EUROPEAN STANDARD EN 15085-4

NORME EUROPÉENNE
EUROPAISCHE NORM October 2007

ICS 45.060.01:25.160.10

English V e r s i o n

Railway applications - Welding of railway vehicles and

components - Part 4: Production requirements

Applications ferroviaires - Soudage des véhicules et des Bahnanwendungen - Schweißen von Schienenfahrzeugen
composants ferroviaires - Partie 4: Exigences de und -fahrzeugteilen - Teil 4: Fertigungsanforderungen
production

This European Standard was approved by CEN on 18 August 2007.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the CEN Management Centre or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the
official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,
Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ E U R O P É E N DE NORMALISATION
E U R O P Ä I S C H E S KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2007 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 15085-4:2007: E
worldwide for CEN national Members.
EN 15085-4:2007 (E)

Contents Page

Foreword 3

Introduction 4

1 Scope 5

2 Normative references 5

3 Terms and definitions 6

4 Preparation before welding 6

4.1 Welding planning documents 6
4.2 Production weld tests 8

5 Requirements for welding 10

5.1 General 10
5.2 General requirements 10
5.3 Welding consumables 13
5.4 Parent metals 14
5.5 Welding processes 15

6 Special requirements for maintenance welding of railway vehicles 16

6.1 General rules for maintenance welding 16
6.2 Testing and documentation 16

Bibliography 17

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 E N 15085-4:2007 (E)

Foreword
This d o c u m e n t ( E N 15085-4:2007) has b e e n prepared b y T e c h n i c a l C o m m i t t e e C E N / T C 256 "Railway
applications", the secretariat of which is held by DIN.

This E u r o p e a n S t a n d a r d shall be given the status of a national s t a n d a r d , either by publication of an identical

text or by e n d o r s e m e n t , at the latest by April 2 0 0 8 , and conflicting national s t a n d a r d s shall be withdrawn at the
latest by April 2 0 0 8 .

This series of E u r o p e a n S t a n d a r d s EN 1 5 0 8 5 " R a i l w a y applications - W e l d i n g of railway vehicles and

c o m p o n e n t s " c o n s i s t s of the following parts:

— Part 1 : G e n e r a l

— Part 2: Quality requirements and certification of welding manufacturer

— Part 3: D e s i g n requirements

— Part 4: Production requirements

— Part 5: Inspection, testing a n d documentation

Attention is drawn to the possibility that s o m e of the elements of this d o c u m e n t m a y be the subject of patent
rights. C E N [and/or C E N E L E C ] shall not be held responsible for identifying a n y or all s u c h patent rights.

A c c o r d i n g to the C E N / C E N E L E C Internal Regulations, the national s t a n d a r d s organizations of the following

countries are bound to implement this E u r o p e a n S t a n d a r d : A u s t r i a , B e l g i u m , Bulgaria, C y p r u s , C z e c h
Republic, D e n m a r k , E s t o n i a , Finland, F r a n c e , G e r m a n y , G r e e c e , Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, L u x e m b o u r g , M a l t a , Netherlands, Norway, P o l a n d , Portugal, R o m a n i a , S l o v a k i a , S l o v e n i a , S p a i n ,
S w e d e n , Switzerland a n d the United K i n g d o m .

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EN 15085-4:2007 (E)

Introduction

Welding is a s p e c i a l p r o c e s s in the manufacture of railway v e h i c l e s a n d their parts. T h e required provisions for

this p r o c e s s are laid d o w n in the standards s e r i e s EN I S O 3 8 3 4 . T h e b a s i s of t h e s e provisions a r e the b a s i c
technical welding standards in respect of the s p e c i a l requirements for the construction of railway v e h i c l e s .

This standard is a i m e d at defining the terms of enforcement applicable to E u r o p e a n S t a n d a r d s , it s h o u l d not

be construed as a substitute to t h e s e s t a n d a r d s .

This standard can also be u s e d by internal a n d external parties, including certification b o d i e s , to a s s e s s the
organisation's ability to meet customer, regulatory and the organisation's o w n requirements.

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 EN 15085-4:2007 (E)

1 Scope

This series of standards a p p l i e s to welding of metallic materials in the manufacture and maintenance of
railway vehicles a n d their parts.

This part of the s e r i e s d e s c r i b e s the production requirements (i.e. preparation a n d execution) of the welding
work.

2 Normative references

T h e following referenced d o c u m e n t s are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated r e f e r e n c e s , the latest edition of the referenced
document (including a n y a m e n d m e n t s ) applies.

