Specification...to minimize porosity. Conformance with the guidelines specified in AWS A5.32,...

Norm Welding fabrication specification for railway applications - valid for the USA

Ersteller Freigeber Freigabedatum Status Matchcode Version Seite

Chaeitani, Fouad ZGraggen, Werner 28.11.2019 Freigegeben NO0296 V1 1 von 21

Specification Welding fabrication for railway applications

- vehicles and components -




Table of Content 1 Scope .......................................................................................................................... 3 2 Purpose ....................................................................................................................... 3 3 Scope of application ...................................................................................................... 3 4 Terms ......................................................................................................................... 3 5 General guidelines ........................................................................................................ 3 6 Normative design and welding guidelines ......................................................................... 3 7 Welding requirements ................................................................................................... 5

7.1 Welding Procedure Qualification ............................................................................... 5 7.2 Welding Processes .................................................................................................. 5 7.3 Welding Consumables ............................................................................................. 6 7.4 Welding Qualification & Certification ......................................................................... 6 7.5 Facility Requirements ............................................................................................. 6 7.6 Name a responsible Welding Coordinator .................................................................. 7 7.7 Welding Coordinator responsibilities ......................................................................... 7 7.8 Minimum internal weld testing and training area equipment ........................................ 7 7.9 Requirements for the welder ................................................................................... 8 7.10 Weld wraparounds ................................................................................................. 8 8. Normative guidelines for inspection of welding work ................................................... 8 8.1 Weld Inspection Class and Acceptance Criteria ........................................................... 8 8.2 Inspection requirements ......................................................................................... 9

9 Documents to be archived and/or submitted .................................................................. 10 10 Contract review ......................................................................................................... 10 11 Specifications from the rWS of Hug Engineering AG ....................................................... 10 12 Materials .................................................................................................................. 10

12.1 Normative guidelines for the materials to be processed ............................................ 10 13 Subcontracting ....................................................................................................... 10 14 Initial Sample Test Report inspection for series projects ............................................... 10 15 Welding symbols on drawings ................................................................................... 11 16 Tests/Documentation/FAT ........................................................................................ 13 17 Documents to be handed over to Hug Engineering AG after the finishing of a product ...... 13 18 Monitoring .............................................................................................................. 13 19 Visual Weld Inspection - Acceptance Criteria (guideline) .............................................. 13 20 Visual Examination Report ........................................................................................ 15




1 Scope

This requirement for suppliers is only applicable for welding-related orders for the manufacturing of converters as well as for other welded components.

The purpose of this specification is to provide Hug engineering’s suppliers in USA with mandatory practices and procedures for all arc welding applied to specially Hug railway products.

AWS D1.1, D15.1, ASME Sec. IX were used as a guide and rules in the HUG welding products, and EN 15085 / EN 15614-1 were used as a guide, rather than a rule, in the formulation of Hug welding standards.

2 Purpose

This specification for suppliers is to ensure the quality of welded fabrication is in fulfilment of the requirements stipulated in the European standard for railway applications EN 15085 (welding of railway vehicles and components) as leading design as well as for the correct execution of all welding work and procedures according to the requirements AWS D15.1 as leading for execution

3 Scope of application - Converters and welded components - For construction of rail-bound vehicles

4 Terms

IWE International Welding Engineer

IWS responsible Welding Supervisor

ISTR Initial Sample Test Report

FAT Factory Acceptance Test

5 General guidelines - Prior to welding, oil, slag, rust and scale must be removed - After the welding, spatters must be generally removed - After the welding, the converters must be generally cleaned from welding- and grinding-dusts

6 Normative welding guidelines

AWS D15.1 (Railroad Welding Specification for Cars and Locomotives) - Leading standards for execution

AWS B5.17 (Specification for the Qualification of Welding Fabricators) or EN ISO 3834

AWS B5.1 (Specification for the Qualification of Welding Inspectors) or EN ISO 14731

AWS B5.16 (Specification for the Qualification of Welding Engineers)

All welding-fabrication related operations must be supervised by the responsible welding Inspector. The responsibilities and tasks of the responsible welding supervison must be organized in accordance with AWS B5.1.




