SIST EN 15085-3:2023+A1:2023
(Main + Amendment)Railway applications - Welding of railway vehicles and components - Part 3: Design requirements
Railway applications - Welding of railway vehicles and components - Part 3: Design requirements
This document applies to welding of metallic materials in the manufacture and maintenance of railway vehicles and their components.
This document specifies applicable design and classification rules.
This document does not define parameters for the dimensioning.
NOTE Requirements on structures can be found in other standards like EN 12663.
Bahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 3: Konstruktionsvorgaben
Dieses Dokument gilt für das Schweißen metallischer Werkstoffe bei der Herstellung und Instandsetzung von Schienenfahrzeugen und fahrzeugteilen.
Dieses Dokument legt anwendbare Konstruktions- und Klassifizierungsregeln fest.
Dieses Dokument legt keine Parameter für die Dimensionierung fest.
ANMERKUNG Anforderungen an Strukturen finden sich in anderen Normen (z. B. EN 12663).
Applications ferroviaires - Soudage des véhicules ferroviaires et des pièces - Partie 3 : Exigences de conception
Le présent document s'applique au soudage de matériaux métalliques réalisé dans le cadre de la fabrication et de la maintenance des véhicules et des composants ferroviaires.
Le présent document spécifie les règles de conception et de classification applicables.
Le présent document ne spécifie pas les paramètres de dimensionnement.
NOTE Les exigences relatives aux structures peuvent être trouvées dans d'autres normes (par exemple, l'EN 12663).
Železniške naprave - Varjenje železniških vozil in elementov - 3. del: Zahteve za projektiranje (vključuje dopolnilo A1)
Ta dokument se uporablja za varjenje kovinskih materialov pri izdelavi in vzdrževanju železniških vozil ter njihovih elementov.
Dokument določa zahteve za projektiranje in pravila za klasifikacijo.
Ta dokument ne določa parametrov za dimenzioniranje.
OPOMBA: Zahteve za konstrukcije je mogoče najti v drugih standardih, kot je EN 12663.
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 15085-3:2023+A1:2023
01-junij-2023
Železniške naprave - Varjenje železniških vozil in elementov - 3. del: Zahteve za
projektiranje (vključuje dopolnilo A1)
Railway applications - Welding of railway vehicles and components - Part 3: Design
requirements
Bahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 3:
Konstruktionsvorgaben
Applications ferroviaires - Soudage des véhicules ferroviaires et des pièces - Partie 3 :
Exigences de conception
Ta slovenski standard je istoveten z: EN 15085-3:2022+A1:2023
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
45.060.01 Železniška vozila na splošno Railway rolling stock in
general
SIST EN 15085-3:2023+A1:2023 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 15085-3:2023+A1:2023
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SIST EN 15085-3:2023+A1:2023
EN 15085-3:2022+A1
EUROPEAN STANDARD
NORME EUROPÉENNE
April 2023
EUROPÄISCHE NORM
ICS 25.160.10; 45.060.01 Supersedes EN 15085-3:2022
English Version
Railway applications - Welding of railway vehicles and
components - Part 3: Design requirements
Applications ferroviaires - Soudage des véhicules Bahnanwendungen - Schweißen von
ferroviaires et des pièces - Partie 3 : Exigences de Schienenfahrzeugen und -fahrzeugteilen - Teil 3:
conception Konstruktionsvorgaben
This European Standard was approved by CEN on 5 September 2022 and includes Amendment 1 approved by CEN on 1 February
2023.
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 of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, 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, Türkiye and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2023 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 15085-3:2022+A1:2023 E
worldwide for CEN national Members.
