Welding quality has always been the focus of welders. Today, the editor will collect some relevant information for everyone to learn together.
Overview
With the rapid development of modern welding technology, the continuous improvement of welding production level and the increasing expansion of international welding product trade, in order to ensure the quality of welding products, effectively utilize resources and protect the interests of users, the quality management of welding products has gradually embarked on the road of standardization and standardization. In March 1987, the International Organization for Standardization (ISO) officially released the ISO9000-9004 standard series on quality management and quality assurance. In 1994 and 2000, the International Organization for Standardization revised the ISO9000 family of standards twice to make it simpler, more focused, more scientific and universal, and raised the quality assurance system to the level of the quality management system. In 2000, my country issued the GB/T19000:2000 “Quality Management System” standard series, which is equivalent to the international standard series.
Modern quality management believes that in order to make the product meet the required quality indicators, it should start from every process of production and ensure it by controlling and adjusting the factors affecting the process quality. The process quality must be achieved through work quality and various management methods.
Therefore, in quality management work, work quality must be used to ensure process quality, and process quality must be used to ensure product quality.
It can be seen that in order to achieve quality goals, an effective and easy-to-operate quality management system must be established in the management system. And this system should be applied to the entire manufacturing process of the product.
Knowledge point 1: Factors affecting welding process quality and countermeasures
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Contents
1. People—–Welding operator factors 2. Machine—–Welding machine equipment factors 3. Materials—–Welding raw material factors 4. Methods—–Welding process method factors
5. Environment—–Environmental factors
Process quality refers to the degree of guarantee of product quality by the processing process during the production process. In other words, product quality is based on process quality, and excellent process processing quality must be achieved to produce excellent products.
The quality of the product is not only achieved after all processing and assembly work is completed, and a number of technical parameters are measured by full-time inspectors and approved by users, but it exists at the beginning of the processing process and runs through the entire production process.
Whether the final product is qualified or not depends on the cumulative result of all process errors. Therefore, the process is the basic link of the production process and the basic link of inspection.
The production of welded structures includes many processes, such as decontamination and rust removal of metal materials, straightening, marking, cutting, groove edge processing, forming during material preparation, assembly, welding, heat treatment of welded structures, etc. Each process has certain quality requirements and there are factors that affect its quality.
Since the quality of the process will ultimately determine the quality of the product, it is necessary to analyze the various factors that affect the quality of the process and take effective control measures to ensure the quality of the welded products.
The factors that affect the quality of the process can be summarized as: personnel, equipment, materials, process methods and production environment, referred to as “people, machines, materials, methods, and environment”. The degree of influence of each factor on the quality of different processes varies greatly, and should be analyzed according to specific circumstances.
Welding is an important process in the production of welded structures, and the factors that affect its quality are also the above five aspects.
1. People—–welding operator factors
Different welding methods have different degrees of dependence on operators.
For manual arc welding, the welder’s operating skills and cautious work attitude are crucial to ensuring welding quality.
For submerged arc automatic welding, the adjustment of welding process parameters and welding also require human operation.
For various semi-automatic welding, the movement of the arc along the welding joint is also controlled by the welder. If the welder has poor quality awareness during welding, is careless in operation, does not comply with the welding process regulations, or has low operating skills and unskilled technology, it will affect the quality of direct welding.
The control measures for welders are as follows:
(1) Strengthen the quality awareness education of welders on “quality first, user first, and the next process is the user”, improve their sense of responsibility and meticulous work style, and establish a quality responsibility system.
(2) Regularly conduct job training for welders, master the process regulations in theory, and improve the level of operating skills in practice.
(3) In production, welders are required to strictly implement the welding process regulations, strengthen the self-inspection of the welding process and the inspection of full-time inspection personnel.
(4) Seriously implement the welder examination system, insist on welders holding certificates, and establish welder technical files.
For the production of important or major welded structures, welders need to be considered in more detail. For example, the length of welder training, production experience, current technical status, age, length of service, physical strength, vision, attention, etc. should all be included in the scope of assessment.
2. Machine—Welding machine and equipment factors
The performance, stability and reliability of various welding equipment directly affect the welding quality. The more complex the equipment structure, the higher the degree of mechanization and automation, and the higher the dependence of welding quality on it.
Therefore, such equipment is required to have better performance and stability. Welding equipment must be inspected and tested before use, and a regular inspection system should be implemented for various in-service welding equipment.
In the welding quality assurance system, starting from ensuring the quality of the welding process, the following points should be achieved for welding machines and equipment:
(1) Regularly maintain, service and overhaul welding equipment, and test important welding structures before production.
(2) Regularly calibrate various instruments such as ammeters, voltmeters, gas flow meters, etc. on welding equipment to ensure accurate measurement during production.
(3) Establish technical files on the status of welding equipment to provide ideas for analyzing and solving problems.
(4) Establish a responsibility system for welding equipment users to ensure the timeliness and continuity of equipment maintenance.
In addition, the use conditions of welding equipment, such as the requirements for water, electricity, environment, etc., the adjustability of welding equipment, the space required for operation, error adjustment, etc. also need full attention to ensure the normal use of welding equipment.
Post time: Nov-25-2024
