SIST EN 15085-3:2023

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 et des composants ferroviaires - 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

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

• Status: Published
• Public Enquiry End Date: 21-Apr-2021
• Publication Date: 01-Dec-2022
• ICS: 25.160.10 - Welding processes
• ICS: 45.060.01 - Railway rolling stock in general
• Technical Committee: IŽNP - Reilway applications
• Current Stage: 6060 - National Implementation/Publication (Adopted Project)
• Start Date: 01-Dec-2022
• Due Date: 05-Feb-2023
• Completion Date: 02-Dec-2022
• Directive: 2008/57/EC - Directive 2008/57/EC of the European Parliament and of the Council of 17 June 2008 on the interoperability of the rail system within the Community (Recast)
• Directive: 2016/797/EU - Directive (EU) 2016/797 of the European Parliament and of the Council of 11 May 2016 on the interoperability of the rail system within the European Union (Text with EEA relevance)
• Mandate: M/483 - Mandate for programming and standardisation addressed to the European standardisation bodies under directive 2008/57/EC in the field of the interoperability of the rail system within the European Union
• Ref Project: EN 15085-3:2022 - Railway applications - Welding of railway vehicles and components - Part 3: Design requirements

Relations

• Revised: SIST EN 15085-3:2008 - Railway applications - Welding of railway vehicles and components - Part 3: Design requirements
• Effective Date: 30-Nov-2016
• Replaces: SIST EN 15085-3:2008 - Railway applications - Welding of railway vehicles and components - Part 3: Design requirements
• Effective Date: 30-Nov-2022
• Replaces: SIST EN 15085-3:2008/AC:2010 - Railway applications - Welding of railway vehicles and components - Part 3: Design requirements
• Effective Date: 30-Nov-2022

Standards Content (Sample)

SLOVENSKI STANDARD
SIST EN 15085-3:2023
01-januar-2023
Nadomešča:
SIST EN 15085-3:2008
SIST EN 15085-3:2008/AC:2010

Železniške naprave - Varjenje železniških vozil in elementov - 3. del: Zahteve za

projektiranje

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 et des composants ferroviaires - Partie

3 : Exigences de conception
Ta slovenski standard je istoveten z: EN 15085-3:2022
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 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
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SIST EN 15085-3:2023
EN 15085-3
EUROPEAN STANDARD
NORME EUROPÉENNE
November 2022
EUROPÄISCHE NORM
ICS 25.160.10; 45.060.01 Supersedes EN 15085-3:2007
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.

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

© 2022 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 15085-3:2022 E

worldwide for CEN national Members.
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SIST EN 15085-3:2023
EN 15085-3:2022 (E)
Contents

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 ...................................................................................... 14

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

7.2.14 Prevention of corrosion problems ............................................................................................... 25

7.2.15 Intermittent welds.............................................................................................................................. 25

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SIST EN 15085-3:2023
EN 15085-3:2022 (E)

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 ......................................................................................... 30

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........................................................................................................................................................ 56

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SIST EN 15085-3:2023
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 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 May 2023, and conflicting national standards shall be

withdrawn at the latest by May 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 supersedes EN 15085-3:2007.

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.

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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SIST EN 15085-3:2023
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, 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
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 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
EN 15085-3:2022 (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

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

EN 15085-4:—, Railway applications — Welding of railway vehicles and components — Part 4:

Production requirements

EN 15085-5:—, Railway applications — Welding of railway vehicles and components — Part 5:

Inspection, testing and documentation

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
Under preparation. Stage at the time of publication: prEN 15085-1:2021
Under preparation. Stage at the time of publication: prEN 15085-4:2020
Under preparation. Stage at the time of publication: FprEN 15085-5:2021
Under preparation. Stage at the time of publication: FprEN 15085-6:2021
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SIST EN 15085-3:2023
EN 15085-3:2022 (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)

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)
Document impacted by A1:2019.
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SIST EN 15085-3:2023
EN 15085-3:2022 (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

For the purposes of this document, the terms and definitions given in EN 15085-1:- apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

— ISO Online browsing platform: available at https://www.iso.org/obp
— IEC Electropedia: available at http://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

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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SIST EN 15085-3:2023
EN 15085-3:2022 (E)
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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SIST EN 15085-3:2023
EN 15085-3:2022 (E)
Table 2 — Weld performance classes
Stress categories Safety categories
High Medium Low
a b
High CP C2
CP A CP B2
Medium CP C2 CP C3
CP B1
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

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

weld performance class CP A, shall be avoided. For application in maintenance see EN 15085-6:- .