EN 2 8 7 - 1 , Qualification test of welders - Fusion welding - Part 1: Steels

EN 1011 (all parts), Welding - Recommendations for welding of metallic materials

EN 10204:2004, Metallic products - Types of inspection documents

EN 13479, Welding consumables - General product standard for filler metals and fluxes for fusion welding of
metallic materials

EN 1 5 0 8 5 - 1 : 2 0 0 7 , Railway applications - Welding of railway vehicles and components - Part 1: General

EN 15085-3:2007, Railway applications - Welding of railway vehicles and components - Part 3: Design
requirements

EN ISO 544, Welding consumables - Technical delivery conditions for welding filler materials - Type of product,
dimensions, tolerances and markings (ISO 544:2003)

EN I S O 4 0 6 3 : 2 0 0 0 , Welding and allied processes - Nomenclature of processes and reference numbers (ISO
4063:1998)

EN ISO 9 0 1 3 : 2 0 0 2 , Thermal cutting - Classification of thermal cuts - Geometrical product specification and
quality tolerances (ISO 9013:2002)

EN ISO 9 6 0 6 - 2 , Qualification test of welders - Fusion welding - Part 2: Aluminium and aluminium alloys (ISO
9606-2:2004)

EN ISO 9 6 0 6 - 3 , Approval testing of welders - Fusion welding - Part 3: Copper and copper alloys (ISO 9606-
3:1999)

EN ISO 9 6 0 6 - 4 , Approval testing of welders - Fusion welding - Part 4: Nickel and nickel alloys (ISO 9606-
4:1999)

EN I S O 9 6 0 6 - 5 , Approval testing of welders - Fusion welding - Part 5: Titanium and titanium alloys, zirconium
and zirconium alloys (ISO 9606-5:2000)

EN ISO 1 4 5 5 5 , Welding - Arc stud welding of metallic materials (ISO 14555:2006)

C E N ISO/TR 15608:2005, Welding - Guidelines for a metallic materials grouping system (ISO/TR
15608:2005)

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EN 15085-4:2007 (E)

EN ISO 15609 (ail parts), Specification and qualification of welding procedures for metallic materials -
Welding procedure specification

EN ISO 15610 Specification and qualification of welding procedures for metallic materials - Qualification
based on tested welding consumables (ISO 15610:2003)

EN ISO 1 5 6 1 1 , Specification and qualification of welding procedures for metallic materials - Qualification
based on previous welding experience (ISO 15611:2003)

EN ISO 15612 Specification and qualification of welding procedures for metallic materials - Qualification by
adoption of a standard welding procedure (ISO 15612:2004)

EN ISO 1 5 6 1 3 , Specification and qualification of welding procedures for metallic materials - Qualification
based on pre-production welding test (ISO 15613:2004)

EN ISO 15614 (all p a r t s ) ) 1

Specification and qualification of welding procedures for metallic materials -
Welding procedure test

EN ISO 15620, Welding - Friction welding of metallic materials (ISO 15620:2000)

EN ISO 1 7 6 5 2 - 1 , Welding - Test for shop primers in relation to welding and allied processes - Part 1: General
requirements (ISO 17652-1:2003)

EN ISO 17652-2, Welding - Test for shop primers in relation to welding and allied processes - Part 2: Welding
properties of shop primers (ISO 17652-2:2003)

3 Terms and definitions

For the p u r p o s e s of this d o c u m e n t , the terms a n d definitions given in EN 1 5 0 8 5 - 1 : 2 0 0 7 apply.

4 Preparation before welding

4.1 Welding planning documents

4.1.1 General

Welding planning d o c u m e n t s shall be p r e p a r e d by the manufacturers with the a s s i s t a n c e of the recognised

welding coordinator L e v e l A for n e w a n d converted vehicles a n d m a i n t e n a n c e of rail v e h i c l e s (see EN 15085-
2). T y p e , s c o p e a n d time of the s u b m i s s i o n and inspection should be a g r e e d b e t w e e n c u s t o m e r and
manufacturer.

Welding planning d o c u m e n t s m a y include working plans, welding s e q u e n c e p l a n s , test planning d o c u m e n t s

and welding procedure specifications.

4.1.2 Working plans

For the production of railway v e h i c l e s it is n e c e s s a r y to have working plans for the following s u b - a s s e m b l i e s :

— bogie ( s u b - a s s e m b l i e s , a s s e m b l y ) ;

1) For railway applications, only EN IS015614-1, EN ISO 15614-2, prEN ISO 15614-3, EN IS015614-4,
EN ISO 15614-7, EN ISO 15614-11, EN ISO 15614-12 and EN ISO 15614-13 are relevant.

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 E N 15085-4:2007 (E)

— underframe (with s u b - a s s e m b l i e s ) ;

— body (side wall, e n d wall, roof);

— further s u b - a s s e m b l i e s with high safety a n d functional requirements (e.g. c a r d a n shafts, brake cross
m e m b e r s , motor h o u s i n g , hollow shaft drive, drawbar coupling, bogie pivot pin, c r o s s bearer).

