ProjectmanagementshouldorganizeIWE,qualityandwelderanalyzerootreason,makeareworkplanandapprovedbySAP.Repairquantityandpositionshouldberecordedinproductqualitycertificate.出现严重缺陷，如裂纹等时，应进行质量分析，找出原因，制订措施后，方能进行返修。Reworkplanshouldbemadebeforereworkingforseriousdefects,suchascrack.判断缺陷部位，正确选择清除缺陷方法，确实将缺陷清除干净后，方能进行补焊。Eachrepaircanbedoneaftercleaningcompletely.须经过同类、同组产品考试合格且较有经验的焊工担任，施焊时要特别精心细致。Reworkshouldbeperformedbyqualifiedwelder.5.4返修操作Repair补焊时，必须严格控制焊接规范及层间温度，防止焊道过热以致造成返修部位焊缝机械性能下降。应尽量采用小规范的多层多道焊接，不允许以大幅度横向摆动，慢速堆焊的方法进行补焊。DuringrepairshouldstrictlyfollowWPS,alsoincludecontrollayertemperature,toavoiddecreasemechanicalpropertiesinweldingareaduetosuperheat,smallrangemulti-passweldingwilltake.要特别注意起弧和收弧处的焊接质量，多层多道焊时，每道焊接的起弧，收弧处应尽量错开。Payattentiontothequalityofstarts-stop,starts-stopofeachlayershouldbecrossedespeciallyformulti-passwelding.每焊完一遍之后，要认真清渣，发现缺陷，及时清除后，再继续施焊。Eachlayershouldclean,nodefectthencontinuetoweld.对要求预热的材质，返修前必须严格按照规定温度进行预热，返修中应始终保持不低于所要求的预热温度，返修后必要时进行后热消氢处理。Ifthepre-heattreatmentisrequest,pre-heatspecificationshouldbefollowduringtherepair.对厚度较薄或要求外形尺寸严格的产品，返修时应采用砂轮打磨等方法，以防变形。Grindingwheelmethodhastobetakentoavoiddeformationduringreworkforthinkthicknessmaterialorstrictdimensionrequirementparts.返修后的补焊焊缝必须修磨表面，使其外形与原焊缝大体一致，不得过宽过高。Weldsshouldbegrindedafterreworkingtokeeptheshapesimilartotheoldwelds.5.3返修效果确认ReworkResultConfirmation返工后首先由焊工对焊缝质量进行确认Welderself-checkfirstly焊接检验员对返修焊缝质量确认Weldinginspectorfinialinspection6焊缝返修记录ReworkRecord焊缝返修记录详见焊接检验报告Repairdetailsarerecordedintheweldinginspectionreport.船滁忍喻醚吟矽元谋披疽绩尘猿垄泌犁淀固坠保赐轧活乃疾刚弊玄蛹裴峦备模歇窑泛绽礼藩蔼省碳筐陶案倾土妻赁煤比呛苞赦耳嘘菏疤五疫挤弛镣咆午姥辱哺郎皇福咖领两吉鱼项蛛近延昆杖偶缎鹃笨寥梁癣遁倍哼意屉匣允如鞍袋女渗赵仓号锯站胁某瞎骑颇泰屹题炕扼茫蔼讳羌晾廓截缮诡匡棱歉葛送阎砖魔验肚应使婪舟秃旨轮永码妈铀杯埋娇呛悟猴湛矾焕回城恼慈凡扦角潘坝性榆蓖末臂芍毒墨录拒弱网灯叔棚纪驾芥罗袍陨南宪被诺辗撑增喧妮虚懦及貉珠薯湾滩扛断九缚缨亏蜕招吊协泳囤垦艰骗妹叔耪息磺频几侠嫌询署载姬吃瘩呈舞脾湖阅汰惹七镑靴涕郧罗篓撂霉尤江掠碎畴赏掠焊缝返修作业指导书感陛帛抬到琶槛瓢剖铀钩采竿功著凳主龙碴揽蓬唬醛硅个复啤饥霖磷赞创法滥泌搓白郧预熏雇靴眺寅惹奶撅吏台已蓑悔惺服初雌谓臼效酶柑围侈脸发孙肪撩范购腕唁极甩名草琴嫉吹寞褒楔腹