T-shaped joint full penetration weld back gouging-free process method

Abstract

The invention relates to the technical field of ship manufacturing, and discloses a T-shaped joint full penetration weld back gouging-free process method which comprises the following steps: 1) preparing a welding tool; (2) processing the welding area before welding; (3) welding parameters are determined; 4) a formal welding operation step; and 5) comparing and counting new and old process welding material consumption. According to the back gouging-free process method for the full penetration weld back of the T-shaped joint, the welding method, the welding wire material and the protective gas are determined, and detailed ideal current needed for different groove modes and weld bead arrangement is determined, so that when the T-shaped joint is welded, welding of the T-shaped joint can be completed without a traditional carbon gouging welding method, and the welding efficiency is improved. Compared with the prior art, the method has the advantages that the workload of workers is reduced, the working intensity of the workers is reduced to a certain extent, and meanwhile, the novel process method does not need carbon gouging back gouging, so that the working time is shortened, the welding speed of the workers is increased to a certain extent, the yield is increased, and the working efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of shipbuilding, in particular to a back-side root cleaning-free process method for a full penetration weld of a T-joint. Background Art

[0002] In the process of making steel structures, there are many T-joints that need to be welded, such as the hull groove and the pier top plate, the unloading plate, the pier and the inner bottom plate, the hatch coaming and the deck, the inner longitudinal wall and the inner bottom plate. The current process is to weld the front side first, then carbon planer the back side to clean the root, then grind to remove the oxide scale, and finally complete the welding of the back side weld. Carbon planing operation produces a lot of smoke and dust, loud noise, strong arc, and consumes a lot of labor and kinetic energy costs (compressed air and electricity). At the same time, the groove formed after carbon planing needs to be filled with welding metal, and the consumption of welding materials is also very large.

[0003] Therefore, it is necessary to develop a welding method with deep penetration, good processability and easy operation, so as to achieve full penetration of the T-joint node on the back without carbon planing and root cleaning, improve production efficiency, reduce welder labor intensity, save welding material consumption, liberate labor and productivity, and improve production efficiency. Summary of the invention

[0004] () Technical issues solved In view of the deficiencies in the prior art, the present invention provides a process method for the back side of a T-joint full penetration weld without root cleaning, which has the advantages of being able to save consumption of welding materials, saving welding costs and saving welding time during welding, thereby reducing the labor intensity of workers and improving production efficiency, and solves the problem that traditional welding processes require the consumption of a large amount of welding materials and traditional welding processes require carbon planing, thereby increasing the construction time of workers, increasing the labor intensity of workers and reducing production efficiency.

[0005] (II) Technical solution To achieve the above object, the present invention provides the following technical solution: a T-joint full penetration weld back side root cleaning-free process method, comprising the following steps: 1) Preparation of welding tools; 2) Processing steps before welding in the welding area; 3) Determine welding parameters; 4) Formal welding operation steps; 5) Comparative statistics of welding material consumption between new and old processes; Preferably, the preparation of the welding tools first begins before welding according to specific needs. The welding tools required for welding mainly include: welding drawings, hair dryer, polisher, oxy-acetylene welding cabinet, welding gun, welding cable quick connector and quick connector, welding tongs, grounding clamp, mask and goggles, electric soldering iron, tin soldering wire, flux, diagonal pliers, magnifying glass and high-temperature sponge.

[0006] Preferably, the processing steps before welding the welding area include the following steps: S1. Observe the condition of the plate and welding position; S2, determining whether cleaning or preheating is required; S3, determine the type of cleaning required; S4, judged to be floating dust such as debris; S5. Use a hair dryer to clean; S6: The plate and welding position are judged to be uneven and have oxides; S7, using a polishing machine to grind and smooth and remove oxides; S8, judging that preheating is required according to the thickness of the plate; S9. Use an oxy-acetylene welding cabinet and welding gun to preheat the plate.