Emphasis is made to the paragraphs, tables and figures referred to below of AWS D15.1:

5.2 Welding Procedure Specification (WPS) Qualification:

10 Procedure Qualification

11 Welder Qualification

14 Inspection – General Requirements

15 NDE - General Requirements

16 NDE Methods

17 Acceptance Criteria

Table 6.2 Joint Dimension Tolerances:

Table 10.1 PQR essential variable changes requiring WPS re-qualification

Table 10.2 Procedure qualification, Number and Type of Test Specimens and Range of Thickness Qualified – Complete Joint Penetration Groove Welds (CJP)

Table 10.3 Procedure qualification, Number and Type of Test Specimens and Range of Thickness Qualified – Partial Joint Penetration Groove Welds (PJP)

Table 10.4 Procedure qualification, Number and Type of Test Specimens and Range of Thickness Qualified – Fillet Welds

Table 11.1 Performance qualification, limitation of essential variables

Table 11.4 Welder and Welding Operator qualification, type and position limitation

Table 17.1 Weld Crater Limitations

Table 17.2 Undercut and Porosity Limitations

Table 17.1 Ultrasonic Testing Acceptance – Rejection Criteria

Figure 3.2 Prequalified PJP Groove Welded Joint Details

Figure 3.3 Prequalified CJP Groove Welded Joint Details

Figure 6.2 Acceptable and Unacceptable Weld Profiles

Figure 16.1 Weld Quality Requirements for Discontinuities Occuring in Cyclically Loaded Non-tubular Tension Welds

Figure 16.2 Weld Quality Requirements for Discontinuities Occuring in Cyclically Loaded Non-tubular Compression Welds

Personnel Qualification in Nondestructive Testing or ANSI/ASNT-CP-189 Standard for Qualification and Certification of Nondestructive Testing Personnel. The welding seam preparation must be made under the consideration of the technical documentation and the drawing related specifications according to the standard: Minimum requirement for general tolerances for the execution of welded constructions according to the standard:

ASTM A6 or ASME Y14.5.




7 Welding requirements

Hug Engineering welding Engineer and the supplier (for purchased components) are responsible for developing and implementing Welding Procedure Qualification Records (WPQR) and Welding Procedures Specifications (WPS) that are used in the production of Hug products.

Welding procedures are to be developed to meet all Engineering requirements of the design as well as assist in the ease of manufacturing. Procedures may be general, such as covering the normal application of the Gas Metal Arc Welding process, or specific, such as the detailed welding procedure.

All procedures must be tested and evaluated before implementation. Testing can be done on actual or a simulation of production parts. Evaluation may include destructive as well as non-destructive tests to assure the soundness of the welded structure.

Welding Engineering or welding inspector will approve each welding procedure, verifying that the procedure meets the engineering requirements prior to production. Welders must have access to and understand the WPS prior to welding.

7.1 Welding Procedure Qualification

WPQRs (welding procedure qualification records) for the various welding processes and weld joints that will be used on Hug products must be developed and qualified prior to starting production. A unique stand-alone WPQR must be developed and qualified for all weld joints that are designated class CT1 (see Section 8.1 for weld classes) or others as defined by Hug Weld Manufacturing Engineering.

Qualification of procedures may follow AWS, ASME or ISO/EN Specifications.

Acceptable minimum standards for welding procedure qualifications include AWS B2.1 Specification for Welding Procedures and Performance Qualification, latest edition, or ASME Section IX Welding and Brazing Qualification, latest edition. Suppliers outside North America may use ISO 15614 Specification and Qualification of Procedures for Metallic Material, latest edition.

