FAZELE CONTROLULUI MBINARILOR SUDATE PHASES CONTROL OF WELDED JOINTS

Ploscaru Ctlin, Popescu Rodica Mariana, Marmandiu Alexandra, Moneag Mihaela UNIVERSITATEA TRANSILVANIA DIN BRAOV TRANSILVANIA UNIVERSITY OF BRASOV
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Rezumat: Controlul calitii este o operaie independent de operaia de execuie, prin care, pe de o parte, se verific dac baza tehnicomaterial (materie prim, utilajele i mainile, standurile de prob etc.) au caracteristicile calitative i precizia prevzute n documentatie, iar pe de alta parte, verific ncadrarea caracteristicilor de calitate ale reperelor, subansamblelor i produselor finite n limitele prevzute de documentaie. Cuvinte cheie: Controlul calitii, mbinri sudate

Abstract: Quality control is an independent execution operation through on one hand technical and material base is checked (raw materials, equipment and machines, test stands etc.) accordingly to the quality features and accuracy from specification files and on the other hand is checking the link between parts quality features, subassemblies and final products within limits from specification files. Key words: Quality control, welding joints

1. Stadiul actual al cercetrilor n domeniu

n functie de metoda aplicat, controlul poate fi: activ sau pasiv; dinamic sau static; preventiv, economic. A. Inspecia

1. The present state of research in domain

Accordingly to the method the control can be: active or passive; dynamic or static; preventive, economical. A. Inspection inspection is also a control operation but with a larger covering area. it follows whether the chosen control method is correct, is control operation has been conducted in a proper manner, if the inspector decision was followed, if the machine or equipment has been shut down due to its instability. Moreover, the inspection can be extended on technical files as well, searching if raw materials have been correctly selected, if the allowance rate is within limits, if fabrication preparation process will enforce the achievement of homologated prototype as prescribed, if necessary modification has been done as a result of spotted deficiencies during fabrication process, final tests or during operation etc. As a modern conception, quality control part
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Inspecia este tot o operaie de control ns cu o sfer de aciune mai larg. Ea urmrete dac metoda de control aleas este corect, dac operatia de control a fost efectuat n mod corespunztor, dac decizia controlorului a fost respectat, dac maina, utilajul sau procesul de fabricaie au fost oprite n cazul instabilitii acestora etc. n plus inspecia se extinde i asupra documentaiei, verificnd dac materiile prime i materialele au fost bine alese, daca toleranele au fost corect stabilite, dac pregatirea fabricaiei asigur realizarea produselor la nivelul prototipului omologat, dac au fost aduse modificrile constructivtehnologice necesare, ca urmare a deficienelor depistate n procesul de fabricaie, la probele finale sau n exploatare etc. n concepia modern, rolul controlului calitii este de a aciona i interveni operativ

oriunde i de ori cte ori este nevoie pentru ca produsul final s corespund condiiilor cerute i astfel s se obin o continu reducere a rebuturilor i eliminarea acestora. Cu alte cuvinte, n conceptia modern, controlul calitiii se atribuie un rol activ i creator i nu numai de depistare i sortare a rebuturilor. Aciunea controlului calitii ncepe din momentul alegerii procesului de productie, continu cu instalarea echipamentului de producie sau cu pregatirea acestuia pentru realizarea optim a fluxului de fabricaie, cu calificarea forei de munc folosit i cu achiziionarea de materii prime i materiale corespunztoare. Acest control se desfoar pe tot parcursul fabricaiei i al expedierii produselor i se ncheie cu asistena tehnic (service) acordat de ntreprinderea respectiv n perioada de garanie. Datorita progresului tehnic ca i exigenei sporite exist tendina ca perioada de garanie a produselor s creasc. Concepia care st la baza acestui principiu const n analizarea cheltuielilor totale necesare pentru utilizarea produselor cu o durata de exploatare mai lung. n concluzie, controlul calitii trebuie s fie prezent n toate etapele premergtoare desfurrii de fabricaie, n timpul acestuia, pentru controlul produsului finit i livrarea lui. Ulterior prin asistena tehnic (service-ul asigurat) se acord beneficiarilor iar n cazul instalaiilor complexe continund n timpul montajului i n perioada efecturii probelor tehnologice. Acest control poart denumirea de control total al calitii. [1] B. Controlul total al calitii Controlul total al calitii are la baz urmtoarele principii: Calitatea trebuie condus i coordonat de ctre un organ specializat, ncepnd de la proiectare i pn la service; Activitate de control s se desfoare concomitent pe trei planuri: Participarea activ la fazele de pregtire a fabricaiei, alegerea i promovarea mainilor i instalaiilor tehnologice, dotarea cu scule, dispozitive i verificatoare, aparate de msura i control, instruirea personalului asupra cerinelor calitative; Verificarea realizrii calitii produselor ncepnd de la recepia materiilor prime i a materialelor aprovizionate, n timpul fluxului de fabricaie pn la produsul finit i controlul ambalrii i expedierii;
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is to act and intervene decisively any time as long as required in order to have a final product in compliance with technical files and to eliminate, if possible any waste. With other words, in a modern conception, quality control has an active and creative part and not only to find and sort scrap. Quality control action begins with the production process selection, and then follows with production equipment installation or preparation in order to realize fabrication program, labor qualification, purchasing raw materials and appropiate. Quality control is present on the entire fabrication program, during shipping and it ends with technical assistance (service) provided by the manufacturer during warranty period. Due to the technological process and increased demanding from the customers the trend is to extend warranty period. Basic idea of this concept consists in analyzing overall expenses in order to use the products a longer period of time. As a conclusion, quality control has to be present during all stages of pre-fabrication, during fabrication, final check and delivering. Next, through technical assistance department (service) final user (the customer) has a permanent support and even more for complex installation is provided during assembly as well during final technological tests. This type of control is named total quality control. [1] B. Total quality control

