Metallni payvandlash

Payvandlash - bu asosiy metallni eritadigan ishlab chiqarish jarayoni, shu bilan birga eritilgan material hovuzini hosil qilish uchun birikmaga plomba qo'shiladi, u termoyadroviy hosil qilish uchun soviydi. Payvandlash asosiy metallni eritmaydigan past haroratli metall-birlashma va lehimlash kabilardan juda farq qiladi.

Payvandlash tartibi va payvandchi malakasi

The welding procedure specification (WPS) is a required document for all code welding, and it describes all of the parameters required to perform a correct welding operation. It covers great details of welding process or processes used, the base materials used, the joint design and geometry, gases and flow rates, welding position and relevant variables.  
Welder qualification indicates the WPS referenced during the qualification test, identifies the welder's name, and specifies qualified limits for the welder. In short, this qualification test demonstrates that the welder has the necessary skills to produce a satisfactory weld under the conditions specified in WPS. As a general rule, the test piece approves the welder not only for the conditions used in the test but also for all joints which are considered easier to weld.
WPS payvandlash operatsiyasi uchun qo'llanma sifatida to'liq ishlatilishidan oldin uni tasdiqlash uchun WPQR (payvandlash protsedurasining malakasi) talab qilinadi. Haqiqiy sinov parametrlari WPS ga rioya qilinishini ta'minlash uchun payvandlash vaqtida qayd etiladi. Umuman olganda, barcha qo'llab-quvvatlovchi hujjatlar, shu jumladan materialning texnik xususiyatlari, elektrod spetsifikatsiyalari va himoya gaz xususiyatlari. Zarur boʻlmagan barcha{0}}buzuvchi va buzuvchi sinovlar ham yozib olinadi. NDT testi odatda rentgen tekshiruvlarini, ultratovush tekshiruvlarini va magnit sinovlarini, buzg'unchi sinovlar esa tortishish va egilish sinovlarini o'z ichiga oladi.

Payvandlash tartibi standartlari

√  Welding procedure test (BS EN ISO 15614)
√  Tasdiqlangan payvandlash materiallari (BS EN ISO 15610)
√  Oldingi payvandlash tajribasi (BS EN ISO 15611)
√  Standart payvandlash jarayoni (BS EN ISO 15612)
√  Ishlab chiqarishdan oldingi{0}}payvandlash sinovi (BS EN ISO 15613)

Fabmann payvandlash tekshiruvlarini qanday amalga oshiradi?

Our welding engineers have over 15 years working experience in metal material and welding operation, and our quality team mostly use 100 percent visual inspection for each production batch, and we also use destructive test solution or NDT solution to verify welding quality based upon client's requirements. For all common welding defects, we have solid training cross the whole welding fabrication team and our QC team, so we can minimize the welding non-conformity to lowest level, and this practice also maximizes the possibility to have a sound metal surface treatment. Our visual inspection mainly focuses the following welding defects.

√  Porozlik
√  Kraterlar
√  Chaqmoqlar
√  Shlak
√  Yoriq
√  Pastki kesilgan
√  Yomon penetratsiya
√  Yonish-orqali
√  Lap ustidan
√  Buzilish; xato ko'rsatish
√  Tugallanmagan sintez
√  Arc Strike uzluksizligi
√  Haddan tashqari mustahkamlash
√  Pastki kesilgan mustahkamlash

What are The Common Welding Defects, and What's the Cause and How to Solve Them?

Based upon Fabmann's welding fabrication experience, we have identified around fourteen different welding defects, and most of them are quite easy to solve, and it does require extremely high welding skills and knowledge.

1. Porosity, often caused by contamination, whether it is from the surrounding air at the weld site or the surface of the base metal, and contamination of metal includes dirt, debris, dust, grease, and rust. Therefore, it's critical that the operator needs to clean the base metal before starting the welding process, and contamination in the base metal can contribute to excess porosity and cracking in the metal. The second reason is that striking arc is too long, and the remedy is that the operator performs a quick strike or vertical strike.

2. Yoriq, u tez sovutishdan ifloslanishgacha bo'lgan turli xil muammolardan kelib chiqqan issiq yorilish, sovuq yorilish, mikrofissura va krater yoriqlarini o'z ichiga oladi. Asosiy sabab shundaki, ichki kuchlanish payvand chokidan, asosiy metalldan yoki ikkalasidan ham oshib ketadi. Eng samarali retseptlar
√  Kirlarni olib tashlang.
√  Plitalarning chekkalarini bir-biriga moslash uchun cho'tka bilan tozalang.
√  Ish joyidagi harorat odatdagi xona haroratidan past bo'lsa, bo'g'inning ikkala tomonini oldindan qizdiring.
√  Plitalarni bir-biriga mahkamlang yoki yopishtiring yoki to'g'ri qo'shma dizayndan foydalaning.
√  Payvandlash boshlanishidan oldin kerakli issiqlik miqdori terilganligini tekshirish uchun mashina sozlamalarini sinab ko'ring.
√  Payvandlash joyini to'g'ri sovutish
√  Tegishli metalldan foydalaning
√  Use proper welding speed and amperage current 
√  Kirlarni olib tashlang.
√  Plitalarning chekkalarini bir-biriga moslash uchun cho'tka bilan tozalang.
√  Ish joyidagi harorat odatdagi xona haroratidan past bo'lsa, bo'g'inning ikkala tomonini oldindan qizdiring.
√  Plitalarni bir-biriga mahkamlang yoki yopishtiring yoki to'g'ri qo'shma dizayndan foydalaning.
√  Payvandlash boshlanishidan oldin kerakli issiqlik miqdori terilganligini tekshirish uchun mashina sozlamalarini sinab ko'ring.
√  Payvandlash joyini to'g'ri sovutish
√  Tegishli metalldan foydalaning
√  Use proper welding speed and amperage current 