The use of AWS or other codes’ pre-qualified joints and/or standard procedures (SWPS) still requires that the supplier furnish this information in their company's approved WPS format with actual parameters used.

References to AWS or other code specifications only, is NOT acceptable.

A WPQR and WPS must be tested and submitted to Hug Weld Manufacturing Engineering when a change to a process essential variable occurs. Copies of all qualified procedures that will be used on Hug products must be submitted to Hug Weld Manufacturing Engineering for review and approval. If there are questions or concerns, Hug Welding Engineering may request actual weld samples for further evaluation.

Weld Class CT1/2 joint samples must be reviewed by Hug Weld Manufacturing Engineering.

7.2 Welding Processes

Hug Weld Manufacturing Engineering and the supplier are responsible for determining the welding process to be used in the fabrication of Hug products when not specifically defined on the Engineering drawing, provided they have been properly qualified and approved by Hug Weld Manufacturing Engineering.

Follow the requirements in Section 7.1 for each welding process.

A. Class CT1 or CT2 welds are not to be produced using the GMAW short circuit mode of metal transfer unless accepted by Hug Weld Manufacturing Engineering and covered by an approved WPQR.




B. Shielding gas mixtures used in the production of Hug products must be of welding grade quality to minimize porosity. Conformance with the guidelines specified in AWS A5.32, Specifications for Welding Shielding Gases or ISO 14175, Gases and gas mixtures for fusion welding and allied processes, is acceptable.

7.3 Welding Consumables

All consumables and electrodes, regardless of the welding process, must have an AWS classification, unless an alternative is accepted by Welding Engineering. In addition to the AWS classification, an ISO classification may also be required on certain products, if required the Engineering drawing.

Regarding consumable long-term storage area, all welding consumables must be stored in a dry location and handled in a manner that avoids damage to consumables and packaging. The storage area must protect consumable from the weather (rain or snow), water, shop cutting oils or lubricants, excessive grinding dust and paint overspray.

If welding plain carbon steel, AWS class E60XX or E70XX welding electrodes or equivalent shall be employed. If welding high strength low alloy steels, AWS class E70XX welding electrodes or equivalent shall be employed.

In applications where plain carbon steel is welded to high strength low alloy steel, AWS class E70XX welding electrodes or equivalent shall be used.

For austenitic steel and If not otherwise specified, the GTAW AWS A5.9 ER19-10H or A308LSi filler metal shall be used for the austenitic material grade (P-No. 8).

For materials see Section 12.

These rules are general and will govern most shop applications. Any special electrode application will be indicated on the Hug Engineering drawings.

All welding consumables must comply with the requirements of the corresponding AWS/SFA or EN ISO specification and shall be inspected accordingly.

All filler metals shall be procured with a CMTR (certified material test report) or 3.1 batch inspection certificate (acc. EN 10204) to the corresponding AWS/SFA or EN ISO specification.

7.4 Welding Qualification & Certification

All welders (including welding operators & tack welders) who are to work on Hug products must be qualified in accordance with AWS, ASME or ISO/EN Standards, or an in-house procedure if approved by either Hug Weld Manufacturing Engineering. A copy of the welder performance qualification procedures that are used must be submitted to Hug Weld Manufacturing Engineering for approval. The procedures should include a statement as to how qualification of welders is reviewed, maintained and updated.

Acceptable minimum standards for welder qualifications include AWS D15.1 welder qualification section, AWS B2.1 Specification for Welding Procedures and Performance Qualification, latest edition, or ASME Section IX, Welding and Brazing Qualification, latest edition.

Suppliers outside North America may use ISO 9606 Qualification testing of welders – Fusion Welding, latest edition.

7.5 Facility Requirements

All facilities fabricating Hug products must satisfy all additional requirements below.