4.1.3 Other welding planning documents

For more complicated a s s e m b l i e s welding s e q u e n c e plans are n e c e s s a r y , e . g . for:

— bogies (bogie bolster, bogie centre plate including bogie pivot pin m e m b e r , s o l e b a r , headstock, bogie
pivot pin c r o s s m e m b e r , traction bar coupling, a s s e m b l y of s o l e b a r and c r o s s m e m b e r ) ;

— underframe (including c r o s s m e m b e r , solebar, headstock, bogie pivot pin c r o s s m e m b e r , traction bar

coupling).

Standardised welding s e q u e n c e plans (that applies for different types of vehicles) are a l s o allowed.

Furthermore, other welding planning d o c u m e n t s m a y be n e c e s s a r y (e.g. tacking s e q u e n c e plans, repairing

plans, test p l a n s , d o c u m e n t s for jigs a n d tools, remarks for protection of labour a n d health, plans for
separating of d a m a g e d parts, s p e c i a l instructions for electronic parts). T h e s e details shall be determined by
the responsible welding coordinator and/or the customer.

4.1.4 Welding procedure specification

For welds with welding p e r f o r m a n c e c l a s s e s C P A , C P B , C P C 1 , C P C 2 a n d C P C 3 , welding procedure

specifications according t o E N I S O 15609-1 t o E N I S O 1 5 6 0 9 - 5 , t o E N I S O 1 4 5 5 5 o r t o E N I S O 15620 are
n e c e s s a r y . F o r weld p e r f o r m a n c e c l a s s CP D this is only n e c e s s a r y if the c u s t o m e r d e m a n d s it.

Dependent on the weld performance c l a s s e s a c c o r d i n g to EN 15085-3, the following e v i d e n c e s are n e c e s s a r y

for the welding procedure specification:

— W e l d performance c l a s s C P A :
E v i d e n c e a c c o r d i n g t o a n y o f the following standards: E N I S O 1 5 6 1 4 ) o r E N I S O 15620; E N I S O 15613
2

only if a W P Q R a c c o r d i n g to EN ISO 15614 exists; for materials with > 5 0 0 M P a or fully m e c h a n i s e d

welding p r o c e s s e s : E N I S O 15614. F o r the W P Q R the a c c e p t a n c e criteria o f w e l d performance c l a s s
CP A ( E N 1 5 0 8 5 - 3 : 2 0 0 7 , T a b l e 5 and T a b l e 6) shall be fulfilled.

— W e l d performance c l a s s e s C P B , C P C 1 , C P C 2 :
E v i d e n c e a c c o r d i n g t o a n y o f the following standards: E N I S O 15613, E N I S O 14555, E N I S O 15620; i f
n e c e s s a r y for c o m p o n e n t or the material: EN ISO 15614.

— W e l d performance c l a s s C P C 3 :
E v i d e n c e a c c o r d i n g t o a n y o f the following standards: E N I S O 1 5 6 1 0 , E N I S O 1 5 6 1 1 , E N I S O 15612,
E N ISO 1 5 6 1 3 , E N I S O 1 4 5 5 5 , E N I S O 15620; i f n e c e s s a r y for c o m p o n e n t o r the material: E N ISO 15614.

— W e l d performance c l a s s C P D :
A c c o r d i n g to the requirements of the customer.

I n g e n e r a l , e v e r y W P S shall b e c o v e r e d b y a W P Q R , except for weld p e r f o r m a n c e c l a s s C P D unless

specified in the contract.

2) See footnote 1).

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EN 15085-4:2007 (E)

NOTE For the validity of W P S and W P Q R according to EN ISO 15614-1 and EN ISO 15614-2, see Introduction of
EN ISO 15614-1:2004 and EN ISO 15614-2:2005.

4.2 Production weld tests

4.2.1 General

4.2.1.1 Aim and objective of production weld tests

If n e c e s s a r y , production w e l d tests shall be carried out.

T h e aim a n d objective of production weld tests is:

— to c h e c k and ensure that the d e s i g n is satisfactory as specified in EN 1 5 0 8 5 - 3 ;

— to prove the welding conditions;

— to demonstrate the skill of the welders;

— to demonstrate the quality of the w e l d .

O n e production weld test c a n be u s e d for s e v e r a l t a s k s indicated a b o v e .

4.2.1.2 Realization and amount of testing of production weld test

T h e production weld test shall be carried out under the s a m e manufacturing conditions as the real product.
T h e y shall be carried out under the supervision of the responsible welding coordinator a n d they shall be
documented.

Production weld tests s h o u l d be w e l d e d in a c c o r d a n c e with EN I S O 15613. T h e y m a y be w e l d e d separately

as test plates, as s a m p l e s u b - a s s e m b l i e s (mock-ups) or together with s u b - a s s e m b l y , for e x a m p l e , as an
extension of the weld.

T h e production weld tests and the amount of testing should be listed in the test plan or specified by the
welding coordinator. If no details for the testing of the production weld tests are defined in the test plan,
E N ISO 15613 applies.