3. Inclusions, it will occur when slag and oxides are trapped between the base metal and the weld, and it can lead to the weakening of the weld. The most effective way of preventing inclusion is keeping the base metal clean, and the cleaning main focuses on: 
√  Mill Scale
√  Rust
√  Corrosion
√  Preexisting slags from previous welds 

4. Undercutting, caused by failure to get good tie-in with both toes of a weld which the base metal meets the face of the weld. It occurs when the digging arc of the electrode leaves a pit in the base metal that will not be fully filled with the appropriate filler material. The risk factors are:
√  An arc is too long
√  Incorrect weld angle, which will mislead the heat
√  Welding speed is too fast or too slow
√  Welding with too much current 

Kesishning oldini olish uchun operator quyidagi jihatlarga e'tibor berishi kerak:

For the last two defects, the solution is to control the feeding of filler, and make sure that the deposition of filler is at a reasonable level, and of course, welding angle and amperage setting are fine tuned by the operator.  

20. Payvandlash jarayonini isitish va sovutish davrida payvandlash metallining va qo'shni asosiy metallning kengayishi va qisqarishi natijasida yuzaga keladigan buzilish. Uzunlamasına qisqarish, ko'ndalang siqilish, burchakli buzilish, egilish va egilish, burish va burish kabi buzilishlarning ko'p turlari mavjud. Payvandlashning buzilishining murakkab sabablari bor:
√  Asosiy materialning xususiyatlari
√  Cheklov miqdori
√  Qo'shma dizayn
√  Qism mos-
√  Payvandlash tartibi

Asosiy printsip sifatida, payvandlash hajmi minimal darajada saqlanishi kerak, shuningdek, payvandlash ketma-ketligi va texnikasi komponentning neytral o'qi atrofida termal induktsiyalarni muvozanatlashi kerak.

Payvandlash ishlab chiqarish xizmati

In average, our welders have over 15-year experience, Fabmann has the expertise and modern equipment including welding robots to handle variety of material types and thickness. Our welding department mainly handles welding work like argon arc welding, spot welding, carbon dioxide protection welding, stainless steel sheet welding, aluminium sheet welding manual arc welding, and our welding engineers will make WPS prior to the welding task, which will minimize welding defect and lower down total manufacturing cost. For high quality welding tasks, our welding engineers will perform WPQR to make sure all welding seams are qualified before metal surface treatment starts.  
Turli xil payvandlash talablari va hajmini engish uchun Fabmann payvandlash ishlab chiqarish vazifalari uchun to'rtta payvandlash echimini ishlab chiqdi.
√  Aylanadigan jig bilan robotli payvandlash, u bir oz murakkab payvandlash talablari bilan o'rta va katta hajmlarni bajara oladi. 
√  Full automation rotary welding machine for handling volume and full circular welding. 

Rotary jig bilan robotli payvandlash

Avtomatik aylanma payvandlash

Auto Rotation Welding for Post  Support

Qo'lda spotli payvandlash

Qo'lda payvandlash alyuminiy strukturasi

To reach 100 percent welding repeatability for high volume product like post qo'llab-quvvatlash, Fabmann uses full automation rotation welding solution, and our welding engineer will make welding strength test from each production batch. Circular welding generates precise welding effects with fixed horizontal positioned torch, and we can use this welding solution for cylindrical, rectangular, oval, triangular, and other complex forms.
Fabmann has developed interchanging fixture tools pneumatic clamping fixtures, thus we can ensure jigging time is within welding cycle. Meanwhile, we work closely with customers to design cost-effective weld fixtures to achieve precise alignment and maintain tight tolerances. 
Payvandlash eritmasi va protsedurasini har tomonlama tahlil qilib, Fabmann raqobatbardosh narxda yuqori sifatli payvandlarni doimiy ravishda amalga oshirishi mumkin.
Payvandlash uchun metall material
√  Steel, stainless steel, aluminum plates (max thickness 20mm)
√  Steel, stainless steel, aluminum tubes (max diameter 1200mm)
√  Steel, stainless steel, aluminum profile sections 
√  Steel, stainless steel, aluminum angles (max 8mm)√  Steel, stainless steel, aluminum bar (max diameter 30mm)

Fabmann has a professional welding team, and we also have various welding facilities like robots and automized welding jig for volume projects. We are supplying a wide range of metal structure products for various industries: 

√  Suvni tozalash
√  Infratuzilma
√  Oziq-ovqat mahsulotlarini qayta ishlash
√  Quyosh energiyasi
√  Uy va panjara qurilishi
√  Dock qurilishi
√  Suv yetishtirish
√  Telekommunikatsiya 

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