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SIST EN 15085-3:2023+A1:2023
EN 15085-3:2022+A1:2023 (E)
Contents Page
European foreword . 4
Introduction . 6
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 9
4 Design requirements . 9
4.1 General. 9
4.2 Dimensioning of welded joints . 10
4.3 Stress categories and stress factors . 10
4.4 Safety categories . 10
4.5 Weld performance classes . 10
4.6 Weld inspection classes . 11
5 Quality levels for imperfections . 12
5.1 General. 12
5.2 Quality levels for imperfections for fusion welded joints (beam welding excluded) 12
5.3 Quality levels for imperfections for beam welded joints . 13
5.3.1 General. 13
5.3.2 Quality levels for imperfection for friction stir welding. 14
5.3.3 Quality levels for imperfections for stud welding related to the weld performance
class . 14
5.3.4 Quality requirements for resistance spot welding, projection welding and resistance
seam welding related to the weld performance class . 14
5.3.5 Quality requirements for flash welding . 15
5.3.6 Defining quality requirements for other welding processes . 15
6 Selection of parent metals and welding consumables . 15
6.1 Selection of parent metals . 15
6.2 Selection of welding consumables . 15
7 Weld joint design . 16
7.1 General. 16
7.2 Design guidelines . 16
7.2.1 Fabricated box sections . 16
7.2.2 Butt welds on parts of dissimilar thickness . 17
7.2.3 Plug welds and slot welds . 18
7.2.4 Proximity of two joints . 19
7.2.5 Stiffeners welded across a butt weld . 19
7.2.6 Openings . 20
7.2.7 Design guidelines for stiffeners and gussets ends . 20
7.2.8 Gusset shape . 20
7.2.9 Weld return . 21
7.2.10 Fillet weld . 22
7.2.11 Use of run-on and run-off plates . 23
7.2.12 Highly restrained joints . 23
7.2.13 Mixing of joining techniques . 24
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EN 15085-3:2022+A1:2023 (E)
7.2.14 Prevention of corrosion problems . 25
7.2.15 Intermittent welds . 25
7.3 Joint preparation. 26
7.4 Methods to improve the fatigue strength (Post weld improvement) . 26
7.4.1 General . 26
7.4.2 Improvement of shape of weld toe . 27
7.4.3 Post Weld Heat Treatment (PWHT) — stress relief . 27
7.4.4 Introduction of compressive stress . 28
8 Design documentation related to welding . 28
8.1 Information on design drawings or documentation linked to the drawings . 28
8.2 Design review of welded components . 29
8.3 Use of existing drawings not according to EN 15085 . 30
Annex A (informative) List of welded joints (example) . 31
Annex B (informative) Joint preparation of welds . 32
Annex C (informative) Joint 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. 55
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SIST EN 15085-3:2023+A1:2023
EN 15085-3:2022+A1:2023 (E)
European foreword
This document (EN 15085-3:2022+A1:2023) has been prepared by Technical Committee CEN/TC 256
“Railway applications”, the secretariat of which 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 October 2023, and conflicting national standards shall
be withdrawn at the latest by October 2023.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document includes Amendment 1 approved by CEN on 1 February 2023.
This document supersedes !EN 15085-3:2022".
The start and finish of text introduced or altered by amendment is indicated in the text by tags !".
This series of European Standards EN 15085 “Railway applications — Welding of railway vehicles and
components” consists of the following parts:
— Part 1: General
— Part 2: Requirements of the organization of welding manufacturer
— Part 3: Design requirements
— Part 4: Production requirements
— Part 5: Inspection, testing and documentation
— Part 6: Maintenance
EN 15085-3:2022 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 of its 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
of this document.
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SIST EN 15085-3:2023+A1:2023
EN 15085-3:2022+A1:2023 (E)
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.
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, 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, Türkiye and the United
Kingdom.
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SIST EN 15085-3:2023+A1:2023
EN 15085-3:2022+A1:2023 (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 of standards applies to welding of metallic 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 of the weld, and the demonstration of the 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.
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SIST EN 15085-3:2023+A1:2023
EN 15085-3:2022+A1:2023 (E)
1 Scope
This document applies to welding of metallic 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 Requirements for structures can be found in other standards (e.g. EN 12663).
2 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 of railway vehicle bodies - Part
1: Locomotives and passenger rolling stock (and alternative method for freight wagons)
EN 12663-2:2010, Railway applications - Structural requirements of railway vehicle bodies - Part 2: Freight
wagons
EN 13749:2021, Railway applications - Wheelsets and bogies - Method of specifying the structural
requirements of bogie frames
1
EN 15085-1:—, Railway applications — Welding of railway vehicles and components — Part 1: General
EN 15085-2:2020, Railway applications - Welding of railway vehicles and components - Part 2:
Requirements for welding manufacturer
2
EN 15085-4:—, Railway applications — Welding of railway vehicles and components — Part 4:
Production requirements
3
EN 15085-5:—, Railway applications — Welding of railway vehicles and components — Part 5:
Inspection, testing and documentation
4
EN 15085-6:—, Railway applications — Welding of railway vehicles and components — Part 6:
Maintenance welding requirements
EN 15827:2011, Railway applications - Requirements for 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+A1:2023 (E)
EN ISO 2553:2019, Welding and allied processes - Symbolic representation on drawings - Welded joints (ISO
2553:2019, Corrected version 2021-09)
EN ISO 3452-1:2021, Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 3452-
1:2021)
EN ISO 4063:2010, Welding and allied processes - Nomenclature of processes and reference numbers (ISO
4063:2009, Corrected version 2010-03-01)
EN ISO 5817:2014, Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding
excluded) - Quality levels for imperfections (ISO 5817:2014)
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 of geometric imperfections in metallic
materials - Part 2: Welding with pressure (ISO 6520-2:2013)
EN ISO 10042:2018, Welding - Arc-welded joints in aluminium and its alloys - Quality levels for
imperfections (ISO 10042:2018)
EN ISO 10675-2:2021, Non-destructive testing of welds — 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 levels for 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 14555:2017, Welding - Arc stud welding of metallic materials (ISO 14555:2017)
5
EN ISO 15614-1:2017, Specification and qualification of welding procedures for metallic materials —
Welding procedure test — Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys
(ISO 15614-1:2017)
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 of welds — Radiographic testing — Part 1: X- and gamma-
ray techniques with film (ISO 17636-1:2022)
EN ISO 17637:2016, Non-destructive testing of welds - Visual testing of fusion-welded joints (ISO
17637:2016)
5
Document impacted by A1:2019.