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

is defined in Table 3. Details of weld inspection are further defined in EN 15085-5:- , Table 1.

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SIST EN 15085-3:2023
EN 15085-3:2022 (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
High High CP A B CT 1 100 % 100 % 100 %
High Medium CP B2 B CT 2 10 % 10 % 100 %
High Low CP C2 C CT 3 Not Not 100 %
required required
Medium High CP B1 B CT 2 10 % 10 % 100 %
Medium Medium CP C2 C CT 3 Not Not 100 %
required required
Medium Low CP C3 C CT 4 Not Not 100 %
required required
Low High CP C1 C CT 2 10 % 10 % 100 %
Low Medium CP C3 C CT 4 Not Not 100 %
required required
Low Low CP D D CT 4 Not Not 100 %
required required
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 6520-1:2007 and

EN ISO 652
...

SLOVENSKI STANDARD
oSIST prEN 15085-3:2021
01-april-2021

Železniške naprave - Varjenje železniških vozil in elementov - 3. del: Zahteve za

projektiranje

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 et des composants ferroviaires - Partie

3 : Exigences de conception
Ta slovenski standard je istoveten z: prEN 15085-3
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
45.060.01 Železniška vozila na splošno Railway rolling stock in
general
oSIST prEN 15085-3:2021 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN 15085-3:2021
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oSIST prEN 15085-3:2021
DRAFT
EUROPEAN STANDARD
prEN 15085-3
NORME EUROPÉENNE
EUROPÄISCHE NORM
January 2021
ICS 25.160.10; 45.060.01 Will supersede EN 15085-3:2007
English Version
Railway applications - Welding of railway vehicles and
components - Part 3: Design requirements

Applications ferroviaires - Soudage des véhicules et des Bahnanwendungen - Schweißen von

composants ferroviaires - Partie 3 : Exigences de Schienenfahrzeugen und -fahrzeugteilen - Teil 3:

conception Konstruktionsvorgaben

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee

CEN/TC 256.

If this draft becomes a European Standard, 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.

This draft European Standard was established by CEN 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, Turkey and

United Kingdom.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are

aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without

notice and shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels

© 2021 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 15085-3:2021 E

worldwide for CEN national Members.
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Contents Page

European foreword ....................................................................................................................................................... 4

Introduction .................................................................................................................................................................... 5

1 Scope .................................................................................................................................................................... 6

2 Normative references .................................................................................................................................... 6

3 Terms and definitions ................................................................................................................................... 8

4 Design requirements ..................................................................................................................................... 8

4.1 General ................................................................................................................................................................ 8

4.2 Dimensioning of welded joints ................................................................................................................... 8

4.3 Stress categories and stress factors ......................................................................................................... 8

4.4 Safety categories .............................................................................................................................................. 9

4.5 Weld performance classes ........................................................................................................................... 9

4.6 Weld inspection classes ............................................................................................................................. 10

5 Quality levels for imperfections ............................................................................................................. 11

5.1 General ............................................................................................................................................................. 11

5.2 Quality levels for imperfections ............................................................................................................. 11

5.2.1 Quality levels for imperfections for fusion welded joints (beam welding excluded) ......... 11

5.2.2 Quality levels for imperfections for beam welded joints .............................................................. 12

5.2.3 Quality levels for imperfection for friction stir welding ................................................................ 13

5.2.4 Quality levels for imperfections for stud welding related to the weld performance

class ................................................................................................................................................................... 13

5.2.5 Quality requirements for resistance spot welding, projection welding and resistance

seam welding related to the weld performance class ..................................................................... 13

5.2.6 Defining quality requirements for other welding processes ....................................................... 13

6 Choice of parent metals and welding consumables ......................................................................... 13

6.1 Choice of parent metals.............................................................................................................................. 13

6.2 Choice of welding consumables .............................................................................................................. 14

7 Weld joint design .......................................................................................................................................... 14

7.1 General ............................................................................................................................................................. 14

7.2 Manufacturing provisions ......................................................................................................................... 15

7.2.1 Fabricated box sections ............................................................................................................................. 15

7.2.2 Butt welds on parts of dissimilar thickness ....................................................................................... 15

7.2.3 Plug welds and slot welds ......................................................................................................................... 16

7.2.4 Proximity of two joints ............................................................................................................................... 17

7.2.5 Stiffeners welded to a longitudinal weld ............................................................................................. 18

7.2.6 Filler and drain ports .................................................................................................................................. 18

7.2.7 Gusset ends and stiffener ends ................................................................................................................ 19