[0007] Preferably, the welding parameters are determined by first selecting the hull structural steel AH36 plate according to the welding drawing requirements, then determining the welding method as gas metal arc welding (GMAW), determining the welding wire material as TM-56 (compliant with AWS ER70S-6), with a diameter of φ1.2 mm, and determining the shielding gas as 80% Ar+20% CO2 Mixed gas, then use the empirical formula I=(35-55)d to preliminarily calculate the required welding current, and rotate the current adjustment knob on the welding machine until the current number on the welding machine is the same as the calculated current number to complete the operation, and then start welding tests on the voltage and current required for different welding forms. After testing the current, voltage, and welding speed required for different groove forms and weld bead arrangements, a large number of welding parameters are obtained. These numerous welding parameters are classified, summarized, and analyzed according to different groove forms and weld bead arrangements, and then a relatively ideal parameter is obtained. Then, the welding test is continued using this relatively ideal parameter, and the finished weld is sent for inspection. If the inspection shows success, the welding parameter is recorded and saved to form a welding form table and a corresponding welding parameter and inspection result table. If the inspection result is not ideal, continue testing until a method and parameters suitable for the new process are detected.

[0008] Preferably, the formal welding operation steps include the following steps: S1, connect the power supply; S2, grounding clamp connected to the ground wire; S3, welding clamp connected to welding machine; S4. Determine the type and thickness of the plate as well as the welding angle and depth; S5. Select suitable welding rod; S6, welding clamp connects welding rod; S7. Wear a mask and goggles; S8. Adjust the welding machine to the ideal welding current; S9, start welding; S10, welding is completed, waiting for cooling; S11. Determine whether the welding meets the standards; S12, judgement of reaching the standard; S13: If it is judged that the standard is not met, re-weld; S14, re-welding; S15. Observe whether the welded parts need post-welding treatment; S16, determining that processing is required; S17, use tools for processing; S18, determining that no processing is required to complete welding.

[0009] Preferably, the comparative statistics of welding material consumption of the old and new processes first determine whether the category of the plate welded by the traditional process is consistent with the category of the new welding process, then determine the consistency of the welding materials, and finally compare the previous traditional process data with the current new process data using data analysis. The average value of the data of welding consumables in the traditional process data is compared with the average value of the data of the current new process welding consumables, and then the coefficient of variation is used to measure the fluctuation of the overall data, and then comparative analysis is used to analyze the change of data trends. Finally, the comparison of the data of welding consumables in the traditional process data and the data of welding consumables in the current new process data is obtained, and a statistical comparison of welding material consumption is obtained.

[0010] Another technical problem to be solved by the present invention is to provide a T-joint full penetration weld back side root cleaning-free process method, comprising the following steps: 1) Preparation of welding tools; 2) Processing steps before welding in the welding area; 3) Determine welding parameters; 4) Formal welding operation steps; 5) Comparative statistics of welding material consumption between new and old processes; (III) Beneficial effects Compared with the prior art, the present invention provides a T-joint full penetration weld back-side root cleaning-free process method, which has the following beneficial effects: 1. The T-joint full penetration weld back side root cleaning-free process method determines the welding method, welding wire material, shielding gas, and confirms the ideal current required for different groove methods and weld bead arrangements in detail. When welding T-joints, the traditional carbon planing welding method can be used to complete the welding of T-joints. This undoubtedly reduces the workload of workers and alleviates the work intensity of workers to a certain extent. At the same time, because the new process method no longer requires carbon planing root cleaning, it reduces the working time, which also speeds up the welding speed of workers to a certain extent, thereby increasing production and improving work efficiency.

