EN 15082 part 5 Railway applications welding of railway vehicles and - vehicle parts Part 5: Inspection, Testing and Documentation

SCOPEDefines the welds to be carried out in exams;Shall carry out the destructive and non destructive tests to determine;Defines the necessary documentation for the release of the product conformity

En 15085 contents1Scope 2Normative references3Terms and definitions 4Inspection and testing of welded joints 4.1General4.2Inspection and testing before welding 4.3Inspection and testing during welding 4.4Inspection and testing after welding

5Test planning and test criteria5.1Test planning5.2Test criteria

En 15085 contents6Documentation7Non-conformance and corrective actions.. 7.1General7.2Management of non-conformance 7.3Additional tests 8Sub-contractors 9Declaration of conformity 10Traceability

En 15085 contentsAnnex A (normative) Inspection and testing of welded joints

Tables

Table 1 Tests which have to be performed during production

Table A.1 Relationship between essential welding related tasks and the manufacturing phasesto be performed

4.1 GeneralThe relationship between the welding-related tasks of the responsible welding supervisor or his authorized representative in the production phase is given in Table A.1.4.2 Checks before weldingIn addition to Table A.1 the welding supervisor is responsible for : planning the preparation of the root and the support; additional welding detail in the drawings.The implementation of the design review in Table A.1 and the above tests must be documented

The welder / operator has any type of welding the following points to consider before beginning: that the welding equipment in working order; availability of work instructions; the state of the weld preparation and the correct specification of the welded seams workspieces (purity and state of assembly of work pieces, according to the drawing and / or WPS); Identification of the welded work pieces; that the welding consumables comply with the WPS.

4.3 Test during weldingThe welder or welding operator has the following items for review during andensure: the proper cleaning and the form of the compounds during the Zwischenlagenschweiung; compliance with the prescribed pre-heating and / or intermediate layer temperatures; compliance with the WPS and / or operating procedures; compliance with the order of operations, if in the specific work instruction is required (such as welding sequence diagram).

4.4 Testing after welding

4.4.1 Tests by the welder or operator

the welding, the welder or operator after check whether: the weld is complete; the weld is cleaned; the shape and dimensions of the drawing correspond to the weld.

4.4.2 worker self-examination by the welder or operatorIf a self-inspection system is employed, the self examination shall be done in an appropriate manner with regard to the implementation of the visual inspection and the requirementsEN 15085-3:2007, clause 5, by the responsible welding supervisor or a representative (Representative of the welding supervisor or VT 2-examiner in accordance with EN 473).

The tests, the welder or operator of the need to be carried out in accordance with Table 1 shall be clearly defined (acceptance criteria, dimensions, etc.) and are recorded.These records and calculations are of the welder or operator who has performed the audit under review, and the test documents attached to another.A copy of the personal signatures of names in publication is for the staff, the audit documents to sign store, too.Alternatively, electronic systems are used.

4.4.3 Verification of the conformity of the welding seamsAfter welding, the non-destructive tests carried out by qualified experts

The percentages shown are based on the total length of all welds.This applies: 100% means: examination of all welds of all components; 10% means test for 10% of the welds of all components, or 100% testing of a component of 10 components.The test methods are shown in Table 1 Mindestprfanforderungen of welded joints.

weld Test classVolumetric testRT or UTSurface examinationMT or PTCT1100%a100%CT210%a b10%bCT3Not requiredNot requiredCT$Not requiredNot required

The percentages expressed refer to the total length to be examined for one given weld. Thus: 100 % means: request for testing of the entire length of the weld and on all the pieces built; 10 % means: testing of 10 % of the entire length of the weld on all the pieces built or 100 % testing on 1 of every 10 items builtThe test methods indicated in Table 1 shall be the minimum capable of ensuring compliance of the welded joints. Additional tests depending on the material, the design or customer requirements may be necessary.All NDT (RT, UT, MT or PT) shall be performed by personnel certified according to EN 473 and shall be documented.For inspection classes CT 1 and CT 2, the visual examination shall be performed by personnel certified according to EN 473 and shall be documented.For inspection class CT 3, the visual examination shall be performed as a minimum by personnel qualified by the manufacturer and should be documented.For inspection CT 4, the visual examination shall be performed as a minimum by welders who are trained in visual examination and documentation is not required.

Volumetric tests applicable only for butt welds and T-welds with full penetration.bWhere volumetric testing is not feasible for welds of the weld performance class CP B in medium safety category or CP C1, 100 % surface testing is required. When five consecutive items are acceptable, surface testing may be reduced to 25 %. A production weld test according to EN 15085-4 for every welder or operator of a robot who carries out this weld before the start of the production is necessary. The production weld test is valid for six months and may be prolonged by the responsible welding coordinator if the welder or operator is still in the production (for information on weld performance classes, see EN 15085-3:2007, Table 2).

In the case of fully mechanised or automatic welding procedures with process monitoring for weld performance class CP B and CP C1 the extent of testing can be reduced in agreement with the responsible welding coordinator. If required, the agreement of the customer shall be obtained.

5 test plan and test criteria5.1 Inspection PlanningProduction planning are the verification procedure, the verification time and the necessary amount of tests in a test plan, depending on the weld test class , the weld shape and the material set.For simple welding components in the verification plan to work plan be integrated.Particularly complex or important case of welded components is recommended that a Test plan is created, the various phases of the tests clearly describes.5.2.1 weld gradesIn accordance with the technical documentation (eg, drawing) specified weld quality classes are according to EN 15085-3, Section 5 of the specified evaluation for imperfections of standards EN ISO 5817 or EN ISO 10042 for steel aluminum and aluminum alloys should be met with.For the resistance welding method is EN 15085-3:2007, Annex F.5.2.2 inspection stages and acceptance levelsEN 12062 is in the test stages and acceptable limits to the quality levels in terms of applied non-destructive test methods referenced. A CP is not completely contained in EN 12062 (see EN 15085-3:2007, clause 5).In specific cases where a more accurate assessment of the extent and type of irregularity is needed to verify its compatibility mode, it may be necessary, that other as contained in the EN tests are performed.

4.4.3Conformity control of weldsAfter welding, the NDT (Non-Destructive Testing) is carried out by certified personnel (except VT; see Table 1). Table 1 defines the type and frequency of the testing to be carried out during series production. This is basedon the relationship between the weld performance class of the welded joint assigned by the design engineer and the resulting inspection class (see EN 15085-3).Testing at the beginning of production: shall be according to the inspection class, 100 % testing of all welds on each initial item of the series if testing is required in Table 1.Testing during series production: the tests described in Table 1 shall be carried out on products manufactured during series production in accordance with the frequencies indicated therein and as per the weld performance class indicated on the drawing by the design engineer.In the case of detecting unacceptable defects during the tests indicated in Table 1, the procedure for management of non-conformance shall be applied, with the extension of the testing as indicated in Clause 7.