4.2.2 Production weld tests to check and ensure the design

Test s p e c i m e n s to demonstrate the weldability of the design shall be w e l d e d as a s a m p l e s u b - a s s e m b l y . T h e y

are n e c e s s a r y to demonstrate:

— practicability (design w h i c h is convenient for welding);

— selection of the material;

— possibility of testing;

— quality requirements;

— m e c h a n i c a l property d a t a (e.g. strength, ductility).

4.2.3 Production weld tests to prove the welding conditions

For special welds where no proof is p o s s i b l e in a c c o r d a n c e with EN I S O 1 5 6 1 4 , production weld tests are
n e c e s s a r y for proving t h e s e w e l d s to e n s u r e the fusion of the w e l d . T h e s e c a n b e , for e x a m p l e :

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 EN 15085-4:2007 (E)

— welds without full penetration on butt a n d T joints;

— HV welds on T joints with single side a c c e s s .

T h e production weld tests s e r v e to demonstrate that the specified weld p e r f o r m a n c e c l a s s has b e e n a c h i e v e d .

4.2.4 Production weld tests to demonstrate the skill of the welder

For welds which require a s p e c i a l skill in welding a n d are not specified in standards EN 287-1 or
EN ISO 9606-2 to EN I S O 9 6 0 6 - 5 , production weld tests are n e c e s s a r y to qualify the welders. T h e testing of
the production w e l d tests shall be carried out as specified in EN 287-1 or in EN I S O 9606-2 to EN ISO 9606-5.
If the testing cannot be carried out according to these standards the r e s p o n s i b l e welding coordinator should
specify the testing. EN 287-1 or EN ISO 9606-2 to EN ISO 9 6 0 6 - 5 a p p l i e s to the range a n d the duration of the
validity and the prolongation.

Production weld tests for the qualification of welders (depending on their specific tasks) m a y be n e c e s s a r y :

— for HV or HY w e l d s on T joints;

— for welds with s e v e r a l d e g r e e s of difficulty, e.g. three plate butt w e l d s , plug w e l d s , c r o s s weld, complica-
ted w e l d s on extrusion profiles;

— for welds under c o m p l i c a t e d conditions, e.g. repairing;

— for poor accessibility;

— for materials with poor weldability;

— for pipe b r a n c h e s a n d pipe collars;

— for lap joints and corner w e l d s in thin s h e e t s (t ≤ 3 mm);

— for especially high quality requirements, e.g. weld performance c l a s s CP A as specified in EN 15085-3;

— w h e n taking on n e w w e l d e r s or welding operators, e.g. staff on loan.

T h e production weld tests s h o u l d be listed in the planning d o c u m e n t s or specified by the welding coordinator.

4.2.5 Production weld tests to demonstrate the quality of the weld

T h e weld quality m a y be demonstrated with production w e l d tests. F o r e x a m p l e the following conditions

should b e c o n s i d e r e d (see E N 15085-3:2007, 4.7):

— to e n s u r e the weld quality for inspection c l a s s CT 2, production weld tests are n e c e s s a r y if neither X - r a y
nor ultrasonic inspection is possible;

— kind of the production w e l d test and the frequency should be given in the test p l a n ;

— production weld tests shall be taken from the a s s e m b l y or from an extension of the work piece or from a
similar work p i e c e ;

— production weld tests s h o u l d be c h e c k e d in a c c o r d a n c e with EN I S O 1 5 6 1 3 . T h e tests shall be

documented.

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EN 15085-4:2007 (E)

4.2.6 Production weld tests to check electron beam and laser beam welding

Before the start of the fabrication, production weld tests should be p r o d u c e d a n d a s s e s s e d in a c c o r d a n c e with
EN ISO 15613. For a c h a n g e of the d e s i g n , of the material, in the w a y of fabrication or in the production other
production weld tests could a l s o be n e c e s s a r y , if the c h a n g e s c a n influence the quality of the w e l d .

4.2.7 Production weld tests to check resistance spot, roll seam and proj ection welds

With resistance spot, r e s i s t a n c e s e a m a n d projection welding, production w e l d tests shall be produced

according to EN 1 5 0 8 5 - 3 : 2 0 0 7 , T a b l e F.2. Simplified weld production tests shall be d o n e before the daily start
of the fabrication and shall be recorded in a log book. Normal weld production tests shall be d o n e to prove the
quality in the production at regular intervals depending on w e l d v o l u m e , weld equipment and weld
performance c l a s s .

4.2.8 Production weld tests to check flash butt welding

For flash butt welds at the beginning of a n e w production run or w h e n c h a n g i n g the manufacturing conditions
(e.g. materials etc.) it is n e c e s s a r y to demonstrate by production weld tests a c c o r d i n g to EN I S O 15614-13
and testing with a notch b e n d i n g test, a fracture surface a s s e s s m e n t or a non-destructive testing that the
m e c h a n i c a l and technical quality v a l u e s of the weld are in a c c o r d a n c e with the specification.

