BSI BS EN 15085-3 - Railway applications - Welding...
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BS EN 15085-3:2022
Railway applications — Welding of
railway vehicles and components
Part 3: Design requirements
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BS EN 15085-3:2022
BRITISH STANDARD
National foreword
This British Standard is the UK implementation of EN 15085-3:2022. It
supersedes BS EN 15085-3:2007, which is withdrawn.
The UK participation in its preparation was entrusted to Technical
Committee RAE/3/-/11, Railway Applications - Structural requirements
and Welding.
A list oforganizations represented on this committee can be obtained on
request to its committee manager.
Contractual and legal considerations
This publication has been prepared in good faith, however no
representation, warranty, assurance or undertaking [express or
implied] is or will be made, and no responsibility or liability is or will be
accepted by BSI in relation to the adequacy, accuracy, completeness or
reasonableness ofthis publication. All and any such responsibility and
liability is expressly disclaimed to the full extent permitted by the law.
This publication is provided as is, and is to be used at the
recipient’s own risk.
The recipient is advised to consider seeking professional guidance with
respect to its use ofthis publication.
This publication is not intended to constitute a contract. Users are
responsible for its correct application.
This publication has been prepared under a mandate given to the
European Standards Organizations by the European Commission and the
European Free Trade Association. It is intended to support requirements
ofthe EU legislation detailed in the European Foreword. A European
Annex, usually Annex ZA or ZZ, describes how this publication relates to
that EU legislation.
For the Great Britain market (England, Scotland and Wales], ifUK
Government has designated this publication for conformity with UKCA
marking [or similar] legislation, it may contain an additional National
Annex. Where such a National Annex exists, it shows the correlation
between this publication and the relevant UK legislation. Ifthere is no
National Annex ofthis kind, the relevant Annex ZA or ZZ in the body
ofthe European text will indicate the relationship to UK regulation
applicable in Great Britain. References to EU legislation may need to be
read in accordance with the UK designation and the applicable UK law.
Further information on designated standards can be found at
www.bsigroupcom/standardsandregulation.
For the Northern Ireland market, UK law will continue to implement
relevant EU law subject to periodic confirmation. Therefore
Annex ZA/ZZ in the European text, and references to EU legislation, are
still valid for this market.
UK Government is responsible for legislation. For information on
legislation and policies relating to that legislation, consult the relevant
pages ofwww.gov.uk.
© The British Standards Institution 2022
Published by BSI Standards Limited 2022
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BRITISH STANDARD
BS EN 15085-3:2022
ICS 25160.10; 45.06001
Compliance with a British Standard cannot confer immunity from
legal obligations.
This British Standard was published under the authority ofthe
Standards Policy and Strategy Committee on 30 November 2022.
Amendments/corrigenda issued since publication
Date
Text affected
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BS EN 15085-3:2022
EUROPEAN STANDARD
EN 15085-3
NORME EUROPEENNE
November 2022
ICS 25.160.10; 45.06001
Supersedes EN 15085-3:2007
English Version
Railway applications - Welding of railway vehicles and
components - Part 3: Design requirements
Applications ferroviaires - Soudage des véhicules
ferroviaires et des pieces - Partie 3 : Exigences de
conception
Bahnanwendungen - Schweifien von
Schienenfahrzeugen und -fahrzeugteilen - Teil 3:
Konstruktionsvorgaben
This European Standard was approved by CEN on 5 September 2022.
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-CENELEC 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 ofa CEN member into its own language and notified to the CE N-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies ofAustria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Tiirkiye and
United Kingdom.
/"
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITE EUROPEEN DE NORMALISATION
EUROPAISCHES KOMITEE FUR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-104-0 Brussels
© 2022 CEN
All rights of exploitation in any form and by any means reserved
worldwide for CEN national Members.
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Ref. No. EN 15085-3:2022 E
BS EN 15085-3=2022
EN 15085-3=2022 (E)
Contents
European foreword ............................................................................................................................................ 4lntroduction .......................................................................................................................................................... 6
1
Scope .......................................................................................................................................................... 7
2
Normative references .......................................................................................................................... 7
3
Terms and definitions ......................................................................................................................... 9
44-.1
4-.2
4-.3
4-.44-.5
4-.6
Design requirements ........................................................................................................................... 9
General...................................................................................................................................................... 9
Dimensioning of welded joints ...................................................................................................... 10
Stress categories and stress factors ............................................................................................. 10
Safety categories ................................................................................................................................. 10
Weld performance classes ............................................................................................................... 10
Weld inspection classes .................................................................................................................... 11
5
5.1
5.2
5.3
5.3.1
5.3.2
5.3.3
5.3.5
5.3.6
Quality levels for imperfections .................................................................................................... 12
General.................................................................................................................................................... 12
Quality levels for imperfections for fusion welded joints (beam welding excluded) 12
Quality levels for imperfections for beam welded joints ..................................................... 13
General.................................................................................................................................................... 13
Quality levels for imperfection for friction stir welding....................................................... 14Quality levels for imperfections for stud welding related to the weld performance
class.......................................................................................................................................................... 14Quality requirements for resistance spot welding, projection welding and resistance
seam welding related to the weld performance class ........................................................... 14Quality requirements for flash welding...................................................................................... 14Defining quality requirements for other welding processes .............................................. 15
6
6.1
6.2
Selection of parent metals and welding consumables .......................................................... 15
Selection of parent metals ............................................................................................................... 15
Selection of welding consumables ................................................................................................ 15
7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.47.2.5
7.2.6
7.2.7
7.2.8
7.2.9
7.2.10
7.2.11
7.2.12
7.2.13
7.2.147.2 .15
Weld joint design ................................................................................................................................ 16
General.................................................................................................................................................... 16
Design guidelines ................................................................................................................................ 16
Fabricated box sections .................................................................................................................... 16
Butt welds on parts of dissimilar thickness .............................................................................. 17
Plug welds and slot welds ................................................................................................................ 18
Proximity of two joints...................................................................................................................... 19
Stiffeners welded across a butt weld ........................................................................................... 19
Openings ................................................................................................................................................20
Design guidelines for stiffeners and gussets ends ..................................................................20
Gusset shape .........................................................................................................................................20
Weld return ...........................................................................................................................................2 1
Fillet weld ..............................................................................................................................................22
Use of run-on and run-off plates....................................................................................................23
Highly restrained joints ....................................................................................................................23
Mixing of joining techniques ...........................................................................................................24Prevention of corrosion problems ...............................................................................................2 5
Intermittent welds.............................................................................................................................. 2 5
5.3.4-
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EN 15085-3=2o22 (E)
7.3
7.47.4-.1
7.4-.2
7.4-.3
7.4-.4-
Ioint preparation.................................................................................................................................2 6
Methods to improve the fatigue strength (Post weld improvement) ..............................26
General....................................................................................................................................................2 6
Improvement of shape of weld toe ...............................................................................................2 7
Post Weld Heat Treatment (PWHT) — stress relief...............................................................2 7
Introduction of compressive stress ..............................................................................................28
8
8.1
8.2
8.3
Design documentation related to welding.................................................................................28
Information on design drawings or documentation linked to the drawings ................28
Design review of welded components ......................................................................................... 30
Use of existing drawings not according to EN 15085 .............................................................30
Annex A (informative) List of welded joints (example) .....................................................................31
Annex B (informative) Ioint preparation of welds ..............................................................................32
Annex C (informative) Ioint preparation for plug welds ...................................................................40
Annex D (informative) Types of joints in relation to stresses and inspection classes............41
Annex E (informative) Flash welding........................................................................................................42
Annex F (normative) Resistance spot, seam and projection welding ..........................................45
F.1
General.................................................................................................................................................... 45
F.2
Minimum shear pull forces.............................................................................................................. 50
Annex G (informative) Determination of safety category for welded joints .............................. 52
Annex ZA (informative) Relationship between this European Standard and the Essential
requirements of Directive (EU) 2016 / 797 aimed to be covered ....................................... 53
Bibliography........................................................................................................................................................ 56
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BS EN 15085-3:2022
EN 15085-3=2022 (E)
European foreword
This document (EN 15085—3:2022) has been prepared by Technical Committee CEN/TC 256 “Railway
applications", the secretariat ofwhich is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by May 2023, and conflicting national standards shall be
withdrawn at the latest by May 202 3.
