SIST EN 15085-4:2023
(Main)Railway applications - Welding of railway vehicles and components - Part 4: Production requirements
Railway applications - Welding of railway vehicles and components - Part 4: Production requirements
This series of standards applies to welding of metallic materials in the manufacture and maintenance of railway vehicles and their parts.
This part of the series describes the production requirements (i.e. preparation and execution) of the welding work.
Bahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 4: Fertigungsanforderungen
Applications ferroviaires - Soudage des véhicules et des composants ferroviaires - Partie 4: Exigences de production
Le présent document définit les exigences de production (par exemple : préparation et exécution) des travaux de soudage sur les véhicules et composants ferroviaires.
Železniške naprave - Varjenje železniških vozil in komponent - 4. del: Zahteve za proizvodnjo
Ta skupina standardov se uporablja za varjenje kovinskih materialov pri izdelavi in vzdrževanju železniških vozil ter njihovih delov.
Ta del skupine standardov opisuje zahteve za izvedbo (tj. priprava in izvedba) varjenja.
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN 15085-4:2023
01-maj-2023
Železniške naprave - Varjenje železniških vozil in komponent - 4. del: Zahteve za
proizvodnjo
Railway applications - Welding of railway vehicles and components - Part 4: Production
requirements
Bahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 4:
Fertigungsanforderungen
Applications ferroviaires - Soudage des véhicules et des composants ferroviaires - Partie
4: Exigences de production
Ta slovenski standard je istoveten z: EN 15085-4:2023
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
45.060.01 Železniška vozila na splošno Railway rolling stock in
general
SIST EN 15085-4:2023 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN 15085-4:2023
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SIST EN 15085-4:2023
EN 15085-4
EUROPEAN STANDARD
NORME EUROPÉENNE
March 2023
EUROPÄISCHE NORM
ICS 25.160.10; 45.060.01 Supersedes EN 15085-4:2007
English Version
Railway applications - Welding of railway vehicles and
components - Part 4: Production requirements
Applications ferroviaires - Soudage des véhicules et des Bahnanwendungen - Schweißen von
composants ferroviaires - Partie 4: Exigences de Schienenfahrzeugen und -fahrzeugteilen - Teil 4:
production Fertigungsanforderungen
This European Standard was approved by CEN on 23 January 2023.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2023 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 15085-4:2023 E
worldwide for CEN national Members.
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
Contents Page
European foreword . 4
Introduction . 6
1 Scope . 7
2 Normative references . 7
3 Terms and definitions . 9
4 Preparation before welding . 10
4.1 Welding planning documents . 10
4.1.1 General . 10
4.1.2 Working plans . 10
4.1.3 Additional welding planning documents . 11
4.1.4 Welding procedure specification (WPS) . 11
4.1.5 Training and qualification of welders and operators . 11
4.2 Supplementary weld tests . 12
4.2.1 General . 12
4.2.2 Production weld tests to demonstrate the suitability of the design . 13
4.2.3 Production weld tests to demonstrate the suitability of the welding conditions . 13
4.2.4 Production weld tests to demonstrate the skill of the welder . 14
4.2.5 Production weld tests to demonstrate the quality of the welded joint . 14
4.2.6 Production weld tests to demonstrate the quality of electron beam, laser beam and
laser-arc hybrid welds . 15
4.2.7 Production weld tests to demonstrate the quality of resistance spot, roll seam and
projection welds . 15
4.2.8 Production weld tests to demonstrate the quality of flash welds . 15
4.2.9 Production weld tests to demonstrate the quality of stud welds . 15
4.2.10 Production weld tests to demonstrate the quality of friction stir welded joints . 15
5 Requirements for welding . 15
5.1 General . 15
5.2 General requirements . 15
5.2.1 Weld preparation and other requirements . 15
5.2.2 Execution of the welding . 16
5.2.3 Weld quality . 17
5.3 Welding consumables . 18
5.3.1 Choice of welding consumables . 18
5.3.2 Conformity of welding consumables . 18
5.3.3 Storage and handling . 18
5.4 Parent materials . 19
5.4.1 Choice of parent materials . 19
5.4.2 Conformity of parent materials . 19
5.4.3 Additional rules for welding carbon and fine grained structural steels . 19
5.4.4 Additional rules for welding of cast irons . 19
5.4.5 Additional rules for welding stainless steels . 19
5.4.6 Additional rules for welding carbon or fine grain structural steels with stainless
steels . 20
5.4.7 Additional rules for welding aluminium and aluminium alloys . 20
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
5.5 Welding processes . 20
Annex A (informative) Guidance on the choice of filler material . 22
A.1 General . 22
A.2 Non-alloy steel with non alloy steel . 22
A.3 Stainless steel with stainless steel or non alloy steel . 22
A.4 Aluminium and its alloys . 23
A.5 Other parent metals . 23
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of Directive (EU) 2016/797 aimed to be covered . 26
Bibliography . 28
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
European foreword
This document (EN 15085-4:2023) has been prepared by Technical Committee CEN/TC 256 “Railway
applications”, the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by September 2023, and conflicting national standards shall
be withdrawn at the latest by September 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 15085-4:2007.
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 for welding manufacturers;
— Part 3: Design requirements;
— Part 4: Production requirements;
— Part 5: Inspection, testing and documentation;
— Part 6: Maintenance welding requirements.