4.2.9 Production weld tests to check stud welding

For stud welding, simplified production tests according to EN I S O 14555 shall be d o n e before starting
production or w h e n c h a n g i n g the manufacturing conditions and shall be recorded in a log book.

5 Requirements for welding

5.1 General

Listed below are the technical requirements for the welding of railway v e h i c l e s a n d their c o m p o n e n t s . In
addition the r e c o m m e n d a t i o n s of series of standards EN 1011 s h o u l d be o b s e r v e d for welding.

5 . 2 General requirements

5.2.1 Weld preparation

1) T h e weld preparation shall be d o n e as specified on the drawing or in other work d o c u m e n t s . T h e

requirements specified in EN 15085-3 should be o b s e r v e d .

2) T h e cut s u r f a c e s of dynamically loaded c o m p o n e n t s shall meet the requirements of cut quality 33

according to EN I S O 9 0 1 3 : 2 0 0 2 . T h e cut surface of s h e a r e d cuts or s t a m p e d j o g s shall be free of
notches and c r a c k s . If n e c e s s a r y , t h e s e imperfections shall be ground out.

3) R u n - o n a n d run-off plates shall be u s e d according to EN 1 5 0 8 5 - 3 : 2 0 0 7 , 7.3.11. F o r t ≥ 8 mm they

shall h a v e the s a m e joint preparation as the actual w e l d . T h e run-on and run-off plates shall be m a d e
so as to e n a b l e the welding to be started or stopped b e y o n d its n e c e s s a r y length. T h e parts to be
a s s e m b l e d a n d the plates, which are "integrated" into the d e s i g n or implanted as small plates on the
parts to be w e l d e d , are h o m o g e n o u s . T h e preparation of t h e s e plates shall be the s a m e as that u s e d
on the joints to be m a d e . T h e plates shall either be fixed by m e c h a n i c a l or magnetic m e a n s and c a n
be w e l d e d . After having completed the joint, the plates c a n either be m e c h a n i c a l l y r e m o v e d or cut
using a blowpipe or p l a s m a . A longitudinal grinding shall be m a d e after the r e m o v a l of the plates.
A n y rupture c a u s e d by s h o c k is prohibited.

4) If welding of temporary attachments is n e c e s s a r y this shall be a g r e e d with the d e s i g n department.

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5) T h e s u r f a c e s in the w e l d shall be free from d a m p a n d contamination s u c h as dirt, rust, s c a l e , s l a g , oil

and paint. F o r multi-run welding the surface of the previous run shall be prepared so that a
satisfactory welding of the next run is possible. Dirt, s l a g a n d u n a c c e p t a b l e imperfections shall be
removed.

6) F o r corrosion protection on overlap joints a n d other a r e a s that are no longer a c c e s s i b l e after welding,
the application of s h o p primer paint or coating is a c c e p t a b l e if the following conditions are met:

— using t h e s e primers or coatings is acceptable to the customer, if c u s t o m e r approval is required;

— the requirement is included in the d e s i g n ;

— the W P Q R h a s b e e n qualified with the primer being applied;

— the requirements of EN ISO 17652-1 a n d EN I S O 17652-2 are met.

7) T h e w e l d joints s h a l l be visible a n d accessibility s h o u l d be optimized for the w e l d e r (see 4.2.4).

8) Before w e l d i n g , a n y irregularities shall be a d v i s e d to the welding coordinator, e.g. incorrect weld

preparation, faulty or unsuitable filler metals or unsuitable welding m a c h i n e s .

5.2.2 Execution of the welding

1) W e l d build up, weld direction a n d weld s e q u e n c e shall be c h o s e n so that the welding produces
minimized residual s t r e s s e s a n d distortion, so that the weld quality a n d the required mechanical
properties are a c h i e v e d .

2) At the e n d of g u s s e t s or stiffeners, the weld shall run around t h e m . S e e a l s o EN 15085-3:2007, 7.3.9.

3) If possible the welding should be d o n e in position PA or P B . If p o s s i b l e rotating equipment should be

used.

4) T h e welding s h o p shall be protected against the effects of detrimental w e a t h e r when welding (e.g.
against wind, rain, s n o w a n d draughts in the shop).

5) T h e welding current return line (work piece clamp) shall be attached directly to the component to be
w e l d e d so that there is a satisfactory electrical contact with low r e s i s t a n c e . It is r e c o m m e n d e d to
attach the welding current return line as near as possible to the welding a r e a .

6) W h e n welding on rail v e h i c l e s the welding current return line shall be attached to the vehicle in
vicinity of the p l a c e w h e r e the welding will be d o n e . B e c a u s e of the d a n g e r of d a m a g i n g bearings by
current flowing through them attaching the welding current return line to the rails is forbidden.

7) If n e c e s s a r y , before the beginning of the. welding work the batteries s h o u l d be b o n d e d out and the
vehicle electronics s h o u l d be protected, e.g. by removing or electrically disconnecting them.