Attention is drawn to the possibility that some of the elements ofthis document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN 15085-3:200 7.
This series of European Standards EN 15085 "Railway applications — Welding of railway vehicles and
components” consists ofthe following parts:
—
Part 1: General
—
Part 2: Requirements of the organization ofwelding manufacturer
—
Part 3: Design requirements
—
Part 4: Production requirements
—
Part 5: Inspection, testing and documentation
—
Part 6: Maintenance
EN 1508 5-3:2022 includes the following changes with respect to EN 15085-3:2007.
— The weld performance class CP B has been divided into CP B1 and CP B2 (see Table 2);
— Terms and definitions have been updated;
— The following annexes have been reworked accordingly;
— Annex H has been deleted and part ofits content has been integrated into the main text (see 6.2
and 7.1);
— Annex ZA has been added.
This document has been prepared under a Standardization Request given to CEN by the European
Commission and the European Free Trade Association, and supports essential requirements of EU
Directive(s) / Regulation(s).
For relationship with EU Directive(s) / Regulation(s), see informative Annex ZA, which is an integral part
ofthis document.
Any feedback and questions on this document should be directed to the users’ national standards body.
A complete listing of these bodies can be found on the CEN website.
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BS EN 15085-3=2022
EN 15085-3=2022 (E)
According to the CEN-CENELEC Internal Regulations, the national standards organisations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia,
Cyprus, Czech Republic, Denmark, Estonia, Finland, Fiance, Germany, Greece, Hungary, Iceland, Ireland,
Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North
Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Tiirkiye and the United
Kingdom.
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BS EN 15085-3:2022
EN 15085-3=2022 (E)
Introduction
Welding is a special process in the manufacture of railway vehicles and their parts. The required
provisions for this process are laid down in the standards series EN ISO 3834. The basis of these
provisions is the basic technical welding standards with respect to the special requirements for the
construction of railway vehicles.
This series ofstandards applies to welding ofmetallic materials in the manufacture and maintenance of
railway vehicles and their parts.
It describes the control for the welding process for railway vehicles and their components for new
manufacture and maintenance.
With respect to the railway environment, this series of standards defines the quality requirements for
the welding manufacturer to undertake new building and repair work.
Components, parts and subassemblies are assigned a classification level, based on their safety relevance.
According to these levels, qualifications for welding personnel of the manufacturer are specified.
This series provides an essential link between the weld performance class defined during design, the
quality ofthe weld, and the demonstration ofthe required quality by inspection.
This series of standards does not deal with product qualification.
NOTE
This series of standard can also be used by internal and external parties, including certification bodies,
to assess the organization's ability to meet customer, regulatory and the organization's own requirements.
6
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BS EN 15085-s=2022
EN 15085-3=2022 (E)
1
Scope
This document applies to welding ofmetallic materials in the manufacture and maintenance of railway
vehicles and their components.
This document specifies applicable design and classification rules.
This document does not specify parameters for the dimensioning.
NOTE
2
Requirements for structures can be found in other standards (e.g. EN 12663).
Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
EN 1011-2:2001, Welding - Recommendations for welding of metallic materials - Part 2: Arc welding of
ferritic steels
EN 12663-1:2010+A1:2014, Railway applications - Structural requirements ofrailway vehicle bodies - Part
1: Locomotives and passenger rolling stock (and alternative methodforfleight wagons)
EN 12663-2 :20 10, Railway applica tions - Structural req uirements ofrailway vehicle bodies - Part 2: Freigh t
wagons
EN 13749:2021, Railway applications - Wheelsets and bogies - Method of specijj/ing the structural
requirements of bogie frames
EN 15085-1:—,1 Railway applications — Welding ofrailway vehicles and components — Part 1: General
EN 15085-2:2020, Railway applications - Welding of railway vehicles and components - Part 2:
Requirements for welding manufacturer
EN 15085-4:—,2 Railway applications — Welding of railway vehicles and components — Part 4:
Production requirements
EN 15085-5:—,3 Railway applications — Welding of railway vehicles and components — Part 5:
Inspection, testing and documentation
EN 15085-6:—,4 Railway applications — Welding of railway vehicles and components — Part 6:
Maintenance welding requirements
EN 1582 7:2011, Railway applications - Requirementsfor bogies and running gears
1 Under preparation. Stage at the time of publication: prEN 15085-1:2021
2 Under preparation. Stage at the time of publication: prEN 15085-4:2020
3 Under preparation. Stage at the time of publication: FprEN 15085-5:2021
4 Under preparation. Stage at the time of publication: FprEN 15085-6:2021
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EN 15085-3=2022 (E)
EN ISO 2 553 :2019, Welding and allied processes - Symbolic representation on drawings - Weldedjoints (ISO
2553:2019, Corrected version 2021-09)
EN ISO 3452-1:2021, Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 34521.-2021)
EN ISO 4063:2010, Welding and allied processes - Nomenclature ofprocesses and reference numbers (ISO
4063:2009, Corrected version 201 0-03-01)
EN ISO 5817:2014, Welding - Fusion-weldedjoints in steel, nickel, titanium and their alloys (beam welding
excluded) - Quality levels for imperfections (ISO 581 7.-2014)
EN ISO 6520-1:2007, Welding and allied processes - Classification of geometric imperfections in metallic
materials - Part 1: Fusion welding (ISO 6520-1.2007)
EN ISO 6520—2:2013, Welding and allied processes - Classification ofgeometric imperfections in metallic
materials - Part 2: Welding with pressure (ISO 6520-2.2013)
ENISO10042:2018, Welding - Arc-welded joints in aluminium and its alloys - Quality levels for
imperfections (ISO 1 0042:2018)
EN ISO 10675-2:2021, Non-destructive testing ofwelds — Acceptance levels for radiographic testing —
Part 2: Aluminium and its alloys (ISO 10675—2:2021)
EN ISO 13919-1:2019, Electron and laser-beam welded joints - Requirements and recommendations on
quality levelsfor imperfections - Part 1: Steel, nickel, titanium and their alloys (ISO 13919-1.-2019)
EN ISO 13919-2:2021, Electron and laser-beam welded joints - Requirements and recommendations on
quality levels for imperfections - Part 2: Aluminium, magnesium and their alloys and pure copper (ISO
13919-2.-2021)
EN ISO 13920:1996, Welding - General tolerances for welded constructions - Dimensions for lengths and
angles - Shape and position (ISO 13920-1996)
EN ISO 14555:2 01 7, Welding - Arc stud welding ofmetallic materials (ISO 14555:201 7)
EN ISO 15614-1:2017,5 Specification and qualification of welding procedures for metallic materials —
Welding procedure test — Part 1: Arc and gas welding ofsteels and arc welding of nickel and nickel alloys
(ISO 15614-1:201 7)
EN ISO 15614-12:2021, Specification and qualification of welding procedures for metallic materials Welding procedure test - Part 12: Spot, seam and projection welding (ISO 15614-12.2021)
EN ISO 17636-1:2022, Non-destructive testing ofwelds — Radiographic testing— Part 1: X- and gammaray techniques with film (ISO 17636-1:2022)
EN ISO 17637:2016, Non-destructive testing of welds - Visual testing of fusion-welded joints (ISO
176372016)
5 Document impacted by A1:2019.
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EN ISO 17653:2012, Resistance welding - Destructive tests on welds in metallic materials - Torsion test of
resistance spot welds (ISO 1 7653:2012)
EN ISO 17663:2009, Welding - Quality requirements for heat treatment in connection with welding and
allied processes (ISO 1 7663:2009)
EN ISO 23277:2015, Non-destructive testing of welds - Penetrant testing - Acceptance levels (ISO
232 77:2 01 5)
EN ISO 25239-5:202 0, Friction stir welding - Aluminium - Part 5: Quality and inspection requirements (ISO
25239-5.-2020)
EN ISO 10447:2015, Resistance welding - Testing ofwelds - Peel and chisel testing of resistance spot and
projection welds (ISO 10447.-2015)
3
Terms and definitions
For the purposes ofthis document, the terms and definitions given in EN 15085-1:-1 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
—
ISO Online browsing platform: available at https:L/www.iso.org_/obp
—
IEC Electropedia: available at http:,(/www.electropedia.org_(
3.1
stress factor
ratio ofthe calculated / measured fatigue stress to the admissible fatigue stress ofthe joint type, adjusted
by the appropriate safety factor
3.2
admissible fatigue stress
maximum fatigue stress applicable to the welded joint according to the applicable standard /
specification
4
Design requirements
4.1 General
All welded joints produced under the scope of the EN 15085 series shall be designed according to the
requirements of this document unless more stringent product / project specific requirements are
defined.
A stress assessment shall be done for new designs. For existing designs not according to EN 15085, the
requirements ofEN 15085-6:-4 shall apply.
Results ofthe stress assessment shall be used in combination with the safety category to define the weld
performance class (CP) according to Table 2. The weld performance class for each weld shall be identified
on the manufacturing drawing or associated technical documentation.
Ifthe strength assessment procedure already considers the weld performance class (i.e. the quality levels
for imperfections and the weld inspection class), and the safety category according to the definition given
in this document, then Table 1 and 2 do not need to be applied.
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EN 15085-3=2022 (E)
NOTE
EN 17149-3:-5 provides such a procedure.
Irrespective of the method of assessment, for welded joints with high safety category the weld
performance classes according to this document (CP A, CP B1, CP C1) shall be chosen.
CP D is only allowed for low safety category.
4.2 Dimensioning of welded joints
For dimensioning and preparation ofdifferent types ofwelded joints see Annexes B and C.
4.3 Stress categories and stress factors
The stress category is determined by the stress factor according to Table 1, (see 3.1).
The fatigue strength value can be obtained by calculation according to the appropriate standard /
guideline or fatigue tests on representative joint samples.
The statistical evaluation of the fatigue tests shall be done according to an appropriate standard. The
verification of strength should be carried out using only one coherent system for calculation.
European standards for structural requirements of railway vehicles, e.g. EN 12663-1:2010+A1:2014,
EN 12663-2:2010, EN 13749:2021, EN 15827:2011, shall be applied.
Table 1 — Stress categories
Stress category
Stress factor (S)
High
2 0,9
Medium
0,75 '5 S <1 0,9
Low
5 0,75
4.4 Safety categories
The safety category defines the consequences of failure ofa single welded joint with respect to its effect
on persons, facilities and the environment.
The safety categories are differentiated as follows:
Low:
Failure ofthe welded joint does not lead to any direct impairment ofthe overall
function. Consequential events with personal injuries are unlikely.
Medium:
Failure ofthe welded joint leads to an impairment of the overall function or can
lead to consequential events with personal injuries.
High:
Failure ofthe welded joint leads to consequential events with personal injuries and
breakdown of the overall function.
For a more detailed explanation ofthe safety category, Annex G should also be considered.
4.5 Weld performance classes
Weld performance classes shall be defined in the design phase depending on the safety category and the
stress category. A welding coordinator should be consulted with respect to practicability and testing of
the welded joints.
Welded joints of railway vehicles are divided into seven weld performance classes (see Table 2).
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EN 15085-3=2022 (E)
Table 2 — Weld performance classes
Stress categories
a
Safety categories
High
Medium
Low
High
CPA “
CP E2 "
CP C2
I\/IECIILIITI
CP B1 3
CP C2
CP ‘C3
LOW
Cl) C1 P
CI) C3
CI) I)
Weld performance classes CP A and CP B1: CP A and CP B1 are only applicable for welds with full penetration
and full accessibility for inspection in production and maintenance.
b Weld performance classes CP B2 and CP C1: CP B2 and CP C1 are also applicable for welds where volumetric
NDT is not possible. Where this is the case, see EN 15085-5:-3, Table 1, footnote b. This should be noted on the
related weld inspection documentation with a note "increase of surface test is required”.
For new manufacturing, the combination of high safety category and high stress category, which leads to
weld performance class CP A, shall be avoided. For application in maintenance see EN 15085-6:-4.
The inspection ofall welded joints shall be performed according to EN 15085-5:-3, Table 1 as a minimum.
When the weld performance class assessment leads to CP B1, CP B2 orCP C1, and the weld is inaccessible
for inspection or repair during maintenance, one of the following actions shall be performed:
—
Increase the weld inspection class to CT 1.
—
change the design:
— to reduce the stress category;
— to allow access for inspection and repair in maintenance.
Ifit is not possible to fulfil the requirements of a weld performance class, the designer shall reduce the
stress category or change the design, see Annex D.
Different post weld treatment methods to increase the fatigue strength are possible. These methods can
lead to a downgrading ofthe stress category.
4.6 Weld inspection classes
The weld inspection class is determined based on the weld performance class.
The correlation between the weld performance class, weld inspection class and inspection requirements
is defined in Table 3. Details ofweld inspection are further defined in EN 15085-5:- 3, Table 1.
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EN 15085-3=2022 (E)
Table 3 — Correlation between weld performance classes and weld inspection classes
Stress
category
Sa fety
category
Weld
performance
class
Quality levels for
imperfections
EN ISO 5817:2014
EN ISO 10ll42:2018
EN ISO 13919-1:2tI19
EN ISO 13919-2:2021
Weld
inspection
class
Volumetric
tests
_
min.
Surface
tests
_
mm.
Visual
examination
_
min.
Minimum
requirements
High
High
CPA
Ba
CT1
100 %
100 %
100 %
High
Medium
CP B2
Ba
CT2
10 %
10 %
100 %
High
Low
CP C2
Ca
CT3
Not
required
Not
required
100 %
Medium
High
CPB1
Ba
CT2
10 %
10 %
100 %
CT3
Not
required
Not
required
100 %
100 %
Medium
Medium
CP C2
Ca
Medium
Low
CP C3
Ca
CT4
Not
required
Not
required
Low
High
CP C1
Ca
CT2
10 %
10 %
100 %
Low
Medium
CP C3
Ca
CT4
Not
required
Not
required
100 %
Low
Low
CPD
Da
CT4
Not
required
Not
required
100 %
it
For detail see Table 4 to 6
In case of higher weld inspection class than that defined in Table 3 it shall be shown on drawings or in
other documents, e.g. parts lists.
5
Quality levels for imperfections
5.1 General
The definition and classification of weld imperfections in accordance with EN ISO 6520-1:200? and
EN ISO 6520—2:2013, are applicable.
5.2 Quality levels for imperfections for fusion welded joints (beam welding excluded)
The quality levels for imperfections related to the weld performance class are described below.
The quality levels for imperfection for fusion welding ofsteel and aluminium alloys are listed in Table 4
in accordance to EN ISO 5817:2014 and EN ISO 10042:2018.
EN ISO 5817:2014, Annex C, is not applicable in the production and maintenance ofrailway vehicles and
components.
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Table 4 — Quality levels for imperfections for steel and aluminium alloys related to weld
performance classes
Weld performance classes
lmperfection No.
according to
CPA
|
CPB1/CPB2
CPC1/CPC2/
CP C3
EN ISO 6520-1:2007
|
CPD
Level of Imperfections according to EN ISO 5817:2014 and
EN ISO 10042:2O 18
Group 100
B
B
C
It
Group 200
B
B
C
It
Group 300
B
B
C
It
Group 400
B
B
C
Ii
Not permitted
B
C
It
5071, 5072, 601
B
B
C
D
503, 5213, 512*‘, 61 7
Not applicable
B
C
D
505 and Multiple
Imperfections
B
5011, 5012, 5013,
502, 504, 506, 509
511, 510, 515, 516
517
I
I
52 14 [steel]
Not applicable
5214 [aluminium]
Not applicable
602, 610 [steel]
B
These imperfections are not assessed
B
|
C
|
D
refer to geometrical dimension defined into design
documentation (e.g. avoid interference during assembly)
B
|
C
|
D
602 [aluminium]
Acceptance depends on application, e.g. material, corrosion protection
610 [aluminium]
Not applicable
a
512: Excessive asymmetry of fillet weld (unequal leg length) is not assessed if the fillet weld is an addition on a
HY-weld or HV-weld at T-joint (see Annex B, No. 10c and 11c). The throat thickness of these fillet welds depends on
the shorter leglength
5.3 Quality levels for imperfections for beam welded joints
5.3.1 General
The quality levels for imperfections related to the weld performance class are described below.
Quality levels for imperfections shall be according to EN ISO 13919-1:2019 and EN ISO 13919-2:2021
and are given in Table 5 and Table 6.
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BS EN 15085-3:2022
EN 15085-3:2022 (E)
Table 5 — Quality levels for imperfections for laser and electron beam welding for steel related
to the weld performance class
Imperfections
Weld performance classes
according to
EN ISO 13919-1:2019
CP A
CP B1 / CP B2
CP C1 / CP C2 / CP C3
CP D
1 to 4, 6, 7, 18
B
B
C
D
5, 8, 10 to 16
Not permitted
B
C
D
9, 17
Not applicable
B
C
D
Table 6 — Quality levels for imperfections for laser and electron beam welding for aluminium
and its alloys related to the weld performance class
Imperfections
Weld performance classes
according to
EN ISO 13919-2:2021
CP A
CP B1 / CP B2
CP C1 / CP C2 / CP C3
B
B
C
6, 9, 11 to 18
Not permitted
B
C
10, 19
Not applicable
B
C
1 to 5, 7, 8, 20
CP D
5.3.2 Quality levels for imperfection for friction stir welding
The visual inspection shall be carried out according to EN ISO 17637:2016.
The assessment criteria ofall weld performance classes for destructive and non-destructive testing shall
be in accordance with EN ISO 25239-5:2020, Table A.1. Cracks, worm-holes and lack of fusion are not
permitted.
Penetrant Testing:
The assessment shall be in accordance with EN ISO 3452-1:2 021 with the acceptance levels according to
EN ISO 23277:2015 group 2x.
Radiographic Testing:
Radiographic testing shall be carried out in accordance with EN ISO 17636-1:2022, class B. The
acceptance level 1 according to EN ISO 10675-2:2021 shall be fulfilled.
5.3.3 Quality levels for imperfections for stud welding related to the weld performance class
Stud welded joints are permitted for weld performance classes CP C3 and CP D only. The requirements
according to EN ISO 14555:2017 shall be fulfilled.
5.3.4 Quality requirements for resistance spot welding, projection welding and resistance seam
welding related to the weld performance class
The quality requirements for resistance spot welding, projection welding and resistance seam welding
are defined in Table F.2. For the surface quality, Table F.3 applies.
Resistance spot welding, projection welding and resistance seam welding is not permitted for weld
performance classes CP A, CP B1 and CP B2.
5.3.5 Quality requirements for flash welding
The quality requirements for flash welding of steels are defined in Annex E.
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EN 15085-3:2022 (E)
5.3.6 Defining quality requirements for other welding processes
The quality requirements for other welding processes shall be defined before starting the production.
6
Selection of parent metals and welding consumables
6.1 Selection of parent metals
Parent metals shall be selected according to the material grouping.
NOTE
CEN ISO/TR 15608 (CEN ISO/TR 20172) provides a uniform system for grouping materials for welding
purposes.
For a parent metal without proven weldability it shall be demonstrated, by means ofWelding Procedure
Qualification Record (according to the relevant standard), that the characteristics of the joints achieved
by using the parent metals comply with the requirements defined by the design office or engineering
department (see EN 15085-4:-2).
For components with welded joints ofhigh or medium safety category, only parent metals with proven
fatigue strength shall be used.
The likely decrease of mechanical properties in the Heat Affected Zone (HAZ) shall be considered,
especially when welding aluminium alloys (material group 21 to 26 accordingto CEN ISO/TR 15608) and
high strength steels (e.g. with ReH > 690 MPa).
6.2 Selection of welding consumables
When specific properties of the welded joint are required (e.g. corrosion resistance), they shall be
indicated on the drawing or technical documentation.
When welding 6000 series aluminium alloys, for welds in the longitudinal direction ofthe car body, the
use of5000 series alloy welding consumables is recommended as these have significantly better fracture
toughness than 4000 series consumables, particularly in partial penetration welds.
A welding coordinator shall be consulted with respect to the selection of the appropriate welding
consumables for the materials specified in the design. This shall be supported by Welding Procedure
Qualification Record (WPQR), for more details please see EN 15085-4:-2.
Welding consumables shall
recommendations.
be stored and handled in accordance with the manufacturer's
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EN 15085-3:2022 (E)
7
Weld joint design
7.1 General
Weld seams should be avoided in highly stressed areas.
For economy and ease of manufacture when designing welds, preference should be given to the use of
fillet welds. Where these do not satisfy structural requirements, partial penetration or partial penetration
with fillet weld reinforcement should be considered. Full penetration welds should only be specified
when no other weld types satisfy the structural or corrosion protection requirements.
Welded joints with sharp edges and steep changes of cross-section should be avoided. The stress path
should be distributed as evenly as possible.
Where possible, the neutral axes ofthe welded components should be aligned.
Where evidence ofthe design throat thickness is required, it shall be proven by a production weld test.
For steel components with stresses in the through thickness direction advice given in EN 1011-2:2001,
Annex F shall be followed.
Material with improved deformation properties perpendicular to the surface of the product should be
considered.
Welds made with permanent backing shall have the backing material included in the design calculation.
For full penetration butt welds in aluminium alloys made from one side it is recommended that backing
is used.
Ifhard stamping is to be used, the location shall be specified on the drawing.
In order to minimize distortion and shrinkage, welded joints should be positioned along or symmetrical
to the neutral axis ofthe component. Assemblies shall be designed to allow suitable access for welding
and inspection.
To avoid an excessive number of welded joints in close proximity, forged or cast components should be
considered.
The welding of non-structural / secondary attachments to the tension surface of components should be
used with caution. Ifnecessary, the effect ofthe attachment shall be verified by an appropriate structural
assessment.
For longitudinal structural welds in heat treatable aluminium alloys, the geometry of extrusions should
ensure the weld and strength ofthe heat affected zone is matched to the parent material strength. Where
this is not possible, (e.g. Window pillars) the welded joint should be designed to be at least as strong as
the connected parent material.
Requirements for resistance spot welding are given in Annex F.
Only fasteners (e.g. bolts, screws, nuts) with proven weldability may be welded (e.g. to prevent turning).
7.2 Design guidelines
7.2.1 Fabricated box sections
In the case of fabricated box sections subjected to bending stresses, welds on both sides are
recommended for the joints subjected to tensile stresses (the flange in tension). Figure 1 shows an
example ofa box section with the preferred welds.
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2
‘<3
2
i;>'
'<<1_)
1
cw I
=\/.
I
| QC.»
CY) ,
3
3
Key
1
Fabricated box section
2
Compression flange
3
Tension flange
Figure 1 — Example of box section with high stress level in the tension flange
7.2.2 Butt welds on parts of dissimilar thickness
For butt welds in dissimilar thicknesses, the transition between the sections shall be gradual, with the
slope less than or equal to the values given in Figure 2, to reduce the notch effect. Exceptions may be used
only for weld performance class CP D.
The external shape ofthe weld shall provide a smooth transition.
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EN 15085-3:2022 (E)
Dimensions in millimeters
E
rt
E3
E -d Ii
rr 7
i
I
W
E ..-511:1
rliirrlliw-!§\\\ I
a)
b)
1:1 for CP C3 and CP D
‘-
54114
"
i// ///
54114
i7//%7//
5‘T\ll:1i
C)
Cl)
joint preparations are shown on the drawings. Slope < 1:1 is an angle of< 45°, slope < 1:4 is an angle
of-: 15°. For CP B1, CP B2, CP C1 and CP C2 welding beads — use.
al.__
(“J
"Ii-e
B]
Key
1
Slope
Figure 2 — Butt joint on parts of dissimilar thickness
7.2.3 Plug welds and slot welds
Plug and slot welds are only permitted for weld performance classes CP C2, CP C3 or CP D. Plug and slot
welds can only accommodate shear stress.
Plug welds with circular holes or slots shall allow access ofthe electrode or the welding torch at an angle
of45° minimum (see Figure 3).
When filling the plug or slot welds completely, (e.g. welding wrongly drilled holes, etc.) the integrity of
the weld should be demonstrated with a production weld test as per EN 15085-4:-2, 4.2.2.
