南沙大桥索鞍焊接及热处理工艺实践与探讨

Practice and Discussion on Welding and Heat Treatment Process of Cable Saddle of Nansha Bridge

摘要: 索鞍是悬索桥的重要受力构件，超大型索鞍尺寸及重量大，结构复杂，索鞍鞍头为铸钢件，底座部位为钢板组件，铸钢件与钢板对接焊缝采用一级焊缝，索鞍焊接、焊缝检测、热处理工艺复杂，针对南沙大桥索鞍焊接需要预热、人工焊接质量不稳定的难点，首次在索鞍焊接中采用机器人厚板焊接工艺技术，针对铸钢与钢板焊缝采用铸钢超声波标准探伤要求较低的问题，首次采用了焊缝探伤标准进行检测，对索鞍焊接应力大，效应效果不好特点，首次采用了计算机模拟热处理工艺分析，保证了充分去除内应力，保证了索鞍质量，使该项目索鞍总体制造水平达到了国内领先水平。

Abstract: The cable saddle is an important stress component of a suspension bridge. The oversized cable saddle is large in size and weight, and has a complicated structure. The saddle head of the cable saddle is made of steel, and the base part is made of steel components. Welding seam, cable saddle welding, welding seam detection, and heat treatment processes are complex. For the difficult points of Nansha Bridge cable saddle welding that require preheating and unstable manual welding quality, robot thick plate welding process technology is used for cable saddle welding for the first time, and for casting steel welding with steel plates using cast steel ultrasonic standard flaw de-tection requirements is low. For the first time, weld flaw detection standards are used for testing. The saddle has a large welding stress and has a poor effect. For the first time, a computer simulation heat treatment process analysis is used to ensure sufficient performance. The internal stress is removed to ensure the quality of the cable saddle, and the overall manufacturing level of the cable saddle for this project has reached the domestic leading level.