[0011] 2. The T-joint full penetration weld back side root cleaning-free process method uses the new and old process welding material consumption comparison statistics. After the traditional process method and the new process method are welded with the same batch of tools, the consumables data are processed, integrated and compared to form a comparison table, so that it can be clearly seen that the amount of consumables after welding with the new process method consumes much less material than that with the traditional process method. This undoubtedly reduces the material consumption during welding, helps the company save material expenses to a certain extent, and also controls the cost expenditure during shipbuilding to a certain extent. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 A text flow diagram of the processing steps before welding in the welding area of ​​a T-joint full penetration weld back side root cleaning-free process method proposed by the present invention; Figure 2 A text flow chart of the formal welding operation steps of a T-joint full penetration weld back side root cleaning-free process method proposed by the present invention; Figure 3 A test schematic diagram of a welding form of a T-joint full penetration weld back side root cleaning-free process method proposed by the present invention; Figure 4 A schematic diagram of welding parameters and test results of a T-joint full penetration weld back-side root cleaning-free process method proposed by the present invention; Figure 5 This is a statistical comparison chart of welding consumables for a T-joint full penetration weld back side root cleaning-free process method proposed by the present invention. DETAILED DESCRIPTION

[0013] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0014] Embodiment 1: A T-joint full penetration weld back side root cleaning-free process method, comprising the following steps: 1) Preparation of welding tools. The preparation of welding tools first requires the preparation of welding tools required for welding according to specific needs before welding. These tools mainly include: welding drawings, hair dryers, grinders, oxy-acetylene welding cabinets, welding guns, welding cable quick connectors and quick connectors, welding tongs, grounding clamps, masks and goggles, electric soldering irons, tin soldering wires, flux, diagonal pliers, magnifying glasses and high-temperature sponges.

[0015] Prepare the tools needed for welding in advance before welding, so that there will be no shortage of tools when preparing for welding and during the welding process, which will cause workers to frequently return to find the corresponding tools. This will not only slow down the progress of the work, but also waste a lot of time and reduce production. However, preparing the tools in advance and bringing them to the welding site will enable workers to easily face various problems that may occur during welding. Workers will also reduce physical exertion because they do not have to frequently return, and can devote themselves to the welding work, ensuring that the welded parts meet the quality requirements, while also increasing production.

[0016] 2) The processing steps before welding of the welding area include the following steps: S1. Observe the condition of the plate and welding position; S2, determining whether cleaning or preheating is required; S3, determine the type of cleaning required; S4, judged to be floating dust such as debris; S5. Use a hair dryer to clean; S6: The plate and welding position are judged to be uneven and have oxides; S7, using a polishing machine to grind and smooth and remove oxides; S8, judging that preheating is required according to the thickness of the plate; S9. Use an oxy-acetylene welding cabinet and welding gun to preheat the plate.

[0017] By processing the welding area in advance, the welded product will not have quality defects such as incomplete weld penetration, porosity and slag inclusions in the weld due to the influence of unnecessary impurities such as debris, uneven cuts and some oxides during the formal welding. This guarantees the success of the subsequent formal welding to a certain extent. At the same time, because some unnecessary things are removed in advance, the success rate of welding is increased and rework due to quality problems is reduced.

[0018] 3) Determine the welding parameters. First, according to the requirements of the welding drawings, select the hull structural steel AH36 plate, then determine the welding method as gas metal arc welding (GMAW), determine the welding wire material as TM-56 (in accordance with AWS ER70S-6), diameter φ1.2mm, and determine the shielding gas as 80%Ar+20%CO2 Mixed gas, then use the empirical formula I=(35-55)d to preliminarily calculate the required welding current, and rotate the current adjustment knob on the welding machine until the current number on the welding machine is the same as the calculated current number to complete the operation, and then start welding tests on the voltage and current required for different welding forms. After testing the current, voltage, and welding speed required for different groove forms and weld bead arrangements, a large number of welding parameters are obtained. These numerous welding parameters are classified, summarized, and analyzed according to different groove forms and weld bead arrangements, and then a relatively ideal parameter is obtained. Then, the welding test is continued using this relatively ideal parameter, and the finished weld is sent for inspection. If the inspection shows success, the welding parameter is recorded and saved to form a welding form table and a corresponding welding parameter and inspection result table. If the inspection result is not ideal, continue testing until a method and parameters suitable for the new process are detected.

[0019] By determining the welding method, welding wire material, shielding gas, and confirming the ideal current required for different groove methods and weld bead arrangements, it is possible to complete the welding of T-joints without using the traditional carbon planer welding method. This undoubtedly reduces the workload of workers and alleviates their work intensity to a certain extent. At the same time, because the new process method no longer requires carbon planer root cleaning, it reduces working time, which also speeds up the welding speed of workers to a certain extent, thereby increasing production and improving work efficiency.

[0020] 4) Formal welding operation steps, the formal welding operation steps include the following steps: S1, connect the power supply; S2, grounding clamp connected to the ground wire; S3, welding clamp connected to welding machine; S4. Determine the type and thickness of the plate as well as the welding angle and depth; S5. Select suitable welding rod; S6, welding clamp connects welding rod; S7. Wear a mask and goggles; S8. Adjust the welding machine to the ideal welding current; S9, start welding; S10, welding is completed, waiting for cooling; S11. Determine whether the welding meets the standards; S12, judgement of reaching the standard; S13: If it is judged that the standard is not met, re-weld; S14, re-welding; S15. Observe whether the welded parts need post-welding treatment; S16, determining that processing is required; S17, use tools for processing; S18, determining that no processing is required to complete welding.

[0021] By determining the formal welding operation steps, workers will not violate the regulations during formal welding. This not only standardizes the workers' welding process, but also ensures the workers' safety during welding. While protecting the workers' safety during welding, it can also, to a certain extent, guarantee the quality of the welded parts after welding and improve the pass rate of product quality.

[0022] 5) Comparative statistics of welding material consumption between the old and new processes. The comparative statistics of welding material consumption between the old and new processes first determine whether the category of plates welded by the traditional process is consistent with the category of the new welding process, then determine the consistency of welding materials, and finally compare the previous traditional process data with the current new process data using data analysis. By comparing the average value of the data of welding consumables in the traditional process data with the average value of the data of welding consumables in the current new process, and then using the coefficient of variation to measure the fluctuation of the overall data, and then using comparative analysis to analyze the change of data trend, finally, the comparison of the data of welding consumables in the traditional process data and the data of welding consumables in the current new process data is obtained, and the statistical comparison of welding material consumption is obtained.

[0023] By comparing the consumption of welding materials between the old and new processes, the consumables data of the traditional and new processes were processed, integrated and compared after welding with the same batch of tools to form a comparison table. It can be clearly seen that the amount of consumables after welding with the new process method consumes much less material than that with the traditional process method. This undoubtedly reduces the consumption of materials during welding, helps the company save material expenses to a certain extent, and also controls the cost expenditure during shipbuilding to a certain extent.

[0024] The beneficial effects of the present invention are as follows: the back-free root cleaning process method of the full penetration weld of the T-joint can be completed without the traditional carbon planing welding method when welding the T-joint by determining the welding method, welding wire material, shielding gas, and confirming the ideal current required for different groove methods and weld bead arrangements. This undoubtedly reduces the workload of workers and alleviates the work intensity of workers to a certain extent. At the same time, because the new process method no longer requires carbon planing and root cleaning, this reduces the working time, which also speeds up the welding speed of workers to a certain extent, thereby increasing production and improving work efficiency. By comparing the consumption of welding materials of the old and new processes, the consumables data of the traditional process method and the new process method are processed, integrated, and compared after welding with the same batch of tools to form a comparison table, so that it can be clearly seen that the amount of consumables after welding with the new process method consumes much less material than that of the traditional process method, which undoubtedly reduces the consumption of materials during welding, helps the company save material expenses to a certain extent, and also controls the cost expenditure during shipbuilding to a certain extent.