7.2.8 Gusset shape .................................................................................................................................................. 19

7.2.9 Weld return .................................................................................................................................................... 20

7.2.10 Fillet weld........................................................................................................................................................ 20

7.2.11 Butt welds and welds at T-Joints ............................................................................................................ 21

7.2.12 Highly restrained joints ............................................................................................................................. 22

7.2.13 Mixed joining techniques .......................................................................................................................... 23

7.2.14 Prevention of corrosion problems ......................................................................................................... 24

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7.2.15 Intermittent welds ....................................................................................................................................... 24

7.3 Joint preparation .......................................................................................................................................... 25

7.4 Methods to improve the fatigue strength (Post weld improvement) ........................................ 25

7.4.1 General ............................................................................................................................................................. 25

7.4.2 Improvement of shape of weld toe ......................................................................................................... 25

7.4.3 Heat treatment to decrease residual tensile stresses ..................................................................... 26

7.4.4 Introduction of compressive stress ....................................................................................................... 27

8 Design related welding documentation ............................................................................................... 27

8.1 Information on design drawings or documentation linked to the drawings .......................... 27

8.2 Welding Design Review .............................................................................................................................. 28

8.3 Use of existing drawings not according to EN 15085 ....................................................................... 28

Annex A (informative) List of welded joints .................................................................................................... 29

Annex B (informative) Joint preparation of welds ........................................................................................ 30

Annex C (informative) Joint preparation for plug welds ............................................................................. 38

Annex D (informative) Types of joints in relation to stresses and inspection classes ..................... 39

Annex E (informative) Flash butt welding ........................................................................................................ 40

Annex F (normative) .................................................................................................................................................. 42

F.1 General ............................................................................................................................................................. 42

F.2 Minimum shear pull forces ....................................................................................................................... 48

Annex G (informative) Determination of safety category for welded joints ........................................ 50

Annex ZA (informative) Relationship between this European Standard and the Essential

requirements of Directive (EU) 2016/797 aimed to be covered................................................. 51

Bibliography ................................................................................................................................................................. 56

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European foreword

This document (prEN 15085-3:2021) has been prepared by Technical Committee CEN/TC 256 “Railway

applications”, the secretariat of which is held by DIN.
This document is currently submitted to the Enquiry.
This document will supersede EN 15085-3:2007.

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 organisation of welding manufacturer
— Part 3: Design requirements
— Part 4: Production requirements
— Part 5: Inspection, testing and documentation
— Part 6: Maintenance.

This document has been prepared under a mandate given to CEN by the European Commission and the

European Free Trade Association, and supports essential requirements of EU Directive(s).

For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this

document.
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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 in respect of the special requirements for the

construction of railway vehicles.

This European Standard is aimed at defining the terms of enforcement applicable to European Standards;

it is not construed as a substitute to these standards.

This document can also be used by internal and external parties, including accredited certification bodies,

to assess the organisation's ability to meet customer, regulatory and the organisation's own

requirements.
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1 Scope

This series of documents applies to welding of metallic materials in the manufacture and maintenance of

railway vehicles and their components.

This document specifies design and classification rules applicable to the manufacture and maintenance

of railway vehicles and their parts. Upon agreement with the customer, drawings issued prior to this

document may be subject to the provisions of this European Standard.

This document does not define parameters for the dimensioning (refer to other standards e.g. on fatigue

testing).
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, Welding — Recommendations for welding of metallic materials — Part 2: Arc welding of ferritic

steels

EN 1708-2, Welding — Basic weld joint details in steel — Part 2: Non internal pressurized components

EN 12663-1, Railway applications - Structural requirements of railway vehicle bodies - Part 1: Locomotives

and passenger rolling stock (and alternative method for freight wagons)

EN 12663-2, Railway applications - Structural requirements of railway vehicle bodies - Part 2: Freight

wagons

EN 13749, Railway applications — Wheelsets and bogies — Methods of specifying structural requirements

of bogie frames

EN 15085-1:2007, Railway applications — Welding of railway vehicles and components — Part 1: General

EN 15085-2:2007, Railway applications — Welding of railway vehicles and components — Part 2: Quality

requirements and certification of welding manufacturer

EN 15085-4:2007, Railway applications — Welding of railway vehicles and components — Part 4:

Production requirements

EN 15085-5:2007, Railway applications — Welding of railway vehicles and components — Part 5:

Inspection, testing and documentation
EN 15827, Railway applications - Requirements for bogies and running gears

EN ISO 2553, Welding and allied processes - Symbolic representation on drawings - Welded joints (ISO 2553)