All suppliers must submit the following information to Hug Weld Manufacturing Engineering with copies sent to the Purchasing Department and Supplier Quality prior to the start of production for approval as part of the original process:




All facilities fabricating Hug products must demonstrate a welder certification, qualification testing and training program, by:

A. Demonstrating a functioning weld training and testing program.

B. Providing a new welder qualification test acceptance criteria.

C. Providing welder qualification procedures.

D. Establishing a period of weld audits, along with re-certification period and the training of welders.

1. Welders are to be audited at a six month interval on the production line. “Auditing” may consist of visual examination of a production weld, but it must be documented.

2. Welders are to be retested every two years for each process that they are qualified for. “Re-testing” means fillet break or groove side bend testing, or radiography. Only one test per process is required every two years.

3. If a welder has not used a process for over six months, re-testing is required. Again, “re-testing” means fillet break or groove side bend testing, or radiography.

4. Indicate how weld training is accomplished, internal or by a third party weld lab.

7.6 Name a responsible Welding Coordinator

A Welding Coordinator is the individual or group responsible for the welding operations in the facility producing Hug welded components as they apply to welder training and testing, weld procedure process development and testing.

A. The responsible welding coordinator shall have a thorough knowledge of welding and fabrication operations, welding processes, and welding procedure specifications.

B. The responsible welding coordinator must have the ability to read engineering drawings, interpret welding symbols, and have knowledge of weld fault causes and cures, welding quality control and inspection methods.

C. The responsible welding coordinator shall have practical knowledge of the proper operation and basic maintenance of the welding equipment used in the companies welding operations.

7.7 Welding Coordinator responsibilities

A. Qualify welding procedures to be used on Hug products by the usage of WPQR's. The use of AWS or other codes pre-qualified joints and/or WPS’s still requires that the supplier furnish this information in their company's approved WPS format with actual parameters used. References to AWS or other code specifications only is NOT acceptable.

B. Establish WPQR’s and WPS’s for use in the production of Hug products. All WPS’s must be furnished to Hug Weld Manufacturing Engineering for approval prior to production runs. Include electrode type and size along with shielding gas type if applicable.

C. Establish inspection procedures used on Hug products.

D. Administer welder qualification tests and audits.

E. Establish a list of certified welders and indicated each applicable process and procedure each welder is certified to. Test and audit dates must be included in the list.

7.8 Minimum internal weld testing and training area equipment

Suppliers with an internal weld testing and training capability should have at least one dedicated weld test and training area or weld booth with a table. Peripheral equipment such as tacking fixtures and vises are optional but recommended. Also recommended is the necessary non-destructive and destructive test equipment needed to perform the required testing of welder qualification samples. This equipment must be properly maintained and calibrated according to




the applicable standard. The objective is to have welder training and testing done in an area separate from production, to avoid distraction and interruption.

7.9 Requirements for the welder

Before starting to weld any assembly, the welder must clearly understand the Engineering requirements for welding such as size and length of welds. The welder must follow all specified procedures including all weld parameters settings, directions of welds, their starting and stopping points and sequence of passes in accordance with the WPS, processing drawings, routings or visual routings.

7.10 Weld wraparounds

The following examples of symbol placement and notes on the Engineering drawings indicate that a wrap around (outside corner) or tie-in (inside corner) weld is required. - • The all-around symbol is placed on the weld

symbol. - • When adjoining edges of a part require welds

of the same type. - • A seal weld note is indicated. - • An air/oil tight note is indicated. - • A wrap or tie-in weld note is specified for certain items.

One method of weld wraparound is that the weld should progress around a corner as shown in Figure 1.3., with no stops unless otherwise specified on the Engineering drawings.

Achieving a wraparound at a square outside corner without rejectable undercut can be aided by the application of a “rosebud” or “triggered” round weld deposit at the corner. The weld must wraparound the corners such that the weld has a minimum (L) of 2 X the thickness (T) of the material, but not less than 0.5” (13 mm) unless specified otherwise on the Engineering drawing. Do not apply welds to edges that are not indicated by a weld symbol on the Engineering drawing.