[0025] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A T-joint full penetration weld back side root cleaning-free process method, characterized in that: The following steps are involved: Preparation of welding tools; Pre-welding treatment steps for the welding area; Determine welding parameters; Formal welding operation steps; Comparative statistics of welding material consumption of new and old processes; According to the process method for the back side of a T-joint full penetration weld without root cleaning as described in claim 1, it is characterized in that the preparation of the welding tools first begins before welding according to specific needs. The welding tools required for welding are mainly prepared: welding drawings, hair dryers, grinders, oxy-acetylene welding cabinets, welding guns, welding cable quick connectors and quick connectors, welding tongs, grounding clamps, masks and goggles, electric soldering irons, tin solder wires, flux, diagonal pliers, magnifying glasses and high-temperature sponges.

2. A T-joint full penetration weld back side root cleaning-free process method according to claim 1, characterized in that: The processing steps before welding of the welding area include the following steps: S1. Observe the condition of the plate and welding position; S2, determining whether cleaning or preheating is required; S3, determine the type of cleaning required; S4, judged to be floating dust such as debris; S5. Use a hair dryer to clean; S6: The plate and welding position are judged to be uneven and have oxides; S7, using a polishing machine to grind and smooth and remove oxides; S8, judging that preheating is required according to the thickness of the plate; S9. Use an oxy-acetylene welding cabinet and welding gun to preheat the plate.

3. The back-side root cleaning-free process method for full penetration weld of T-joint according to claim 1 is characterized in that: The welding parameters are determined by first selecting the hull structural steel AH36 plate according to the welding drawing requirements, then determining the welding method as gas metal arc welding (GMAW), determining the welding wire material as TM-56 (in accordance with AWS ER70S-6), with a diameter of φ1.2mm, and determining the shielding gas as 80%Ar+20%CO2 Mixed gas, then use the empirical formula I=(35-55)d to preliminarily calculate the required welding current, and rotate the current adjustment knob on the welding machine until the current number on the welding machine is the same as the calculated current number to complete the operation, and then start welding tests on the voltage and current required for different welding forms. After testing the current, voltage, and welding speed required for different groove forms and weld bead arrangements, a large number of welding parameters are obtained. These numerous welding parameters are classified, summarized, and analyzed according to different groove forms and weld bead arrangements, and then a relatively ideal parameter is obtained. Then, the welding test is continued using this relatively ideal parameter, and the finished weld is sent for inspection. If the inspection shows success, the welding parameter is recorded and saved to form a welding form table and a corresponding welding parameter and inspection result table. If the inspection result is not ideal, continue testing until a method and parameters suitable for the new process are detected.

4. A T-joint full penetration weld back side cleaning-free process method according to claim 1, characterized in that: The formal welding operation steps include the following steps: S1, connect the power supply; S2, grounding clamp connected to the ground wire; S3, welding clamp connected to welding machine; S4. Determine the type and thickness of the plate as well as the welding angle and depth; S5. Select suitable welding rod; S6, welding clamp connects welding rod; S7. Wear a mask and goggles; S8. Adjust the welding machine to the ideal welding current; S9, start welding; S10, welding is completed, waiting for cooling; S11. Determine whether the welding meets the standards; S12, judgement of reaching the standard; S13: If the standard is not met, re-weld; S14, re-welding; S15. Observe whether the welded parts need post-welding treatment; S16, determining that processing is required; S17, use tools for processing; S18, judging that no processing is required to complete the welding.

5. The back-side root cleaning-free process of a T-joint full penetration weld according to claim 1 is characterized in that: The comparative statistics of welding material consumption between the old and new processes first determine whether the category of plates welded using the traditional process is consistent with the category of the new welding process, then determine the consistency of welding materials, and finally compare the previous traditional process data with the current new process data using data analysis. The average value of the data of welding consumables in the traditional process data is compared with the average value of the data of the current new process welding consumables, and then the coefficient of variation is used to measure the fluctuation of the overall data, and then comparative analysis is used to analyze the trend changes of the data. Finally, the comparison of the data of welding consumables in the traditional process data and the data of welding consumables in the current new process data is obtained, and a statistical comparison of welding material consumption is obtained.

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