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EN 15085-3:2022 (E)
Figure 3 — Weldability access for plug and slot welds
For fillet welds in holes or slots, see Annex C.
7.2.4 Proximity of two joints
Where possible, welds should be positioned to avoid overlapping ofthe heat affected zone (HA2). When
the HAZ are overlapping, mechanical material properties shall be considered in that area (e.g. residual
stresses, drop in strength, hardness decrease). In order to reduce angular deformation and stress buildup, the minimum distance between two joints is determined according to the thickness of the parts
jointed and the clamping arrangement ofthe assembly.
For aluminium alloys and high strength steels it is recommended that for material thicknesses < 20mm a
distance of at least 50 mm is left between welds, (see Figure 4).
Dimensions in millimetres
E
5“
i
E
as
B
/i
B
Key
A
parent material
B
HAZ
C
weld metal
Figure 4 — Minimum distance between welds
7.2.5 Stiffeners welded across a butt weld
Openings on components when crossing a butt weld by a fillet weld should be avoided. The excess weld
material in this area should be ground to enable welding without interruption at crossing welds, see
Figure 5.
Figure 5 — Stiffeners welded across a butt weld
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EN 15085-3:2022 (E)
7.2.6 Openings
Openings (e.g. for drainage) should be avoided. Ifthey are necessary, these openings shall be large enough
to be surrounded by a seal weld. Additionally, they should be made without inducing a stress build-up in
the heat affected zone of any existing weld, see Figure 6.
1
_
Q
_
‘V
\"
Key
r
radius in mm; r2 25 mm + t, but not less
than 30 mm
t
thickness ofthe stiffener in mm
d
12 20 mm
Figure 6 — Typical opening
7.2.7 Design guidelines for stiffeners and gussets ends
Figures 7 and 8 show examples ofstiffener and gusset design. To allow correct weld returns, gusset and
stiffener ends should be designed as per Figure 7.
Dimensions in millimeters
X
————
E.-_=.--i/5 + 5
X
I"
Key
a
fillet weld throat thickness in mm
t
thickness ofthe gusset in mm
r
radius in mm; r 2 25 mm + t, but not less than 30 mm
Figure 7 — Example gusset and stiffener end design
On highly stressed assemblies, gussets shall be continuously welded.
7.2.8 Gusset shape
Most failures affecting fatigue stressed parts (dynamic loaded parts) are due to shape-related problems
which poorly channel stresses and induce stress concentration, see Figure 8.
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I
Figure 8 — Gusset shape
7.2.9 Weld return
The weld return is useful to reduce corrosion and fatigue problems at the end ofthe plate.
When a weld return is required, it shall be indicated on the drawing. Ifpossible, the weld return should
be made as one continuous weld (e.g. without stop - start). The minimum length ofthe weld shall be as
indicated in Figure 9. Ifthe weld return without interruption is necessaiy because of highly stressed
edges (e.g. high stress category per Table 1), it shall be indicated in the drawing or technical
documentation linked to the drawing. In this case, the weld return should be done without interruption
over a length I, equal to or greater than 2 t.
l
l
-
—
B5151
'
will
I2 2 t where 1111111: 10 mm
Key
t
plate thickness
l
length ofcontinuation
Figure 9 — Weld return
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EN 15085-3:2022 (E)
7.2.10 Fillet weld
When designing fillet welds the following guidelines should be considered:
Fillet welds should typically be designed with equal leg lengths. Where asymmetric fillet welds are
required by the design, the leg lengths shall be defined on the drawing.
When specifying the throat thickness of the fillet weld, this should not be greater than that prescribed by
the design calculation. However, for small fillet welds, where the size is technically / practically not
achievable, the throat thickness may be increased.
Melting ofthe plate edges should be avoided by allowing sufficient distance (v) from the weld toe to the
plate edges, see Figure 10.
In order to achieve this the following formulas may be used:
— v 2 2,521.
or
— v21,5a+t
Ir’
_i5_
‘I
L
J‘
Figure 10 — Edge distance for fillet welds
For thicknesses less than 20 mm, and particularly for aluminium and high strength steels, it is
recommended to maintain welds at least 50 mm apart, see Figure 11.
"'rriin
-if
a|T‘iHi{
ti
-C
,44
:2 5 i,
Lmm = 3><t2 (min 50 mm for 5 mm 5 t2 5 20 mm)
, _;_1
max
‘J5
The section specified a shall be less than or equal to a,,,,,, calculated.
Figure 11 — Minimum overlapping distance for lap joints
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EN 15085-3:2022 (E)
7.2.11 Use of run-on and run-off plates
Run-on and run-off plates (see Figure 12) shall be used for butt welds and welds at T-joints with weld
performance class ofCP A, CP B1 and CP B2 and they shall be indicated on the drawing. Run-on and runoff plates may be used for other weld performance classes to reduce the risk of weld defects in these
areas.
The run-on and run-off plates shall be made from compatible material as the main joint and have
sufficient thickness and length to allow weld start and stop within them.
Run-on and run-off plates can be either integral to the parent material or as separate plates with the same
joint preparation and attached by mechanical, magnetic or welding methods, see Figure 12.
Run-on and run-off plates shall be removed by thermal cutting, machining or grinding. The removal of
the run-on run-off plates shall not be done using methods that can introduce cracks, e.g. by applying
impact loads, tensile loads or pressure.
Figure 12 — Example of run-on and run-off plates for butt welds
7.2.12 Highly restrained joints
Cold cracking and hot cracking are the cause of many failures. Designers should be aware that highly
restrained joints cause residual stresses that may facilitate the development ofboth types of cracking.
The foI'_owing assemblies should be avoided as their residual stresses may lead to such problems:
— we'_ding full round bars or thick-walled pipes on thick plates, (a) in Figure 13);
— we'_ding small, thick plates (doubler) that will keep their shape (b) in Figure 13);
— we_ding ribs into thick—walled pipes that will keep their shape (c) in Figure 13);
— we_ding rigid parts that maintain their shape during welding, forcing the weld to compensate for all
shrinkage;
— welding a plate to the edge ofa rib using plug welds.
23
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EN 15085-3:2022 (E)
ai
‘ii
N1]
iiiiiiiiiiiii '1‘
by
A-A
30 ir
"M
WM
.
cm
A
Figure 13 —Highly restrained joints
7.2.13 Mixing of joining techniques
Mixing of joining techniques (e.g. welding and bolting or riveting) should be avoided in structural
applications due to the stresses induced by welding, see Figure 14. Furthermore, they are not
complementary for transmitting loads. When mixing techniques, calculation should only be applied to the
weld alone.
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EN 15085-3:2022 (E)
in
Iggljfi/S"
F—
__-""“"-¥
-
“~_.
-._
I
‘i
-..
-_
-.__
--._
-._..
*-.....-1
.._i...-i-"
--._ _,.--
‘\-i_.
‘-._
\-t_.
‘\\_..
‘\-....
.._.--"
.._..-i.._i-I
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.._..i.--P‘
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_,_.-1
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~._.._.~
--_,___»-
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I.-—
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....--i'
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..-/‘
...-/
*-..
‘-t_
\...
i-..
S-t._
.
_
""--_-‘—-
Figure 14 — Mixed assemblies
7.2.14 Prevention of corrosion problems
Corrosion protection shall be considered during the design phase. If necessary, welded joints shall be
sealed (e.g. by welding or suitable sealant between intermittent welds and on the back of partial
penetration and fillet welds), see Figure 15.
\
L
Figure 15 — Corrosion locations
7.2.15 Intermittent welds
The minimum weld length ofintermittent welds should be:
—
for rm <2 l0fl'lI‘?'I : lmin > 5 >< rm , but at least 20 mm for steel and 30 mm for aluminium alloys,
—
fortnia.‘-it
_ > 10mm: Imin. > 3><tmax ’ but at least 50 mm ’ see Figure 16.
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BS EN 15085-3:2022
EN 15085-3:2022 (E)
"~.
\I
Key
e 5 3 >< 1
v
edge distance
v 5 0,5 ><l
I
length ofthe single weld
Figure 16 — Intermittent welds
7.3 Ioint preparation
joint preparation should be defined in accordance with EN ISO 9692-1, EN ISO 9692-2, EN ISO 9692-3.
For more information, see Annex B and Annex C in this document.