8) T h e n e c e s s a r y rules to prevent fire shall be c o n s i d e r e d .

9) If c o m p o n e n t s h a v e to be m o v e d before the welding is complete (rotated or transported) they shall be

able to a c c e p t the loads without plastic deformation.

10) If n e c e s s a r y the preheat a n d interpass temperature of the weld a r e a s h o u l d be specified depending

on the material, the thickness a n d the component to be w e l d e d . Information about the required
temperatures is given in EN 1011-2 a n d EN 1011-4, g u i d a n c e on m e a s u r e m e n t is given in
EN I S O 13916. P r e h e a t a n d interpass temperature shall be maintained during tacking and welding
within the limits specified a n d c h e c k e d .

11) If the temperature of the work piece is below 5 °C, preheating is n e c e s s a r y in a n y c a s e .

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EN 15085-4:2007 (E)

12) If tack welds are incorporated in the final w e l d , they are subject to the s a m e requirements as the
weld.

13) If tack welds s h o u l d not remain in the final weld they shall be carried out in s u c h a w a y or m a c h i n e d
so far that they are correctly melted during welding.

14) If welds of the w e l d p e r f o r m a n c e c l a s s e s CP A, CP B or CP C1 with full penetration a n d s e a l i n g run

(V, are specified by the d e s i g n , before welding the first run on the s e c o n d side the root shall be
removed by grinding or m a c h i n i n g . Otherwise the applied procedure shall be qualified by a procedure
qualification test in a c c o r d a n c e with EN I S O 15613 or EN ISO 15614 or by a production w e l d test.

15) T a c k welds outside the weld a r e a (e.g. on the remaining root backing) are only permissible if they are
provided as part of the d e s i g n . T h e y are subject to the s a m e requirements as the w e l d .

5.2.3 Weld quality

1) Stray arcing on the surface of the work piece is not allowed. If it o c c u r s , stray arcing shall be ground
out. For weld p e r f o r m a n c e c l a s s e s C P A , C P B o r C P C 1 a surface test shall b e carried out (surface
test c o v e r s all s u r f a c e breaking defects including c r a c k s ) .

2) T h e permission of spatters d e p e n d s on the material u s e d a n d on the c a s e of application a n d shall be

agreed by the c u s t o m e r a n d the manufacturer.

3) P e r m a n e n t b a c k i n g is only allowed if it is specified on the drawing.

4) F o r adding temporary attachments the agreement of the designer is n e c e s s a r y . F o r w e l d i n g and

removing these attachments s e e E N 1011-1.

5) After removing notches c a u s e d by finishing work (e.g. grinding n o t c h e s , l e d g e s ) the remaining wall
thickness shall be at least 95 % of the nominal wall t h i c k n e s s . If the nominal wall t h i c k n e s s is
w e a k e n e d more than 5 % a repair operation is n e c e s s a r y (grinding out, welding, grinding, crack
detection). Deviations shall be a g r e e d with the customer.

6) If for r e a s o n s of d e s i g n , the drawing specifies the machining or grinding of the e x c e s s weld metal the
remaining undercuts, craters or other surface defects m a y only remain if they shall meet the quality
requirements.

7) If the drawings specify notch free grinding for strength r e a s o n s , the weld should be ground in the
direction of loading.

8) F o r repair w e l d s only qualified p r o c e d u r e s , suitable for the weld performance c l a s s shall be u s e d .

9) If there is systematic d a m a g e or deviations from the drawing the a g r e e m e n t of the c u s t o m e r shall be

obtained. Before repairing the r e a s o n of the d a m a g e or deviations shall be determined.

10) W e l d i n g over c r a c k s is not permissible.

11) Before the repair of c r a c k s by welding the exact location of the c r a c k shall be e s t a b l i s h e d . If
n e c e s s a r y , the e n d of the crack should be drilled out a n d then the crack s h o u l d be m a c h i n e d out and
re-welded. A s u r f a c e test shall be carried out before a n d after welding.

12) For flame straightening the following principles shall be noted:

— F l a m e straightening m a y only be u s e d w h e n it is permissible for the respective material or the

component a n d d o e s not lead to a reduction of strength. Deviations shall be a g r e e d with the
customer.

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 EN 15085-4:2007 (E)

— W h e n the straightening p r o c e s s is carried out the s p e c i a l technical r e c o m m e n d a t i o n should be

observed.

— T h e m a x i m u m temperature shall not be e x c e e d e d a n d shall be monitored by suitable measuring

equipment for high-strength materials and aluminium. Melting is not permitted.

5.3 Welding consumables

5.3.1 Choice of welding consumables

For unalloyed and low-alloy steels

For parts m a d e of unalloyed or low-alloy steels minimum weld-metal specifications apply. T h e properties of
the welded joint shall be equivalent to the minimum properties specified for the parent material and to EN
standards for classification of welding c o n s u m a b l e s respectively.