EN ISO 3452-1, Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 3452-1)

EN ISO 4063, Welding and allied processes — Nomenclature of processes and reference numbers

(ISO 4063:1998)

EN ISO 5817, Welding — Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding

excluded) — Quality levels for imperfections (ISO 5817:2003)
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EN ISO 6520-1, Welding and allied processes — Classification of geometric imperfections in metallic

materials — Part 1: Fusion welding (ISO 6520-1:2007)

EN ISO 6520-2, Welding and allied processes — Classification of geometric imperfections in metallic

materials — Part 2: Welding with pressure (ISO 6520-2:2001)

EN ISO 10042, Welding — Arc-welded joints in aluminium and its alloys — Quality levels for imperfections

(ISO 10042)

EN ISO 10675-2, Non-destructive testing of welds - Acceptance levels for radiographic testing - Part 2:

Aluminium and its alloys (ISO 10675-2)

EN ISO 13919-1, Welding — Electrons and laser beam welded joints — Guidance on quality levels for

imperfections — Part 1: Steel (ISO 13919-1:1996)

EN ISO 13919-2, Welding — Electron and laser beam welded joints — Guidance on quality levels for

imperfections — Part 2: Aluminium and its weldable alloys (ISO 13919-2:2001)
EN ISO 14555, Welding — Arc stud welding of metallic materials (ISO 14555:2006)

EN ISO 15614-1, 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 15614-1:2004)

EN ISO 15614-12, Specification and qualification of welding procedures for metallic materials — Welding

procedure test — Part 12: Spot, seam and projection welding (ISO 15614-12:2004)

EN ISO 17636-1, Non-destructive testing of welds - Radiographic testing - Part 1: X- and gamma-ray

techniques with film (ISO 17636-1)

EN ISO 17637, Non-destructive testing of welds - Visual testing of fusion-welded joints (ISO 17637)

EN ISO 17653, Destructive tests on welds in metallic materials — Torsion test of resistance spot welds

(ISO 17653:2012)

EN ISO 23277, Non-destructive testing of welds - Penetrant testing - Acceptance levels (ISO 23277)

EN ISO 25239-5:2020, Friction stir welding - Aluminium - Part 5: Quality and inspection requirements (ISO

25239-5:2020)

ISO 10447, Resistance welding — Peel and chisel testing of resistance spot, projection and seam welds

CEN ISO/TR 15608, Welding — Guidelines for a metallic materials grouping system (ISO/TR 15608:2013)

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3 Terms and definitions

For the purposes of this document, the terms and definitions given in EN 15085-1:2007 apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

— ISO Online browsing platform: available at http://www.iso.org/obp
— IEC Electropedia: available at http://www.electropedia.org/
3.1
stress factor

ratio of the calculated fatigue stress to the admissible fatigue stress of the joint type, adjusted by the

appropriate safety factor
3.2
admissible fatigue stress

maximum stress applicable to materials to which a specific coefficient to the assembly to be welded is

applied
4 Design requirements
4.1 General

Regarding welded joints forming an integral part of items of rolling stock, except for specific provisions

laid down within the framework of the project or in the product specification, design and requirements

shall be defined as follows.

A stress assessment shall be done for new designs. For existing designs not according to EN 15085, the

requirements of EN 15085-6 shall apply.

The relation between safety category, stress category and weld performance as described in table 2 shall

be respected in the drawing and the associated technical documentation.

If the strength assessment procedure already considers the weld performance class (regarding the

quality levels for imperfections and the weld inspection class), and the safety category according to the

definition given in EN 15085-3, then Table 1 and Table 2 don’t need to be applied.

NOTE prEN 17149-3 provides such a procedure.

Irrespective of the method of assessment, for welded joints with high safety category the weld

performance classes allowed in EN 15085-3 (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. The stress factor is the ratio

of the calculated fatigue stress to the admissible fatigue stress of the welded joint type.

The fatigue strength value can be obtained from calculation standard or fatigue tests on representative

joint samples. The statistical evaluation of the fatigue tests shall be done according to an appropriate

standard.
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European standards for structural requirements of railway vehicles, e.g. EN°12663 (series), EN°13749,

EN°15827, shall be applied.
Table 1 — Stress categories
Stress category Stress factor
Fatigue strength values from calculation
standard
Fatigue test values for representative joint
sample
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 the single welded joint with respect to the

effects 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, also Annex G should 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. The responsible welding coordinator should be consulted with respect to practicability,

feasibility and testing.