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EN 15085-3:2022+A1:2023 (E)
EN ISO 17653:2012, Resistance welding - Destructive tests on welds in metallic materials - Torsion test of
resistance spot welds (ISO 17653:2012)
EN ISO 17663:2009, Welding - Quality requirements for heat treatment in connection with welding and
allied processes (ISO 17663:2009)
EN ISO 23277:2015, Non-destructive testing of welds - Penetrant testing - Acceptance levels (ISO
23277:2015)
EN ISO 25239-5:2020, Friction stir welding - Aluminium - Part 5: Quality and inspection requirements (ISO
25239-5:2020)
EN ISO 10447:2015, Resistance welding - Testing of welds - Peel and chisel testing of resistance spot and
projection welds (ISO 10447:2015)
3 Terms and definitions
1
For the purposes of this document, the terms and definitions given in EN 15085-1:- apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at https://www.electropedia.org/
3.1
stress factor
ratio of the calculated / measured fatigue stress to the admissible fatigue stress of the 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
4
requirements of EN 15085-6:- shall apply.
Results of the 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.
If the 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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5
NOTE EN 17149-3:- 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 of different types of welded 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 ≥ 0,9
Medium 0,75 ≤ S < 0,9
Low ≤ 0,75
4.4 Safety categories
The safety category defines the consequences of failure of a single welded joint with respect to its effect
on persons, facilities and the environment.
The safety categories are differentiated as follows:
Low: Failure of the welded joint does not lead to any direct impairment of the overall
function. Consequential events with personal injuries are unlikely.
Medium: Failure of the welded joint leads to an impairment of the overall function or can
lead to consequential events with personal injuries.
High: Failure of the welded joint leads to consequential events with personal injuries and
breakdown of the overall function.
For a more detailed explanation of the 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+A1:2023 (E)
Table 2 — Weld performance classes
Stress categories Safety categories
High Medium Low
a b
High CP C2
CP A CP B2
a
Medium CP C2 CP C3
CP B1
b
Low CP C3 CP D
CP C1
a 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
3
NDT is not possible. Where this is the case, see EN 15085-5:- , 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
4
weld performance class CP A, shall be avoided. For application in maintenance see EN 15085-6:- .
3
The inspection of all welded joints shall be performed according to EN 15085-5:- , Table 1 as a minimum.
When the weld performance class assessment leads to CP B1, CP B2 or CP 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.
If it 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 of the 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
3
is defined in Table 3. Details of weld inspection are further defined in EN 15085-5:- , Table 1.
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EN 15085-3:2022+A1:2023 (E)
Table 3 — Correlation between weld performance classes and weld inspection classes
Stress Safety Weld Quality levels for Weld Volumetric Surface Visual
category category performance imperfections inspection tests tests examination
class EN ISO 5817:2014 class
min. min. min.
EN ISO 10042:2018
Minimum
EN ISO 13919-1:2019
requirements
EN ISO 13919-2:2021
a
High High CP A B CT 1 100 % 100 % 100 %
a
High Medium CP B2 B CT 2 10 % 10 % 100 %
a
High Low CP C2 C CT 3 Not Not 100 %
required required
a
Medium High CP B1 B CT 2 10 % 10 % 100 %
a
Medium Medium CP C2 C CT 3 Not Not 100 %
required required
a
Medium Low CP C3 C CT 4 Not Not 100 %
required required
a
Low High CP C1 C CT 2 10 % 10 % 100 %
a
L
...
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