For welding of different g r a d e s of steel, the minimum weld-metal specifications for the lower rated grade of
steel apply. However, the metallurgical properties a n d welding conditions for the higher rated steel grade shall
still be taken into c o n s i d e r a t i o n .

For stainless steels

For similar and dissimilar w e l d s of stainless steels the welding c o n s u m a b l e s s h a l l be selected so that the
mechanical properties of the weld meet the requirements.

For aluminium and aluminium alloys

W e l d i n g c o n s u m a b l e s shall be selected in a c c o r d a n c e with EN 1011-4.

Additional information on the drawing or parts lists shall be taken into account, s e e EN 15085-3:2007, A n n e x
H.

5.3.2 Conformity of welding consumables

All welding c o n s u m a b l e s shall conform to the requirements given in EN 13479 a n d the appropriate European
classification s t a n d a r d s .

T h e range of validity of the certificate shall be in a c c o r d a n c e with the p l a n n e d welding p r o c e s s , material,

welding position and welding current type. T h e certificate is i s s u e d on the b a s i s of qualification test according
to EN 13479. If required by the customer, conformity shall be demonstrated by a certificate according to
EN 14532-1 (steel) or EN 14532-3 (aluminium alloys) i s s u e d by certification body.

T h e delivered welding c o n s u m a b l e s shall be d e c l a r e d in a c c o r d a n c e to EN I S O 5 4 4 , including a certificate

according to EN 10204. T h e level of certificate shall be a g r e e d between manufacturer a n d customer.

T h e producer or supplier of the delivered welding c o n s u m a b l e s shall declare conformity by applying the CE
marking a c c o r d i n g to EN 13479 on a label indicating also the certification body a n d the certificate number.

5.3.3 Storage and handling

T h e r e c o m m e n d a t i o n s given by the producer of welding c o n s u m a b l e s for s t o r a g e a n d handling shall be

considered (see E N 1 0 1 1 - 1 : 1 9 9 8 , 8.2).

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EN 15085-4:2007 (E)

5.4 Parent metals

5.4.1 Choice of parent metals

See EN 15085-3:2007,6.1.

5.4.2 Conformity of parent metals

T h e parent metals shall meet the requirements of the welding planning d o c u m e n t s .

T h e conformity of the parent metals shall be d o c u m e n t e d in a material certificate a c c o r d i n g to EN 10204:2004.

T h e material certificate 3.1 a c c o r d i n g to EN 10204:2004 is n e c e s s a r y for c o m p o n e n t s with welds of
certification level CL 1 or CL 2.

5.4.3 Additional rules for welding carbon and fine grain structural steels

For welding of carbon and fine grain structural steels the preheating temperature a n d the cooling rate shall be
determined according t o E N 1011-2.

For thermal cutting and welding of fine grain structural steels the guidelines a n d the instructions of the steel
manufacturers shall be followed.

With arc welding of c a r b o n , fine grain structural and cast steels the m a x i m u m h a r d n e s s v a l u e s in the heat
affected z o n e shall be in a c c o r d a n c e with EN I S O 15614-1.

5.4.4 Additional rules for welding of cast irons

For welding of cast irons, the r e c o m m e n d a t i o n s of EN 1011-8 shall be followed.

5.4.5 Additional rules for welding stainless steels

Additional to the r e c o m m e n d a t i o n s given in EN 1011-3 the following rules apply:

T h e layers of s c a l e and temper colours produced by welding or by heat treatment of s t e e l s , material groups 7,
8 or 10 according to C E N I S O / T R 1 5 6 0 8 : 2 0 0 5 , produce a break in the p a s s i v e material s u r f a c e which c a n be
o v e r c o m e by removing the temper colours a n d by passivating. T h e following methods c a n be u s e d :

— grinding with suitable grinding d i s c s ;

— brushing with stainless steel b r u s h e s ;

— blasting with iron free blasting grit;

— c h e m i c a l s , as specified by the manufacturer of the etching material.

5.4.6 Additional rules for welding carbon or fine grain structural steels with stainless steels

T h e filler metal shall be c h o s e n using the Schaeffler diagram. T h e c h e m i c a l c o m p o s i t i o n of the weld metal
shall lie within a range w h i c h is not at risk of embrittlement or hot crack formation.

5.4.7 Additional rules for welding aluminium and aluminium alloys

Additional to the r e c o m m e n d a t i o n s given in EN 1011-4 the following rules apply:

Welding p r o c e s s e s m a n u a l metal arc welding (111 a c c o r d i n g to EN I S O 4 0 6 3 : 2 0 0 0 ) a n d g a s welding (3

according to EN I S O 4 0 6 3 : 2 0 0 0 ) are not permitted.

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 EN 15085-4:2007 (E)

Only grinding d i s c s a n d appropriate tools which are suitable for aluminium shall be u s e d .

5.5 Welding processes

Table 1 contains the welding p r o c e s s e s for u s e , provided that the requirements of 4.1.4 are fulfilled.

