SIST EN 15085-3:2023
(Main)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 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
Relations
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.
---------------------- Page: 1 ----------------------
SIST EN 15085-3:2023
---------------------- Page: 2 ----------------------
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.
---------------------- Page: 3 ----------------------
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
2
---------------------- Page: 4 ----------------------
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
3
---------------------- Page: 5 ----------------------
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.
4
---------------------- Page: 6 ----------------------
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.
5
---------------------- Page: 7 ----------------------
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.
6
---------------------- Page: 8 ----------------------
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
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
7
---------------------- Page: 9 ----------------------
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)
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.
8
---------------------- Page: 10 ----------------------
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
1
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
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.
9
---------------------- Page: 11 ----------------------
SIST EN 15085-3:2023
EN 15085-3:2022 (E)
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).
10
---------------------- Page: 12 ----------------------
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
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.
11
---------------------- Page: 13 ----------------------
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
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
Low Medium CP C3 C CT 4 Not Not 100 %
required required
a
Low Low CP D D CT 4 Not Not 100 %
required required
a
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.
---------------------- Page: 1 ----------------------
oSIST prEN 15085-3:2021
---------------------- Page: 2 ----------------------
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.
---------------------- Page: 3 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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
2
---------------------- Page: 4 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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
3
---------------------- Page: 5 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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.
4
---------------------- Page: 6 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (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 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.
5
---------------------- Page: 7 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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)
6
---------------------- Page: 8 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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)
7
---------------------- Page: 9 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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.
8
---------------------- Page: 10 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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
or
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).
9
---------------------- Page: 11 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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
a
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
b
Weld performance class CP B1:
CP B1 is only applicable for welds with full penetration and full accessibility for inspection in
production and maintenance.
c
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
d
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.
10
---------------------- Page: 12 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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
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
Low Medium CP C3 C CT 4 Not Not 100 %
required required
a
Low Low CP D D CT 4 Not Not 100 %
required required
a
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.
11
---------------------- Page: 13 ----------------------
oSIST prEN 15085-3:2021
prEN 15085-3:2021 (E)
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
a
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
...
Questions, Comments and Discussion
Ask us and Technical Secretary will try to provide an answer. You can facilitate discussion about the standard in here.