7.4 Methods to improve the fatigue strength (Post weld improvement)
7.4.1 General
To improve fatigue behaviour of welded joints, the admissible stress can be increased by post weld
improvement. Weld improvements can increase service life (for a given stress level) or fatigue limit (for
a given service life).
The fatigue strength ofwelded joints can be improved by applying one or more ofthe following processes.
Where more than one method is used they shall be used in the following order:
1.
an improvement of the shape ofthe weld toe (by oriented grinding or TIG dressing);
2.
a heat treatment to decrease residual tensile stresses;
3.
introduction of compressive stress (e.g. shot-peening, High Frequency Mechanical Impact, High
Frequency Hammering).
In new manufacturing, ifhigh stress category is obtained after post weld improvement, then a new design
is required. This is to allow maximum flexibility for repairs in maintenance activities.
Where post weld improvements are considered necessary, the admissible stress gains shall be proven in
the design calculations. The applicable weld improvement method shall be specified on the drawing and
design documentation.
26
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EN 15085-3:2022 (E)
Post weld improvement methods and parameters different to those listed in the following subclauses
shall be subjected to investigation and testing in order to demonstrate that the equivalent or intended
characteristics can be achieved.
7.4.2 Improvement of shape of weld toe
Improving the shape of the weld toe provides a smooth transition and reduces the stress concentration
(notch effect). Improving the shape of the fillet weld toe is one of the most relevant examples of this
process.
Improvement of the weld toe shape can be achieved by TIG dressing or oriented grinding.
In the cases of TIG dressing or oriented grinding, the depth shall be k 5 0,3 mm and the radius shall be
r 2 3 mm, see Figure 17.
When grinding is applied, the use of rotary burrs is recommended. Grinding discs shall be avoided, as the
orientation of grinding marks when using this method are typically normal to the stress direction in
transversely loaded welds.
Butt joint
"
of
T-joint
bl
Figure 17 — Weld toe improvement
7.4.3 Post Weld Heat Treatment (PWHT) — stress relief
Post weld heat treatment can significantly reduce residual stresses resulting from heating and welding
operations.
When post weld heat treatment is required, it shall be specified and performed in accordance with
EN ISO 17663:2009.
When post weld heat treating is performed, care shall be taken to minimize distortion and avoid the need
for cold straightening.
27
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BS EN 15085-3:2022
EN 15085-3:2022 (E)
Post weld heat treatment conditions shall be shown on the relevant drawings or defined in related
documents / specifications.
The following information shall be provided:
'1
a,
maximum loading temperature;
b‘
maximum heating rate;
c]
holding temperature;
d]
minimum and, ifrequired, maximum holding time;
e]
maximum cooling rate;
f)
maximum unloading temperature;
g)
if required, cooling condition after unloading;
J
The conditions of the post weld heat treatment (temperature and time) shall be recorded.
7.4.4 Introduction of compressive stress
The improvement of fatigue strength can be achieved by introduction of compressive stresses at the
surface of the welded joint by mechanical methods (e.g. shot peening, ultrasonic peening, hammer
peening, etc.).
Any chosen method of mechanical stress relief shall be undertaken using a qualified procedure and
recorded. When using shot peening, the following parameters shall be considered:
—
suitable steel shot material (type and size);
—
coverage ofweld and heat affected zone.
Recommended values for shot-peening for steel (S355) are as follows:
—
greater than or equal to 260 MPa at 0,1 mm below the surface;
—
greater than or equal to 50 MPa at 0,5 mm below the surface
—
In order to control the process, the peening intensity can be measured according to EN ISO 269101 (Almen arc height (A): (0,6 i 0,1) mm.)
8
Design documentation related to welding
8.1 Information on design drawings or documentation linked to the drawings
Welded joints shall be indicated on drawings using weld symbols according to EN ISO 2553:2019 system
A. These should include enough details with respect to weld shape and joint preparation when necessaiy.
The following deviation and additions to EN ISO 2553 :2019 shall be used for the welding of railway
vehicles and components:
a)
Welds with partial penetration should be avoided in high dynamically loaded welded joints. The
minimum weld throat, determined by the designer, shall be considered in the stress calculation and
shall be achieved in production (proofby production weld tests, see EN 15085-4:-2, 4.2).
28
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Standardsl
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Es EN 15085-s=2022
EN 15085-3:2022 (E)
b)
The weld type and throat thickness shall be indicated on the drawing (see Annex B). For butt welds,
when no throat thickness is defined, the weld shall be considered full penetration as per
EN ISO 2553:2019. Where it is not possible to indicate the required dimensions on the drawing the
welded joint shall be shown graphically.
c)
In all cases the arrow lines ofthe weld symbols shall point to the visible welded joint.
d)
The weld length should be indicated on the drawing. When no weld length is defined, the weld shall
be continuous along the entire length ofthe joint (as per EN ISO 2553:2019).
e)
The weld performance class shall be indicated on the drawing, parts list or technical documentation
linked to the drawing. If a drawing has different weld performance classes, the weld performance
class shall be clearly indicated for these welds.
f)
For classification level CL 1 to CL 3 according to EN 15085-2:2020, the classification level shall be
given on the drawing, parts list or technical documentation linked to the drawing (see also EN 150852:2020).
g)
Material designation for welded components shall be specified on the drawing, parts list or technical
documentation linked to the drawing.
h)
Ifthe expected properties ofthe welded joint are different from those ofthe parent metal (e.g. high
strength steel), they shall be indicated on the drawing, parts list or technical documentation linked
to the drawing.
i)
For fillet weld and T joint, when impact properties are required, they shall be indicated on the
drawing or technical documentation.
j)
For welded joints, which are produced by resistance spot welding, the surface quality shall be
indicated according to Table F.3.
k)
When there is a deviation in the weld inspection class (CT) fi"om Table 3, then this shall be specified
on the drawing.
l)
All welds shall be identified and traceable to link the welding execution drawing and documents to
the design drawing.
m) All component parts shall be specified on the drawing or on a separate parts list.
n)
The requirement and method for any post-weld improvement treatment shall be specified on the
drawing.
o)
The quality of cut edges (e.g. if required for fatigue considerations) shall be specified in the technical
documentation.
An example of a list ofwelded joints that links design and production information is given in Annex A.
Ifno admissible tolerances are given on the drawing, according to EN ISO 13920:1996 the following shall
apply:
— tolerance class B for linear and angular dimensions;
— tolerance class F for straightness, flatness and parallelism.
29
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Es EN 15085-3=2022
EN 15085-3:2022 (E)
8.2 Design review of welded components
The responsible welding coordinator or an authorized nominee shall contribute to the design review of
welded components. Evidence ofthis review shall be available.
8.3 Use of existing drawings not according to EN 15085
For welding of new parts or components, using drawings produced before the introduction of EN 1 5085
series, the drawings do not need to be updated.
However, the following information shall be documented:
—
Classification level according to EN 15085-2:2020;
— Weld type, weld throat thickness and weld length according to this document;
— Weld performance class according to this document or EN 1 5085-6:-4;
—
Parent metals in accordance with current standards.
Ifthe existing drawings re fer to the welding consumables to be used, these shall be updated in line with
current standard.
30
C py ghIB tish Standards lnstit I
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EN 15085-3=2022 (E)
Annex D
[informative]
Types of joints in relation to stresses and inspection classes
Figure D.1 shows possibilities for selecting a type of joint to lower stresses and inspection classes. The
arrows show the type ofjoint appropriate to reduce the weld performance and the inspection class. In all
cases, the magnitude and direction ofloading has to be taken into account.
. %-%-1
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4
welding with access from both sides
2
welding with access from both sides
5
moulded or cast part
3
welding with access from one side only
The weld toe offillet welds may be ground whereas butt welds may be ground flush.
Figure D.1 — Types of joints in relation to stresses and inspection classes
4-1
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BS EN 15085-3=2022
EN 15085-3=2022 (E)
Annex F
(normative)
Resistance spot, seam and projection welding
F.1General
Table F.1 provides minimum parameters for the design ofthe spot spacing and distance from the edge in
dependency on the thickness ofthe thinnest plate for resistance spot welding.
Table F.1 — Spot spacing, distance from edge
Dimensions in millimetres
Plate thickness t1
1
1,25
1,5
1,75
2
2,5
3
Spot spacing e1
25
35
35
35
40
50
50
Distance from edge v
2 10
2 10
2 10
2 10
2 15
2 15
2 15
Deviations to Table F.1 shall be tested by production weld tests according to EN 15085-4:-2 successfully.
Minimum shear pull forces and spot diameters are given in Tables F.4 and F.5.
lfthese values are deviated from for reasons ofthe design, a production weld test shall be taken to verify
the design.
4-5
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EN 15085-3=2022 (E)
Dimensions in millimetres
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bending radius
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h
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I,
smaller plate thickness
11'
vl
distance from edge 1
£2
larger plate thickness
v,
distance from edge 2
Overlap
d1. dz
Bl6C’EI"0ClB diameter
X
Side distance
R
bunching radius ofthe electrode
Figure F.1 — Resistance spot welding of angled profiles and plates
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overlap
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smaller plate thickness
Figure F.2 — Resistance spot welding of plates, single row
Cepynghi E-riiish Siandards Insiiiuiien
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BS EN 15085-3=2022
EN 15085-3=2022 (E)
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b
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Figure F.3 — Resistance spot welding of plates, double row
in
Key
Q1
Spot Spacing
e3
spot spacing, [double row, offset]
v
distance from edge
Figure F.4- — Resistance spot welding of plates, double row, offset
The Figures F.1 to F.-4 show possible configuration ofresistance spot weld Table F.2 defines the quality
requirements for resistance spot welded joints, projection welded joints and resistance seam welded
joints for production welds.
4-7
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BS EN 15085-3=2022
EN 15085-3:2022 (E)
Table F.2 — Quality requirements
Serial
Ref. No. to
N0‘
EN iso 6520-2=2013
Requirements
Weld
performance
class CP C1 and
CP C2
Weld
performance
class CP C3
Weld
performance
class CP D
Quality requirements, general
1
Classification ofwelding
processes according to
EN ISO 4063:2010
21, 22
21,22,23
2
Type of machine
Welding
machines with
programme
cycle control and
process
inspection
Welding
machine with
programme
cycle
The requirements
CP C1, CP C2 and
CP C3 are valid.
For 21 the use of
manual, foot table
machines is
permissible.
3
Field ofapplication
Supporting part of rail vehicles
[side walls, front walls, floors and
outside parts as instrument cases,
flaps, aprons, doors)
Subordinate parts
(panels, cable
ducts, ventilation
grids]
4
Permissible sheet metal
thickness ratio
t;_1_:t| 53:1
No requirements
5
Minimiim shear pulling force
Other sheet metal ratios and
welding ofmore than two sheets
shall be agreed with the customer.
For 21 Table E.4 and Table E.5
For 22 and 23 these Tables are
valid in the sense corresponding
to the connecting sector.
6
Surface appearance of the
various parts
75 % of CP C1,
CP C2 and CP C3
The surface ofthe joined parts shall be free of scale,
rust, paint, dust, grease or other soiiing at the place of
the weld.
Additionally surface coatings, lamination, corrosion
protective, sealing, pastes and glue can be used iftheir
welding suitability has been proved.
7
Maximum hardness values for
steel
The general requirements of
No requirements
EN ISO 15614--12:2021 shall be
applied. For the hardness values,
EN ISO 15614-1:201? shall apply.
Quality requirements — Surface imperfections
9
P 100
Crack
Not permitted
10
P2011
Gas pore
Not permitted
P2012
Uniformly distributed porosity
Permitted by
design review
P 20 1 3
Localized porosity
P 602
Spatter
P 612
Material extrusion
Permitted if agreed between the
contracting parties
Permitted by
design review
12
P 526
Surface imperfection
Surface quality 2 and 3 to
Table F.3 permitted
Surface quality 2, 3
and 4 according to
Table F.3
permitted
13
P 522
Burn through from one side
Not permitted
Permitted
11
Copyright British Standards Institution
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BS EN 15085-3=2022
EN 15085-3=2022 (E)
Serial
N .
0
EN ISO 6520-2:2013
Ref. No. to
14
P 5263
Requirements
Weld
performance
class CP C1 and
CP C2
Adhering electrode material
Weld
performance
class CP C3
Weld
perfo rmance
class CP D
Not permitted
Permitted by
design review
No requirements
Quality requirements — Internal imperfections
15
P 5216
Insufficient depth of
penetration ofnugget
Minimum 30 % max. 90 % ofthe
particular sheet metal thickness
16
P 100
Crack
Permitted for 21 and 23 in the centre area of the
welding lens [maximum half diameter]
17
P2011
Gas pore
P 300
Solid material inclusion
Permitted for 21 and 23 in the middle halfof the
welding lens diameter
Not permitted for 22
18
19
20
P 2012
Uniformly distributed porosity
P 2013
Localized porosity
P 400
Lack offusion
P 401
No weld
P 525
Excessive sheet separation
For22:1-432%
d5()__4,la
For22:/454%
450,52,
Not permitted
immediate next to the welding
point:
Permitted
h§0,l(r,+r,)
Testing and documentation
21
Visual test b
22
Production weld test P
100 %
—
daily before start ofwork
—
at tool modification
—
changing the welding parameter with a qualified
WPS
23
Procedure qualification
according to EN ISO 1561412:2021
required
Not required
H
A = area ofimperfection, d = size ofsingle imperfection [for instance length, width, diameter].
b
Testing the completeness ofwelding and external assessment without use ofoptical instruments.
‘Y
Peel and chisel testing according to EN ISO 10447:2015 or simplified torsion test [weld production test] according to
EN ISO 17653:2012 or for resistance spot welding: shear test.
Table F.3 defines the surface quality for resistance spot welded joints, projection welded joints and
re sistance seam welde d joints.
49
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BS EN 15085-3=2022
EN 15085-3:2022 (E)
Table F.3 — Surface quality
Surface
quality
Requirements
Application
1
Shall be defined in the technical specification
Shall be defined in the technical specification
2
Surfaces where welding marks [electrode
impressions, ring shaped reinforcement-formation,
imperfections, through heat distortion etc.) do not
amount to more than 10 % ofthe particular single
sheet metal thickness.
For surfaces with aesthetic requirements [for
instance side walls, front walls and roofs of
passenger trains].
Note: If required the indentation can be filled in.
3
Surfaces where welding marks do not amount to
more than 25 % of the particular metal thickness. In
this area are also firmly adhering welding spatter
permitted as long as the drawing does not demand
that it shall be free of burrs and splatters.
Surfaces for non-aesthetic requirement [for
instance freight wagons, transport containers,
sheeting offloors].
4
Without quality requirements.
For simple parts ofsubordinate importance
without aesthetic requirements.
F.2Minimum shear pull forces
Table F.4 and Table F.5 contain the minimum shear pull force values for resistance spot welding joints
dependent on metal thickness ofthe thinnest plate for weld performance classes CP C1, CP C2 and CP C3
These shall be proven by the shear pull force test.
— steel: Table F.4;
— aluminium and alloys: Table F.5.
lfthe diameter ofthe spot weld required in Table F.4 / F.5 leads to excessively high shear pull force, the
diameter can be reduced. After this reduction, the resulting shear pull force value shall be at least 10 %
higher than the minimum required shear pull force value given in Table F.4 / F.5. This testing should be
carried out before series production begins and the results shall be recorded in the design documents
and in the relevant WPS.
50
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BS EN 15085-3=2022
EN 15085-3=2022 (E)
Table F.4 — Minimum shear pull forces for resistance spot welding joints of steel for weld
performance classes CP C1, CP C2 and CP C3
tl [mm]
d1. [mm]
Tensile strength R,,, of the parent metal [MPa]
5360
| >3s0m<510 I
510m<620
Minimum shear pull force per spot (kN)
Q8
£5
35
45
80
L0
50
47
80
80
L25
55
55
Z5
1&0
L5
65
Z1
90
120
L75
65
85
1&9
145
Z0
Z0
105
118
110
Z5
85
129
1&5
220
30
85
1&5
2L0
2&0
These values are valid for unalloyed and alloyed steel, also for the combination of them. For the
combination ofparent metals with different tensile strength, the material with the lower value shall be
chosen.
