铁艺大门作为建筑装饰与安全防护的结合体，其焊接工艺直接影响结构强度与美学呈现。从材料预处理到成品检验，每个环节都需遵循严格的技术规范。

　　As a combination of architectural decoration and safety protection, the welding process of wrought iron gates directly affects the structural strength and aesthetic presentation. From material pretreatment to finished product inspection, strict technical specifications must be followed at every stage.

　　焊接材料匹配性是首要准则。母材需选用S235JR或Q235B等低碳结构钢，碳当量控制在0.4%以下，确保焊接热影响区韧性。焊材应与母材力学性能匹配，手工电弧焊推荐使用E43系列焊条，气体保护焊则选用ER50-6实心焊丝。对于装饰性铸件与型材的异种钢连接，需采用过渡层焊接工艺，通过预置镍基焊材解决碳迁移问题。

　　The compatibility of welding materials is the primary criterion. The base material should be low-carbon structural steel such as S235JR or Q235B, with a carbon equivalent controlled below 0.4% to ensure the toughness of the welding heat affected zone. The welding material should match the mechanical properties of the base material. E43 series welding rods are recommended for manual arc welding, while ER50-6 solid welding wire is used for gas shielded welding. For the dissimilar steel connection between decorative castings and profiles, a transition layer welding process is required to solve the carbon migration problem by pre setting nickel based welding materials.

　　坡口制备精度决定熔透质量。对于厚度超过6毫米的板材，需采用机械加工方式制备V型或X型坡口，坡口角度控制在60°±5°，钝边高度不超过2毫米。组装间隙应严格控制在1-3毫米范围内，通过专用夹具实现精准定位，避免强制装配导致的残余应力。

　　The accuracy of groove preparation determines the quality of fusion. For plates with a thickness exceeding 6 millimeters, V-shaped or X-shaped grooves need to be prepared by mechanical processing, with a groove angle controlled at 60 °± 5 ° and a blunt edge height not exceeding 2 millimeters. The assembly gap should be strictly controlled within the range of 1-3 millimeters, and precise positioning should be achieved through specialized fixtures to avoid residual stress caused by forced assembly.

　　焊接工艺参数需量化控制。手工电弧焊时，平焊位置电流控制在120-160A，电压22-24V，焊接速度15-20厘米/分钟。气体保护焊则采用短路过渡模式，电流180-220A，电压18-20V，送丝速度5-7米/分钟。多层多道焊时，层间温度需控制在150℃以下，采用红外测温仪实时监控，防止晶粒粗化。

　　Welding process parameters need to be quantitatively controlled. When performing manual arc welding, the current at the flat welding position should be controlled at 120-160A, the voltage should be 22-24V, and the welding speed should be 15-20 centimeters per minute. Gas shielded welding adopts a short-circuit transition mode, with a current of 180-220A, a voltage of 18-20V, and a wire feeding speed of 5-7 meters per minute. During multi-layer and multi pass welding, the interlayer temperature should be controlled below 150 ℃, and an infrared thermometer should be used for real-time monitoring to prevent grain coarsening.

　　变形控制贯穿整个工艺流程。采用对称施焊原则，对长度超过2米的构件实施分段退焊法，每段长度控制在300-500毫米。对于复杂结构，预先进行焊接变形数值模拟，通过弹性反变形工装抵消角变形。焊后立即进行机械矫正或火焰矫正，矫正温度不超过650℃，避免蓝脆现象。

　　Deformation control runs through the entire process flow. Adopting the principle of symmetrical welding, the segmented back welding method is implemented for components with a length exceeding 2 meters, with each segment length controlled between 300-500 millimeters. For complex structures, numerical simulation of welding deformation is carried out in advance, and angular deformation is offset by elastic anti deformation fixtures. Immediately perform mechanical or flame correction after welding, with a correction temperature not exceeding 650 ℃, to avoid blue brittleness.

　　质量检验体系包含多重关卡。外观检测执行ISO 5817 B级标准，焊缝余高控制在0-3毫米，咬边深度不超过0.5毫米。无损检测采用PT渗透检测与UT超声检测组合，对角焊缝实施100%磁粉探伤，确保裂纹、未熔合等缺陷检出率。力学性能试验需制作标准试样，抗拉强度不低于母材的90%，-20℃冲击功≥27J。

　　The quality inspection system includes multiple checkpoints. The appearance inspection shall comply with the ISO 5817 B-level standard, with the weld seam height controlled at 0-3 millimeters and the undercut depth not exceeding 0.5 millimeters. Non destructive testing adopts a combination of PT penetration testing and UT ultrasonic testing, and 100% magnetic particle inspection is carried out on diagonal welds to ensure the detection rate of defects such as cracks and incomplete fusion. Mechanical performance tests require the production of standard specimens with a tensile strength not less than 90% of the base material and an impact energy of ≥ 27J at -20 ℃.

　　特殊环境需专项处理。沿海区域产品需进行焊缝区域镀锌层修复，采用富锌底漆加氟碳面漆的防护体系，盐雾试验≥1000小时。对于装饰性镂空图案，需制定专项焊接顺序，通过跳焊法控制热输入，确保0.5毫米间距的铁艺花纹不变形。

　　Special environments require special treatment. Coastal products need to undergo galvanized layer repair in the weld area, using a protective system of zinc rich primer and fluorocarbon topcoat, with a salt spray test of ≥ 1000 hours. For decorative hollow patterns, a special welding sequence needs to be developed to control heat input through skip welding, ensuring that the iron patterns with a spacing of 0.5 millimeters do not deform.

　　铁艺大门焊接是材料科学、热力学与结构力学的综合应用。从焊前坡口处理到焊后应力消除，每个技术参数都需精确量化。通过建立工艺参数数据库与质量追溯系统，可实现焊接质量的稳定控制，使铁艺大门在承载安全功能的同时，完美呈现艺术造型的视觉张力。

　　Iron gate welding is a comprehensive application of materials science, thermodynamics, and structural mechanics. From pre weld groove treatment to post weld stress relief, each technical parameter needs to be accurately quantified. By establishing a process parameter database and quality traceability system, stable control of welding quality can be achieved, allowing the wrought iron gate to perfectly present the visual tension of artistic form while carrying safety functions.

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