Quality Control and Consistency Assurance in Rivet Welding Processing: Four Core Measures to Strengthen the Process Defense Line

Quality Control and Consistency Assurance in Rivet Welding Processing: Four Core Measures to Strengthen the Process Defense Line

The quality and consistency of rivet welding processing directly determine the safety and service life of heavy machinery components. A closed-loop management system, encompassing standardized processes, real-time control of key links, precise testing, and personnel management, is essential to avoid structural hazards caused by process deviations and ensure that every batch and every product meets quality requirements.

First, establish full-process standard specifications to define quality benchmarks. A complete set of standards covering materials, processes, and testing must be formulated: On the material side, specify the material standards and incoming inspection requirements for base metals (e.g., Q345 alloy steel), welding wires, and rivets. For instance, verify material certificates and conduct sampling tests for mechanical properties to prevent substandard materials from entering the workshop. On the process side, refine welding parameters (such as current 180-220A, voltage 22-26V), riveting pressure (set to 5-10MPa based on rivet specifications), and heat treatment temperature curves. Develop visual Standard Operating Procedures (SOPs) to ensure uniform implementation of standards by different operators. Meanwhile, clarify quality acceptance criteria—such as 100% qualification rate for weld flaw detection and no more than 0.1mm form and position tolerance of components after riveting—to provide clear basis for quality judgment.

Second, strengthen real-time control of key links to reduce process deviations. In the welding process, replace manual operation with automated equipment (e.g., robotic welding). Precisely control welding speed and path through programs to avoid defects like uneven weld width and undercut caused by manual operation. In the riveting process, use numerical control riveting machines to automatically calibrate rivet position and pressing force, ensuring consistent tightness of each riveting point (e.g., pull-out force ≥50kN for all points). For welding processes sensitive to temperature and humidity, install a constant temperature and humidity system in the workshop (temperature 20-25℃, humidity 40%-60%) to prevent environmental factors from affecting weld formation quality. Additionally, real-time monitor processing parameters via the Manufacturing Execution System (MES). If deviations exceed limits (e.g., current fluctuation over ±10A), the system will immediately shut down and issue an alarm to correct deviations in a timely manner.

Third, apply multi-dimensional testing methods to achieve quality traceability. Conduct pre-inspection of welding wires and rivets before processing—for example, verify the composition of welding wires with a spectrometer and test the hardness of rivets with a hardness tester. During processing, use online testing equipment: monitor the temperature of the weld pool with an infrared thermal imager during welding, and check the perpendicularity of rivets with a laser diameter gauge after riveting. After processing, perform comprehensive final inspection: use Ultrasonic Testing (UT) and Magnetic Particle Testing (MT) to detect internal defects in welds, and conduct sampling tests on the connection strength of riveted parts with a tensile testing machine. Meanwhile, record the testing data of each product and generate a unique quality traceability code, facilitating root cause analysis if problems arise later.

Fourth, enhance personnel training and management to improve operational consistency. Provide pre-job training for operators, who can only take up their posts after passing assessments. The training content includes SOP interpretation, equipment operation, and emergency handling (e.g., weld defect repair procedures). Regularly organize skill competitions and process review meetings to share excellent operational experience and unify operating methods. Implement a "mentorship system" to reduce operational differences between new and experienced employees. Establish a quality responsibility system, linking product qualification rates to personal performance, to enhance operators' quality awareness and ensure operational consistency from the human factor perspective.

Through the above measures, rivet welding processing can transition from "manual control" to "standardized and intelligent control". This effectively avoids quality fluctuations caused by materials, processes, personnel, and other factors, ensuring that each heavy machinery component has stable structural performance and laying a solid foundation for the safe operation of subsequent equipment.