8. Normative guidelines for inspection of welding work

Visual welding inspection is performed by qualified/certified welding inspection personnel (Ref. AWS B5.1 / QC1).

Visual inspection is performed according to AWS B1.11.

The quality control program (inspection & test plan, ITPL) shall include a sequence of examinations performed during all phases of fabrication. The ITPL shall establish hold/witness points that allow for visual examination prior to subsequent operations.

Visual inspection includes examinations prior to-, during – and after welding operations.

Reference is made to paragraph 4.2 / 4.3 / 4.4 of AWS B1.11

Inspection results shall be reported with a Visual examination report (Ref. Figure C.1, extract of AWS B1.11)

8.1 Weld Inspection Class and Acceptance Criteria 8.1.1 Weld Inspection Classes:

Weld joints at Hug are divided into weld performance classes, based on EN 15085.

Welds at Hug products can be classified in four classes (CT1 / CT2 / CT3 / CT4).

Class CT1 is the highest performance level, and class CT4 is the lowest performance level.

These classes have the following different acceptance criteria:




CT1: 100% RT or UT / 100% MT or PT / 100% VT: acceptance criteria B of Table 1 (relevant extract of EN ISO 5817)

CT2: 10% RT or UT / 10% MT or PT / 100% VT: acceptance criteria C of Table 1 (relevant extract of EN ISO 5817)

CT3: 100% VT: acceptance criteria C of Table 1 (relevant extract of EN ISO 5817)

CT4: 100% VT: acceptance criteria D of Table 1 (relevant extract of EN ISO 5817)

Section 19 may be used as a guideline.

A1) Welding Engineering together with HUG design department has the direct responsibility of determining the weld class. Weld classes are determined by the relationship between weld strength and load applied to the weld joint with a factor of safety included.

A2) Unless otherwise noted, all weld joints on Hug engineering drawings are considered CT3. No designation is required in the weld symbol tail for CT3 welds. Weld joints of different classes other than CT3 are to be called out in the weld symbol tail on the Engineering drawing.

A3) Hug Weld Manufacturing Engineering along with Welding Engineering will develop processes for weld joints that have an unusual condition and/or inspection audit procedure including all class CT1 welds.

A4) When required, Welding Engineering and Engineering will determine the type of and sequence of NDT (Non-Destructive Testing) to be employed on a weld joint, unless a customer or contract requires otherwise. When the type of NDT is not specified, suppliers shall choose the inspection methods appropriate to ensure that weld joints meets the designed requirements. At a minimum, all weld joints must be visually inspected as indicated using the acceptance criteria for CT3.

8.2 Inspection requirements

Inspection of all welds and welded products should conform to NDT practices in AWS B1.10 Guide for the Nondestructive Examination of Welds, latest revision.

All welds will be subjected to a 100% visual inspection by someone other than the person performing the weld. Self-inspection alone is not acceptable. Hug Weld Manufacturing Engineering will be responsible for final determination of weld acceptance or rejection in the event of a dispute.

All visual inspection must be performed by a CWI (AWS Certified Welding Inspector) or weld inspectors working under the technical supervision of an internal or external CWI. AWS D15.1:2012 clause 6.7.1 forbids inspection after any painting or coating.

Therefore, Hug visual weld examination shall be performed with the welds cleaned, unpainted or after application of a single primer coat. Visual weld inspection shall not be performed after application of any intermediate or top coats of paint. The following is a list of items that must be followed to attain a quality product:

B1) All parts to be welded must be subjected to inspection before welding for correct joint preparation, correctness and quality of material, heat-treated conditions, and conformance to dimensions as specified on the Engineering drawing.

B2) All welding jigs or fixtures must be inspected before production is started to ensure that finished parts will be dimensionally correct when the proper welding procedure is followed.

B3) In process inspection must be conducted during the welding process to insure proper dimensions, alignment, and conformance to the respective WPS.