Other welding p r o c e s s e s shall be agreed with the customer.

Table 1 — Welding processes for use

Process Ref.-No. as Approved for:

specified in
EN ISO 4063:2000

Steels Al and Al-alloys

G a s welding 3 X
-
S u b m e r g e d arc welding 12 X
-
P l a s m a arc welding 15 X X

R e s i s t a n c e spot w e l d i n g 21 X X

R e s i s t a n c e s e a m welding 22 X X

Projection welding 23 X X

F l a s h welding 24 X X

Friction welding 42 X X

Electron b e a m welding 51 X X

L a s e r b e a m welding 52 X X

Electrogas welding 73 X
-
Stud welding with 78 X X

M a n u a l metal arc welding 111 X

-
Gravity arc welding with c o v e r e d electrode 112 X -
Self-shielded tubular-cored arc welding 114 X
-
Metal inert g a s welding 131 X X

Metal active g a s welding 135 X -

Metal-protection g a s melt spot welding (131) X X
(135) X
Tubular c o r e d metal a r c welding with active g a s 136 X -
Tubular c o r e d metal a r c welding with inert g a s 137 X
-
T u n g s t e n inert g a s welding 141 X X

Foil butt-seam welding 225 X

-
High frequency r e s i s t a n c e welding 291 X X

Drawn arc stud welding with c e r a m i c ferrule or 783 X X

shielding g a s

Short-cycle drawn a r c stud welding 784 X X

C a p a c i t o r d i s c h a r g e d r a w n arc stud welding 785 X X

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EN 15085-4:2007 (E)

Process Ref.-No. as Approved for:

specified in
EN ISO 4063:2000

Steels Al and Al-alloys

Friction stir welding ( F S W )

- X

Laser-Hybrid-Welding X X

6 Special requirements for maintenance welding of railway vehicles

6.1 General rules for maintenance welding

Maintenance welding includes repair welding but not refurbishment or r e v a m p i n g .

If no other requirements are given by the railway operator or the national safety authority the following
requirements shall be fulfilled.

T h e railway operator is r e s p o n s i b l e for m a i n t e n a n c e of his vehicles.

For maintenance welding of railway v e h i c l e s all n e c e s s a r y information about the vehicle s u c h as

documentation of vehicle manufacturer (drawings, operation m a n u a l s , manufacturer requirements) as well as
special guidelines a n d working instructions of the railway operator should be a v a i l a b l e . T h e railway operator
shall be informed w h e n , as a result of m a i n t e n a n c e welding, c o n s i s t e n c y with the drawing is not maintained.
T h e railway operator shall d e c i d e on the further actions.

W h e n c r a c k s and b r e a k a g e (no obvious acts of violence) o c c u r repeatedly on identical c o m p o n e n t s (serial

d a m a g e ) , the vehicle manufacturer shall be informed. T h e vehicle manufacturer a n d the railway operator shall
decide on the further actions.

Welding of materials with heat input or temperature restrictions (e.g. heat affected z o n e of heat treatable
aluminium alloys) and t e m p e r e d c o m p o n e n t s requires specific p r o c e s s i n g a g r e e d by the railway operator or
his representative.

6.2 Testing and documentation

If the design is in a c c o r d a n c e with EN 1 5 0 8 5 - 3 , as a minimum, testing and documentation shall be performed

according to the requirements of EN 15085-3.

If the weld performance c l a s s is not defined at all or not according to EN 1 5 0 8 5 - 3 , testing a n d documentation
have to be determined at least a c c o r d i n g to T a b l e 4 of EN 15085-3:2007.

If the stress level of the w e l d is unknown the highest possible weld performance c l a s s related to the safety
category of the weld shall be u s e d , s e e T a b l e 4 of EN 15085-3:2007.

Additional to T a b l e 4 of EN 15085-3:2007 the following applies:

For repair welding of single defects testing shall be 100 % for welds of weld p e r f o r m a n c e c l a s s CP C1 and
C P B.

For all welds a 100 % v i s u a l examination shall be performed.

All N D T tests shall be r e c o r d e d .

A welding report h a s to be p r o d u c e d by the responsible welding coordinator or his n o m i n e e .

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Bibliography

[1] EN I S O 3834 (ail parts), Quality requirements for fusion welding of metallic materials

[2] EN 15085-2, Railway applications - Welding of railway vehicles and components - Part 2: Quality
requirements and certification of welding manufacturer

[3] EN 1 4 5 3 2 - 1 , Welding consumables - Test methods and quality requirements - Part 1: Primary
methods and conformity assessment of consumables for steel, nickel and nickel alloys

[4] EN 14532-2, Welding consumables - Test methods and quality requirements - Part 2: Supplementary
methods and conformity assessment of consumables for steel, nickel and nickel alloys

[5] EN I S O 13916, Welding - Guidance on the measurement of preheating temperature, interpass

temperature and preheat maintenance temperature (ISO 13916:1996)

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