Total quality control is based on next principles: Quality has to be managed and coordinated by a specialized unit starting from design until service; Control activity has to be focused on three directions: Active participation during fabrication preparing process, machines and technological installations selection, tools, devices and testers, instrumentation, training the personnel; Quality checks starting from raw material reception and supplied inventory, during fabrication process until final product packaging and shipping; Following product operation behavior, reliability and maintenance. Based on the phase, the control can be:

 Urmrirea comportrii n exploatare a produsului, probe de fiabilitate i mentenan. n funcie de faza la care se efectueaz, controlul poate fi: Control de recepie: la faza de recepionare a materialelor i materiei prime; Control de fabricaie: la faza de fabricaie propriu-zis; Control final: pentru produsul finit. n functie de locul de execuie, controlul de calitate este: Centralizat (n puncte fixe); n flux, adica n diferite puncte ale procesului de fabricaie; Volant, la diferite locuri de munc, dup necesiti.[2]

Acceptance control at raw materials receiving; Fabrication control: during fabrication time; Final control: for final product. Based on the execution place quality control can be: Centralized (fixed points); During fabrication process in different stages; Random control at different working places.[2]

Fazele sudate

controlului

mbinrilor

Phases control of welded joints

Welded joints execution process is far more superior to other joining types because all technological operations are no longer required. [3] Welding joints are expanding their area of utilization such as: Chemical installations: seal joints for pressurized tanks, containers, and gas meters. Resistance construction: bridges, metallic structures as well construction frames; Machine construction: cars, tools and equipments, ships, aircrafts etc. In a lot of domains welded joint is the only solution but in order to be functional it has to be correctly executed with an appropriate quality. Therefore an appropriate control in order to detect and avoid welding flaws is a necessity. All welding joints with defects can cause damages, accidents and faulty installation operating.

Procesul de execuie al mbinrilor sudate este superior fa de cel al altor tipuri de mbinri deoarece se elimin toate celelalte operatii tehnologice pregtitoare necesare altor tipuri de imbinri. [3] Imbinrile prin sudura ocupa un loc tot mai mare n diferite domenii tehnice cum ar fi: La utilajele chimice -imbinri de etaneitate pentru cazane de presiune, recipiente, gazometre; La construciile de rezisten -poduri, schelete metalice, schelete pentru cldiri; La construciile de maini -automobile, maini-unelte, nave, avioane etc. n multe domenii, mbinarea prin sudare este soluia cea mai potrivit, ajungnd chiar o soluie de nenlocuit, dar, pentru a-i atinge scopul funcional, trebuie s fie realizat corect i de o calitate corespunztoare. De aceea, apare necesitatea organizrii unui control corespunztor pentru evitarea i depistarea defectelor de sudare. Toate sudurile necorespunztoare ce prezint defecte pot provoca pagube, accidente ireparabile i o funcionare defectuoas a instalaiilor. A. Controlul pieselor supuse sudrii

A.

Control of the parts to be welded

Se verific dac marginile pieselor ce urmeaz a se suda sunt curate de impuriti (zgur, vopsea, ulei, umezeal, etc); Se verific dac marginile de mbinare au fost prelucrate la cotele indicate n documentaia tehnic. Distanele dintre elementele ce se vor mbina (rostul de sudura) se iau din fiele tehnologice sau din desenul de execuie al ansamblului sudat.