Welded joints of railway vehicles are divided into seven weld performance classes (see Table 2).

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Table 2 — Weld performance classes
Stress categories Safety categories
High Medium Low
High a c CP C2
CP A CP B2
Medium b CP C2 CP C3
CP B1
Low d CP C3 CP D
CP C1

For new manufacturing the combination of high safety category and high stress category,

which leads to weld performance class CP A, is forbidden. For application in maintenance see EN

15085-6
Weld performance class CP B1:

CP B1 is only applicable for welds with full penetration and full accessibility for inspection in

production and maintenance.
Weld performance class CP B2:

CP B2 is also applicable for welds without the possibility for a volumetric test; e. g. welds with

partial penetration or fillet welds are possible; in this case a special remark “medium safety

category/increase of surface test is required” shall be indicated on the drawing or technical

documentation linked to the drawing

Weld performance class CP C1:CP C 1 is also valid for welds without the possibility for

volumetric testing; e. g. welds with partial penetration or fillet welds are possible

The inspection of all welded joints shall be carried out according to EN 15085-5:2007, table 1 as

minimum.

For welded joints with weld performance class CP B1, CP°B2 and CP C1, which can be inspected during

production but cannot be inspected and repaired in maintenance one of the following actions shall be

carried out:

— The weld shall be allocated to the next higher inspection class (CT°1) according to Table 3;

— redesign the welded joint:
— in order to reduce the stress category;
— in order 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.

Post-welding improvement is one of the possible ways of increasing the admissible fatigue stresses of an

assembly and may consequently lead to a downscaling of the weld performance class.

Weld performance classes shall be shown on drawings or in other documents, e.g. parts lists.

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.
4.6 Weld inspection classes

The inspection class applicable to each welded joint is defined depending on the weld performance class

defined formerly, see Table 3.
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These inspection classes are used to identify the various types and minimum levels of inspections on the

welded joints in accordance to EN 15085-5:2007, Table 1.
Table 3 — Correspondence between weld performance classes and inspection classes
Stress Safety Weld Quality levels Inspection Volumetric Surface Visual
category category performance for class tests tests examination
class imperfections
Minimum RT or UT MT or PT VT
EN ISO 5817
requireme
EN ISO 10042
Min. Min. Min.
nts
EN 13919-1
EN 13919-2
High High CP A B CT 1 100% 100 % 100 %
High Medium CP B2 B CT 2 10 % 10 % 100 %
High Low CP C2 C CT 3 Not Not 100 %
required required
Medium High CP B1 B CT 2 10% 10 % 100 %
Medium Medium CP C2 C CT 3 Not Not 100 %
required required
Medium Low CP C3 C CT 4 Not Not 100 %
required required
Low High CP C1 C CT 2 10 % 10 % 100 %
Low Medium CP C3 C CT 4 Not Not 100 %
required required
Low Low CP D D CT 4 Not Not 100 %
required required
For detail see Table 4 to 6
5 Quality levels for imperfections
5.1 General

The definition and classification of weld imperfections in accordance with EN ISO 6520-1 and EN ISO

6520-2, are applicable.
5.2 Quality levels for imperfections

NOTE The quality levels for imperfections related to the weld performance class are described below.

5.2.1 Quality levels for imperfections for fusion welded joints (beam welding excluded)

The quality levels for imperfection for fusion welding of steel and aluminium are listed in Table 4 in

accordance to EN ISO 5817 and EN ISO 10042.

EN ISO 5817:2014, Annex C, is not applicable in the production and maintenance of railway vehicles and

components.
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Table 4 — Quality levels for imperfections for steel and aluminium related to weld performance

classes
Imperfection No. Weld performance classes
according to
CP A CP B1 / CP B2 CP C1 / CP C2 / CP C3 CP D
EN ISO 6520-1
Level of Imperfections according to EN ISO 5817 and EN ISO 10042
Group 100 B B C D
Group 200 B B C D
Group 300 B B C D
Group 400 B B C D
5011, 5012, 5013, Not permitted B C D
502, 504, 506, 509,
511, 510, 515, 516,
517
5071, 5072, 601 B B C D
503, 5213, 512 , 617 Not applicable B C D
505 and Multiple B These imperfections are not assessed
Imperfections
5214 [steel] Not applicable B C D

5214 [aluminium] Not applicable refer to geometrical dimension defined into design

documentation (e.g. avoid interference during assembly)
602, 610 [steel] B 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 leg length.
5.2.2 Quality levels for imperfections for beam welded joints
Quality levels for imperfections shall be according to EN ISO 13919
...