05-焊接材料控制程序

W e l d i n g M a t e r i a l C o n t r o l P r o c e d u r e 焊接材料控制程序
1、General
总则
1.1 This procedure is applied to control of welding material such as covered electrode, welding wire
and flux used for fabrication in accordance with the ASME Code.
此程序对用于制造ASME产品时所用到的焊接材料（如用于ASME规范产品制造的药皮焊条、焊丝和焊剂等）的管理作出规定。

1.2 This procedure shall be used in conjunction with Section 4 of the Manual.
此程序与质控手册第4章结合使用。

2、Receiving of Welding Material
焊接材料的接收
2.1 The Welding Material Warehouse Keeper shall obtain the welding material from the Welding
Material Warehouse according to the “Welding Material Summary” (JSSN Form A7-04 of Manual) which specifies the brand, size and quantity of the welding material to be used for the Code Item.
焊材管理员应按照“焊接材料汇总表”（质量控制手册样表A7-04）从焊材库领取焊材，此表中规定了运用于规范产品焊材的牌号，尺寸及数量。

2.2 The quantity actually to be received in one issuance shall not be greater than that consumed for
six days as usual.
一次发放、接收的实际数量不应大于一般情况六天的消耗量。

2.3 When receiving the welding material, the Welding Material Warehouse Keeper shall make an
open-pack inspection to verify that the contents meet the “Welding Material Summary” and that the markings located at rod end are correct and legible.
焊材管理员应在接收时做开包检验，以确认包装内实物符合“焊接材料汇总表”，焊条末端
的标记正确清楚。

2.4 The material received shall be free from damping, rusting, covering stripping or other damage
which shall adversely affect the welding quality. If any of these is present, it shall be returned to the Welding Material Warehouse (Level Ⅰ).
接收的焊材不应有影响焊材质量的潮湿、锈蚀、覆盖层脱落及其它损坏现象，若出现上述任何现象，应将其返回至焊材一级库。

2.5 After the disposition to the nonconformity is determined, shall implement the disposal according
to paragraph 6.4 of the Manual.
不一致品的处理措施确定后，应按质控手册6.4实施。

3、Drying and Holding
烘干和保持
3.1 The received covered electrode and flux shall be dried upon the arrangement of production.
所接收的药皮焊条与焊剂应根据生产计划烘干。

3.2 The covered electrode shall be stowed in the drying oven, lying apart from each other according
to the brand, size, lot and drying number. The intermixing pack is not permissible.
药皮焊条应依据商标、尺寸、批号及烘干编号相互隔离平放装填在烘箱中。

不允许混合装箱。

3.3 The stacking of the covered electrodes shall be carefully arranged by layers, neatly, closely, side
by side. A stack of up to three layers is recommended in order that the heating shall be uniform and the moisture be easily exhausted.
药皮焊条应一层层整齐、紧密、并排小心堆放。

建议三层为一堆，以便均匀加热及平缓排除潮气。

3.4 The covered electrode and flux which will be used in the shop shall be dried in accordance with
the manuf acturer’s specifications, if no requirement of the covered electrode and flux specifications, shall be dried in accordance with the Table 1/ Table 2:
运用到制造过程中的药皮焊条与焊剂应按照制造厂规定进行烘干, 如制造厂未做规定，应
该按表1/表2的要求烘干：
Table 1: ASME Welding Material (U.S. Customary Units)
表1 ASME焊接材料（英制）
Table 2: Welding Material Standard of China (SI Units)
表2 中国焊接材料标准（公制）
3.4.1 It is prohibited to put the covered electrode into an intense hot drying oven or take it out from the
oven all at once. So doing is to prevent the covering from breaking or stripping from thermal shock.
禁止将药皮焊条放入剧热的烘箱中，或立即从烘箱中取出，以防止药皮破裂或因骤
热引起的脱落。

3.4.2 The dried covered electrode shall be kept in the holding oven according to the brand, size, lot and
dried numbers. Intermixing shall not be permitted
烘干后的药皮焊条应按照牌号、尺寸、批号及烘干编号保存在保持一定温度的烘箱中。

不允许混合保存。

3.4.3 The drying temperature, drying time, and holding temperature shall be according to the
manufacturer’s specifications.If there is not the manufacturer’s specifications ,it shall be controlled within the ranges indicated in Table 1/ Table 2 .
烘箱的烘干温度、时间和保持温度应按制造厂规定，如果制造厂没有规定，则按表1/表2规定的范围控制。

3.5 The undried covered electrodes and fluxes shall be piled on the shelves based upon the brand,
size, lot in a room in which the temperature shall be kept at or above 5℃ and the maximum relative humidity shall be 60%.
未烘干的药皮焊条和焊剂应根据牌号、尺寸及批号堆放在室内架子上，此室的温度不低于5℃，最大相对湿度为60%。