To be checked if edges to be welded are clean free of slag, paint, oil, moist etc. To be checked if welding edges have been machined to the dimensions from technical files. The distances between elements are taken from technological specifications or from the blue print. 39

B. Controlul calitii materialelor folosite Se verific dac sunt respectate indicaiile date n desenul de execuie (asupra folosirilor electrozilor, procedeul de sudare utilizat etc.). C. Controlul efectuat n timpul executrii sudrii Se verific dac este respectat regimul de sudare (tensiunea, viteza de naintare, calitatea compoziiei elementelor utilizate); Se controleaz dac zgura este nlturat pentru a se putea efectua un control vizual, lundu-se msuri necesare dac se constat apariia unui defect exterior. D. Controlul mbinrilor sudate

B.

Quality control of utilized materials

To be checked if indications from blue print are followed (electrodes, welding procedure). C. Quality control during welding procedure To be checked if edges welding regime is accordingly to the specifications (voltage, advance speed, elements quality composition). Slag has to be removed in order to perform a visual check for external defects.

D.

Welded joints quality control

Dup terminarea operaiei de sudare se efectueaz controlul propriu-zis al mbinrii sudate care poate fi: control exterior prin observare sau prin ncercri distructive sau nedistructive, cu raze X sau . E. Calitatea custurii

After welding procedure a proper control is conducted such as an external observation one or using destructive or non destructive procedures with X rays or rays. E. Welded seam quality

Este determinat de: -compoziia chimic a metalului depus; -structura, procentul de incluziuni nemetalice; -defecte macrostructurale; -defecte datorate crpturilor. F. Compoziia chimic

Is determined by: -Chemical structure of deposited material; -Structure and percentage of metallic inclusions; -Macro structural defects; -Crack defects. F. Chemical composition

Compoziia chimic a custurii depinde de: - raportul dintre cantitile din metalul de baz i cel de adaos din custur; - arderea elementelor aflate n metalul de baz i n cel de adaos; - capacitatea de nglobare (absorbie) a oxigenului i azotului din aer, din flux. Elementele componente ale custurii se determin prin analiza chimic a probelor ce vor fi luate din aschii metalice extrase special n acest scop. Prin controlul nedistructiv pot fi depistate defecte macrostucturale ale materialului depus, ca: incluziuni de zgur i oxizi, pori, crpturi. Defectele macrostructurale influeneaz direct rezistena custurii i celelalte condiii impuse ei. Defectele interne: porii gazoi, incluziuni
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Chemical composition depends on: -Ratio between base metal and filler metal within the seam; -Burned elements from base metal and filler metal; -Absorption capacity of O2 and N from the air and from flux; Welded seam components are determined by using chemical analysis of test samples from metal chips collected for this reason; By using non destructive procedure can be revealed macro structural defects such as: slag and oxides inclusions, pores, cracks. Macro structural defects are directly responsible for seam resistance and other related aspects.

de zgur, crpturi, lips de penetraie, se determin fr distrugerea custurii, folosind metode radioscopice cu raze X si sau metoda magnetic i ultrasonic. Ali factori care influeneaz calitatea mbinrilor sudate sunt: - mrimea; - caracterul i repartiia tensiunilor interne n custur.
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Internal defects such as: gaseous pores, slag inclusions are determined without damaging the seam by using X rays, rays or magnetic and ultrasonic methods. Other influencing factors are: - Size; - Type of internal tensions within welded seam.
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Concluzii

Conclusions

Controlul total al calitii are o caracteristic modern prin faptul c folosind un numar mic de personal ct mai mic posibil s se obin o conducere a procesului de producie care s garanteze o calitate superioar a produselor. n concluzie, controlul de calitate este un control de conformitate.
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Total quality control has a modern characteristic by using a limited number of personnel in order to manage the production process which is the guarantee of a high quality product. As a final conclusion, quality control is a conformity control.
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Bibliografie

References
[1] xxx SR ISO 9002 Sistemele calitatii-model pentru asigurarea calitatii in productie, instalare si servicii asociate [2] xxx SR ISO 9003 Sistemele calitatii-model pentru asigurarea calitatii in inspectie si cercetari finale [3] xxx Constructii sudate in aeronautica, Editura Tehnica, 1986

[1] xxx SR ISO 9002 Sistemele calitii-model pentru asigurarea caliii n productie, instalare i servicii asociate [2] xxx SR ISO 9003 Sistemele calitii-model pentru asigurarea calitii n inspecie i cercetri finale [3] xxx Construcii sudate n aeronautic, Editura Tehnic, 1986

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