B4) Engineering drawings are designed on the basis of line-to-line fit-up unless otherwise specified. It is recognized that tolerances exist on steel mill products and that these tolerances are necessary with regards to metal working practices. These tolerances can cause gaps that reduce the effective throat of the specified weld on the Engineering drawing. The weld throat for a fillet weld is derived by multiplying 0.707 by the leg size.




9 Documents to be archived and/or submitted

The required documents according to separate order text and the specifications from point 6, have to be archived for at least during 10 years (project based with the Hug order number) and need to be submitted to Hug Engineering AG on request.

10 Contract review

Prior to a confirmation of order by the supplier, it must be guaranteed in form of a contract review, that all requirements to the welding performance/requirement can be properly met. This also includes: - The examination under a construction/design perspective related to arrangement, design and

execution of the welding connections according the presented building documentations (drawings). Related deficiencies that are detected must be reported to Hug Engineering prior to the confirmation of order.

- Examination related to the completeness of the documentation.

11 Specifications from the rWS of Hug Engineering AG

The rWS of Hug Engineering AG decides on a project based necessity of work samples, special tests and photo documentations.

12 Materials

Materials must be used according to their specifications. Basic materials must be marked (short determination e.g. Standard materials eventually colour marked). The marking must be made in a manner that it remains legible at all times during transport and storage. The supplier must guarantee the separated handling and machining of INOX-steels and black-steels.

For the marking and storage of welding auxiliary materials it is to be observed: - Welding sticks must be marked individually by flags or stamping. - Welding wire must be marked at the roll/coil. - Stick electrodes must be marked by stamping at the coating. Appropriate storage conditions

(special storage room for special materials, drying, oven) must be kept.

All material shall be procured with a CMTR (certified material test report) or 3.1 batch inspection certificate (acc. EN 10204) to the corresponding ASTM or EN ISO specification.

12.1 Normative guidelines for the materials to be processed

The processed base materials must be evidenced by an inspection certificate 3.1. The processed welding consumables must be evidenced by an inspection certificate 2.2.

The verification is carried out in accordance with the standard: EN 10204 Metallic products: Types of inspection documents

13 Subcontracting

The subcontracting of the manufacturing of welded parts/components to third parties is only allowed after prior written permission of rWS and the procurement department. Subcontractors must comply with all quality standards and requirements of the present norm.

14 Initial Sample Test Report inspection for series projects

The sampling (ISTR) and quality assurance of series production is agreed on with the contractor prior to the award.




15 Welding symbols on drawings

Symbols for indicating welded joints on engineering drawings may usually be given according to EN ISO 2553.

The following figures provide a brief comparison with the AWS A2.4 system (Standard symbols for welding, brazing and nondestructive examination).




The ISO standard includes two methods to indicate fillet weld sizes:

leg length (z) and throat thickness (a) (see Fig. 10.1).

In the ISO system, to indicate the size of a fillet weld, the dimension is placed to the left of the symbol, preceded by the letter z or a, depending on whether the leg length or throat thickness is to be specified.




16 Tests/Documentation/FAT

Performed tests must be assigned to an individual tester i.e. by a signature. The test characteristics to be documented are detailed in the test-drawing. In case this is not available, they are to be mutually agreed with Hug Engineering.

On the test document, a signature of the Welding Supervisor is mandatory.

An eventual FAT is going to be announced by a separate order text.

17 Documents to be handed over to Hug Engineering AG after the finishing of a product

The documents required according to the separate order text must be provided to the procurement department and the rWS.

18 Monitoring

The monitoring of the required approvals and verifications according to point 6 and 9 are in the supplier’s responsibility.

It is expected that the supplier proactively clarifies any questions and ambiguity with the rWS of Hug Engineering AG.

19 Visual Weld Inspection - Acceptance Criteria (guideline)




20 Visual Examination Report

Specification...to minimize porosity. Conformance with the guidelines specified in AWS A5.32,...

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