3.6 The filler wires rewound into the spool shall be cleaned with acetone or in other suitable ways. The spools shall be attached with
a tag on which the brand, specification and classification designation, lot and size of the rewound electrode shall be stated.
重绕到卷轴上的充填金属丝应用丙酮或其它方法清洗干净。

卷轴应附上标签，标签上应注明牌号、规格、级别、批号及重绕焊丝的尺寸。

4、Issuance and Return 发放及返回
4.1 The Welders and Welding Operators shall receive the welding material from the Welding Material
Warehouse Keeper according to welding practice, fill out and sign on the “Welding Material Request” (JSSN Form A7-05 of Manual) in duplicate.
生产施焊需要，焊工和焊接操作工向焊材管理员领取规定的焊接材料。

并填写“焊材领用单”
（质量控制手册样表A7-05）一式两份。

“焊材领用单”上的签字手续必须完整。

4.2 Prior to the issuance of welding material, the Inspector shall check the welding material required
in the “Welding Material Request” to verify that the welding material conforms to the corresponding WPS.
焊接材料发放前，检验员首先检查“焊材领用单”所需要的焊接材料，以确认其符合相应的焊接工艺规程（WPS）。

4.3 The Welding Material Warehouse Keeper shall distribute the welding material to the Welder and
Welding O perator according to the “Welding Material Request” which shall include the technical specification number, classification number, nameplate, dimension, and the required quantity of the welding material. One of the “Welding Material Request” shall return to the Welder or Welding Operator.
焊材管理员应根据“焊材领用单”将焊材发放给焊工或焊接操作工，此领用单上应标有焊材技术条件号、分类号、牌号、尺寸及所需的数量。

并将其中一份“焊材领用单”还回给焊工或焊接操作工。

4.4 The Welder and Welding Operator is forbidden to enter the Welding Material Warehouse and
fetch welding material on his own.
焊工和焊接操作工不准擅自进入焊材库内，不得私自领取焊接材料。

4.5 The re-dried covered electrodes and fluxes shall be issued preferentially. The amount supplied
one time shall be a less than 3kg for covered electrodes. The amount of the flux issued should be determined according to the production practice. The Welder shall receive the covered electrodes with a portable quiver from the Welding Material Warehouse.
重新烘干的焊条和焊丝应优先分发。

药皮焊条一次发放的数量不应超过3公斤，焊剂每次领发的数量根据生产需要而定。

焊工应携带便携式保温筒到焊材库领用药皮焊条。

4.6 The low hydrogen covered electrodes shall be stored in the quiver for convenient use. The
maximum valid using period of the low hydrogen covered electrodes in the quiver shall be 4 hours.
低氢焊条必须存放在“保温筒”内随取随用，在“保温筒”内不得超过4小时。

4.7 After each shift or any time the welding is completed, the Welder or the Welding Operator shall
return the remaining welding material and the “Welding Material Request” to the Welding Material Warehouse (Except the flux for continuous use).
每天下班前或班中施焊完成后，焊工、焊接操作工应将剩余的焊材和其保管的“焊材领用单”
返回到焊材库。

对连续使用的焊剂例外。

4.8 The Welding Material Warehouse Keeper shall retrieve the “Welding Material Request” and fill
in the returned quantity form, then place the returned welding material in the designated area for identifying the returned times (for covered electrodes).
焊材管理员应收回“焊材领用单”，并填写返回的数量，然后将返回的焊接材料放置到指定区域，以便标识返回次数（对药皮焊条而言）。

4.9 The returned covered electrode shall be re-dried within the total accumulating drying time less
than 6 hours or three times for re-use unless otherwise specified. After re-dried, the reused flux shall be mixed with new flux, and the weight of new flux shall be two or more times than that of the reused flux.
返回药皮焊条的再次使用时，除非另有规定，累计烘干时间应不超过6小时或烘干次数不超过三次。

焊剂重新烘干后，再次使用的焊剂应混合到新使用的焊剂中，且新焊剂的重量应是再次使用焊剂重量的两倍或两倍以上。

4.10 For special wire wound to the spool of the welding machine used for specific welding, if the
spool has been indentified according to 3.6, they can be retained in the working area for further use by the Welding Operator. The Workshop Manager is responsible to control the welding material in the working area.
对于用于特定焊接机器的绕到卷轴上的焊丝，若卷轴已按3.6的要求识别，可由焊接操作
工保留在工作区域以便继续使用。

车间主任应负责适当控制工作区域的焊材。

4.11 The Welding Material Warehouse Keeper shall be responsible for the recording of receiving,
drying, issuance and correcting of the welding material.
焊材库管理员应负责焊材的接收、烘干、发放及更正记录。