Table F.5 — Minimum shear pull force for resistance spot welding joints of aluminium and alloys
for the weld performance classes CP C1, CP C2 and CP C3
tl [mm]
a'L [mm]
Tensile strength Rm of the parent metal [MPa]
524-0
I
>24.-0 to 300
|
>300 to 350
Minimum shear pull force per spot (kN)
0,8
4,5
1,1
1,3
1,5
1,0
5,0
1,5
1,8
2,1
1,25
5,5
2,0
2,3
2,8
1,5
6,0
2,5
2,9
3,5
2,0
7,0
3,5
4,1
4,8
2,5
8,0
4,5
5,3
6,2
3,0
8,5
5,5
6,4
7,6
For parent metals with different tensile strength, the material with the lower value shall be chosen.
51
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BS EN 15085-3=2022
EN 15085-3:2022 (E)
Annex G
[informative]
Determination of safety category for welded joints
The basis for the determination ofthe relevant safety category for the welded joint is the definition of
high, medium and low safety level as defined in 4.4.
In addition, the approach for safety assessment given in the EN 50126 series of standards may be used
for this purpose. Where possible, feedback from previous designs and their in-service behaviour should
be used. According to the safety assumptions and requirements ofthe fatigue strength assessment the
safety categories are differentiated as follows:
Safety category low:
A failure of the considered welded joint does not lead to any impairment of the overall function and
consequential events with personal injuries are unlikely.
Safety category medium:
A failure ofthe considered welded joint leads to a break down ofthe overall function ofthe railway vehicle
or a failure ofthe considered welded joint can lead to consequential events with personal injuries and:
a)
a warning is given before failure; or
b]
the design of the component provides an alternative load path [non statically determined system or
redundant components]; or
c]
the design of the components contains a feature to arrest a propagating crack.
Safety category high:
A failure ofthe considered welded joint leads to consequential events with personal injuries and none of
the criteria a], b] or c] for medium safety category apply.
NOTE
In standards for fatigue assessment of non-welded and welded structures the safety category is
considered by special partial safety factor.
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EN 15085-3=2022 (E)
Annex ZA
[informative]
Relationship between this European Standard and the Essential
requirements of Directive (EU) 2016/797 aimed to be covered
This European Standard has been prepared under a Commission’s standardization request "M/483
Mandate to CEN and CENELEC for Standardisation in the field of interoperability ofthe rail system” to
provide one voluntary means of conforming to [parts of] Essential Requirements of Directive [EU]
2016/797 ofthe European Parliament and ofthe Council of 11 May 2016 on interoperability ofthe rail
system [recast] as specified in the relevant technical specifications for interoperability [TSI].
Once this standard is cited in the Official journal ofthe European Union under that Directive, compliance
with the normative clauses ofthis standard given in Table ZA.1 for locomotive and passenger RST confers,
within the limits of the scope of this standard, a presumption of conformity with the corresponding
Essential Requirements of that Directive as specified in the technical specifications for interoperability
[TSI], and associated EFTA regulations.
Table ZA.1 — Correspondence between this European Standard, the Commission Regulation
N 1302 /20 14 concerning the technical specification for interoperability relating to the rolling
stock — locomotives and passenger rolling stock’ subsystem of the rail system within the
European Union and Directive (EU) 2016/797*
Essential
Requirements of
Directive (EU)
2016 / 797
Section 3 ofthe Annex
to the TSI indicates the
correspondence
between the TSI
clauses and the
Essential Requirements
of Directive [EU]
2016/797
Clauses of the Annex
to the Technical
Specification for
Interoperability [TSl)
Clausef subclauses of
this European
Standard
4.2.2.4 Strength of
vehicle structure, SubClause 8
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
6.1, 6.2
Comments
5.2.1—5.2.6 include
requirements
regarding the quality of
the welds by defining
maximum admissible
defects to guarantee
the strength ofthe
component
6.1 and 6.2 include
requirements
regarding the choice of
parent metals [e.g.
weldability] and
welding consumables
[verification by WPQR
that the joint achieve
the intended
mechanical
characteristics]
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Es EN 15085-3=2022
EN 15085-3:2022 (E)
Essential
Requirements of
Directive [EU]
2 016 / 797
Clauses of the Annex
to the Technical
Specification for
Interoperability (TSI)
Clause/ subclauses of
this European
Standard
Annex C
Special provisions for
mobile railway
infrastructure
construction and
maintenance
equipment
4.1
4.2
4.3
4.4
4.5
4.6
5.2.1
C.1 Strength ofvehicle
structure
5'22
5'23
5.2.4
5.2.5
5.2.6
Annex C
Special provisions for
mobile railway
infrastructure
construction and
maintenance
equipment
4.1
4.2
4.3
4.4
4.5
4.6
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
Comments
4.1-4.6 include design
requirements [stress
assessment, addressing
weld performance
classes depending on
stress level and safety
category, weld
inspection class] to
guarantee the strength
of the vehicle structure
5.2.1—5.2.6 include
requirements
regarding the quality of
the welds by defining
maximum admissible
defects to guarantee
the strength ofthe
structure
4.1-4.6 include design
requirements [stress
assessment, addressing
weld performance
classes depending on
stress level and safety
category, weld
inspection class] to
guarantee the stability
of the structure even in
the case oflifting and
jacking
5.2.1—5.2.6 include
requirements
regarding the quality of
the welds by defining
maximum admissible
defects to guarantee
the stability ofthe
structure even in the
case oflifting and
jacking
* As amended by Commission Regulation [EU] No 2016/919, Commission Regulation [EU] 2018/868,
Commission Implementing Regulation [EU] 2019/776 and Commission Implementing Regulation (EU)
2020/387
NOTE
The Technical Specification for Interoperability [TSI] can refer to other clauses of this standard making the
application ofthose clauses mandatory. Possible references to such clauses are found in the Appendix D to the TSI.
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EN 15085-3=2022 (E)
WARNING 1 — Presumption of conformity stays valid only as long as a reference to this European
Standard is maintained in the list published in the Official journal ofthe European Union. Users ofthis
standard should consult frequently the latest list published in the Official ]ournal ofthe European Union.
WARNING 2 — Other Union legislation may be applicable to the product[s] falling within the scope of
this standard.
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Bibliography
I1]
EN 1011-4, Welding - Recommenda tionsfor welding ofmetallic materials - Part 4: Arc welding of
aluminium and aluminium alloys
I2]
EN 1090-3, Execution ofsteel structures and aluminium structures - Part 3: Technical
requiremen tsfor aluminium structures
I3]
EN ISO 15614-13, Specification and qualification ofwelding proceduresfor metallic materials Welding procedure test- Part 13: Upset (resistance butt) andflash welding (ISO 15614-13)
I4]
EN 1708-2:2018, Welding - Basic weldjoint details in steel - Part 2: Non internal pressurized
components
I5]
EN 17149-3,6 Railway applications - Strength assessment ofrailway vehicle structures - Part 3:
Fatigue strength assessment based on cumulative
I6]
EN 10025-2, Hot rolled products ofstructural steels - Part 2: Technical delivery conditionsfor nonalloy structural steels
I7]
EN ISO 3834 [all parts], Quality requirementsforfusion welding ofmetallic materials
I8]
EN ISO 9692-1, Welding and allied processes - Types ofjointprepara tion - Part 1: Manual metal
arc welding, gas-shielded metal arc welding, gas welding, TIG welding and beam welding ofsteels
(ISO 9692-1.-2013)
I9]
EN ISO 9692-2, Welding and allied processes -jointpreparation - Part 2: Submerged arc welding of
steels (ISO 9692-2.-1998)
I10]
EN ISO 9692-3, Welding and allied processes - Types ofjointprepara tion - Part 3: Metal inert gas
welding and tungsten inert gas welding of aluminium and its alloys (ISO 9692-3:201 6)
I1 1]
CEN ISO/TR 15608:2017, Welding — Guidelines for a metallic materials grouping system
[ISO/TR 15608:2017]
I12]
CEN ISO/TR 20172:2009, Welding - Grouping systems for materials - European material
[ISO/TR 20172:2019]
I1 3]
ISO/TR 581, Weldability — Metallic materials — General principles
6 Under preparation. Stage at the time of publication: prEN 17149-3:2021
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