EN 15085-4:2023 includes the following changes with respect to EN 15085-4:2007:
a) Normative reference have been updated;
b) Clause 4, Preparation before welding has been revised;
c) Clause 5, Requirements for welding has been revised;
d) Clause 6, Special requirements for maintenance welding of railway vehicles has been deleted
e) Annex A, Guidance on the choice of filler material has been added
f) 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 15085-4:2023
EN 15085-4:2023 (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 15085-4:2023
EN 15085-4:2023 (E)
Introduction
Welding is a special process in the manufacture of railway vehicles and their parts. The required
provisions for this process are defined 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 standards 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 15085-4:2023
EN 15085-4:2023 (E)
1 Scope
This document specifies the production requirements (i.e. preparation and execution) of the welding
work on railway vehicles and components.
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 1011-1:2009, Welding - Recommendations for welding of metallic materials - Part 1: General guidance
for arc welding
EN 1011-2:2001, Welding - Recommendations for welding of metallic materials - Part 2: Arc welding of
ferritic steels
EN 1011-3:2018, Welding - Recommendations for welding of metallic materials - Part 3: Arc welding of
stainless steels
EN 1011-4:2000, Welding - Recommendations for welding of metallic materials - Part 4: Arc welding of
aluminium and aluminium alloys
EN 1011-5:2003, Welding - Recommendations for welding of metallic materials - Part 5: Welding of clad
steel
EN 1011-6:2018, Welding - Recommendation for welding of metallic materials - Part 6: Laser beam welding
EN 1011-7:2004, Welding - Recommendations for welding of metallic materials - Part 7: Electron beam
welding
EN 1011-8:2018, Welding - Recommendations for welding of metallic materials - Part 8: Welding of cast
irons
EN 287-6:2018, Qualification test of welders - Fusion welding - Part 6: Cast irons
EN 10204:2004, Metallic products - Types of inspection documents
EN 14532-1:2004, Welding consumables - Test methods and quality requirements - Part 1: Primary
methods and conformity assessment of consumables for steel, nickel and nickel alloys
EN 14532-2:2004, Welding consumables - Test methods and quality requirements - Part 2: Supplementary
methods and conformity assessment of consumables for steel, nickel and nickel alloys
1
EN 15085-1:— , Railway applications — Welding of railway vehicles and components — Part 1: General
EN 15085-3:2022, Railway applications - Welding of railway vehicles and components - Part 3: Design
requirements
1
Under preparation. Stage at time of publication: prEN 15085-1:2021.
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
EN 15085-5:2023, Railway applications - Welding of railway vehicles and components - Part 5: Inspection,
testing and documentation
EN 10025-1:2004, Hot rolled products of structural steels - Part 1: General technical delivery conditions
EN 10340:2007, Steel castings for structural uses
EN ISO 544:2017, Welding consumables - Technical delivery conditions for filler materials and fluxes - Type
of product, dimensions, tolerances and markings (ISO 544:2017)
EN ISO 4063:2010, Welding and allied processes - Nomenclature of processes and reference numbers (ISO
4063:2009, Corrected version 2010-03-01)
EN ISO 9606-1:2017, Qualification testing of welders - Fusion welding - Part 1: Steels (ISO 9606-1:2012
including Cor 1:2012 and Cor 2:2013)
EN ISO 9606-2:2004, Qualification test of welders - Fusion welding - Part 2: Aluminium and aluminium
alloys (ISO 9606-2:2004)
EN ISO 9606-3:1999, Approval testing of welders - Fusion welding - Part 3: Copper and copper alloys (ISO
9606-3:1999)
EN ISO 9606-4:1999, Approval testing of welders - Fusion welding - Part 4: Nickel and nickel alloys (ISO
9606-4:1999)
EN ISO 9606-5:2000, Approval testing of welders - Fusion welding - Part 5: Titanium and titanium alloys,
zirconium and zirconium alloys (ISO 9606-5:2000)
EN ISO 14555:2017, Welding - Arc stud welding of metallic materials (ISO 14555:2017)
EN ISO 14732:2013, Welding personnel - Qualification testing of welding operators and weld setters for
mechanized and automatic welding of metallic materials (ISO 14732:2013)
EN ISO 15609-1:2019, Specification and qualification of welding procedures for metallic materials -
Welding procedure specification - Part 1: Arc welding (ISO 15609-1:2019)
EN ISO 15609-2:2019, Specification and qualification of welding procedures for metallic materials -
Welding procedure specification - Part 2: Gas welding (ISO 15609-2:2019)
EN ISO 15609-3:2004, Specification and qualification of welding procedures for metallic materials -
Welding procedures specification - Part 3: Electron beam welding (ISO 15609-3:2004)
EN ISO 15609-4:2009, Specification and qualification of welding procedures for metallic materials -
Welding procedure specification - Part 4: Laser beam welding (ISO 15609-4:2009)
EN ISO 15609-5:2011, Specification and qualification of welding procedures for metallic materials -
Welding procedure specification - Part 5: Resistance welding (ISO 15609-5:2011, Corrected version 2011-
12-01)
EN ISO 15609-6:2013, Specification and qualification of welding procedures for metallic materials -
Welding procedure specification - Part 6: Laser-arc hybrid welding (ISO 15609-6:2013)
EN ISO 15613:2004, Specification and qualification of welding procedures for metallic materials -
Qualification based on pre-production welding test (ISO 15613:2004)
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
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, Corrected version 2017-10-01)
EN ISO 15614-2:2005, