铸钢件内孔缺陷焊补工艺

Specification of weld repairs for defect in the casting

一、 缺陷清理：

Removal of defect

1.补焊前必须将缺陷彻底清除，坡口面应修整平滑，不得尖角的存在。

Before repair welding, the defect should be completely removed, and

the grooves should be smoothly trimmed ,no sharp corners are

permitted.

2.根据铸钢件缺陷情况，对补焊区域将采用打磨清砂清除缺陷。

According to the real situation of the defect, the defect in repair

welding areas will be removed by mechanical machining.

3.补焊区周围 100mm 以内的粘沙、油、水、锈等赃物必须彻底清除。All slogs,

darts, grease, water and rusts in the areas need to be repaired

including surrounding areas within 100mm from edges of defective area

should be cleaned thoroughly.

4.为防止裂纹扩展，在裂纹两端钻直径不小于ø10mm 的止裂孔后，再进行坡

口处理。

In order to prevent the cracks from expanding, each end of the crack

will be drilled a stop hole with the diameter not less than 10mm,

then trimming the grooves.

5.补焊前，应先采用 MT 或 PT 及其他方法，按有关规定对铸钢件补焊部位
进行检验，以证实缺陷被完全清除。

Before repair welding, non-destructive testing should be carried

out for the areas need to be repaired to ensure that all defects

have been removed thoroughly.

一． 焊前预热：

Preheating before welding

1. 焊前预热的预热温度为 150 摄氏度。

The temperature of preheating is 150℃.

2. 预热采用局部预热，用履带加热器进行加热，并覆盖以防火岩棉，预

热时必须缓慢且均匀，以避免出现裂纹和变形（约 60~100℃/h）
。缺陷处

每边预热范围的宽度应不小于补焊部位铸钢件壁厚的 2 倍，并且不得小于

75mm。

The method of preheating is local preheating. The areas are to be

preheated include defective area and surrounding areas with the

width from the edge of defective area is at least two times the

thickness of casting needs to be repaired and should be no less

than 75mm, whichever is greater.

3. 控制层间温度，较合适的层间温度为 125~250℃，其温度下限用以保

证在多层焊中后道焊缝有起码的预热条件，其温度上限以避免出现热应

力裂纹。通过补充加热或缓慢焊接来控制层间温度。

二． 焊条的选择和使用：

Choice of electrodes

1. 用于铸钢件缺陷焊补的焊条，应符合 GB984、GB/T5117、GB/T5118 和
 JB3223 的规定。本次补焊将采用 J506 或者 J507 低氢碱性结构焊条。

Electrodes used for repair welding should conform to such national

standards as GB984、GB/T5117、GB/T5118 and JB3223. We will choose

low-hydrogen basic electrodes for the propose of structural welding

for this time, and the designation of which is J506 or J507.

2. 焊条在使用前，必须烘干。本次焊补使用碱性低氢型结构焊条，在

350-400 摄氏度的条件下烘干 1-2 小时，烘干的焊条放置于 100-150 摄氏度

的保温桶（箱）内，随用随取。使用时注意保持干燥。

Before electrodes are used, they must be baked. The weld repair will

use low-hydrogen electrodes. The kind we chose needs to be baked under

the temperature of 350-400℃ for 1-2 hours, then put them in the

temperature-keeping box and keep the temperature in the range of

100-150℃.Special attention should be given to keeping dry.

4. 如低氢焊条在常温下放置超过 4 小时，应该重新烘干。重新烘干次数不

超过 3 次。

If the low-hydrogen electrodes had been put in the ambient environment

for 4hours, they should be baked again, the total amount of baking

should be no more than 3 times.

5. 不在空气对流的场所进行补焊，保证室温不低于 10 摄氏度。

Repair welding should not be carried out in the cross-ventilated

location, and the room temperature is in no way less than 10℃.

四．补焊技术要求;

Requirements for repair welding

 1. 铸钢件缺陷的补焊应在铸钢件预热后进行，消除应力采用预热方式，预

热温度为 120-150℃。

Repair welding should only be carried out after stress-relieving

for that casting.

2. 尽可能在水平位置施焊。

Welding in the down hand or flat position is preferred.

3. 补焊工作在条件许可的情况下，应连续进行。若在不得已中断时，必须

采取保温措施,保温温度为 200℃。再次补焊时应重新预热。

Repair welding should be carried out in a continuous way as far as

possible. If the interruption occurs, attention should be given to

keeping temperature. Preheating is needed once more if repair

welding going on.

4. 补焊时，焊条不应作过大的横向摆动。摆动幅度不得超过焊条直径的 3

倍。长度大的焊缝应分段、交错焊接，减少变形应力产生。

During welding, the weaving of the electrodes should be not too great,

and the width of weaving is no more than 3 times the diameter of

electrode. In order to avoid deformation, welding in sections and

intermittent welding are preferred for long welding seam.

5. 补焊过程中，若发现裂纹、未熔合、夹渣、气孔等影响质量的缺陷时，

应报告现场监督验船师，得到现场监督验船师许可后再采取措施清除缺陷。

在确认缺陷已经被 清除后，并且在验船师认可后才能继续补焊。

During welding, if cracks, lack of fusion, slag inclusion, air holes

were found, welder should report the attending surveyor about this
immediately. taking measures to remove defects after getting

permission from the surveyor. investigating the cause and getting

permission from the surveyor before going on welding.

6. 铸钢件表面堆焊时，焊道间的重叠量不得小于焊道宽度的三分之一。

When build-up welding on the surface of casting in needed, overlap

between welding runs should be no less than one third of the width

of a welding run.

7. 补焊时，除第一层和最后一层外，其余各层的每一焊道，都应用平圆头

风铲适度锤击。

During repair welding, every welding run on every welding layer

should be suitably hammered by pneumatic chipping hammer excluding

the first and the last layer.

五．焊后热处理：

Post-welding heat treatment

1. 补焊后应进行回火保温以消除应力。

Heat treatment for stress relieving should be performed after repair

welding.

2. 有必要时可以在补焊到坡口深度的三分之一到二分之一处进行一次中

间消除应力热处理，消除应力热处理后继续焊满坡口，最后再做一次消除

应力热处理。

If necessary, an intermediate stress-relieving heat treatment can

be performed when welding for one third or half of the groove height

has been finished, then go on welding until all welding work has
 been finished, at last, another stress-relieving heat treatment

should be performed.

六．检验：

Examination

1. 检验人员应按本工艺规定，对补焊区域缺陷的清理、坡口的开制情况

以及焊条的烘干情况进行检查。经检验合格后，才能补焊。

Inspector should inspect the removing of defects and grooving for

welding and the baking for electrodes in accordance with this

specification, repair welding can only be carried out after finding

the inspection result is ok.

2. 检验应该在现场验船师在场情况下进行。

Inspection should be carried out in the presence of surveyor.

3. 要制作必要的补焊记录。认真记录层间温度及焊接电流等数据，以便现

场验船师的验收。

Essential records should be documented. Parameters such as

interlayer temperatures and electric current should be recorded so

as to be easily accessible to surveyor’s verification.

泰州市万里船舶机械制造有限公司

Taizhou City Wanli Ship Machinery Manufacturing Co.,Ltd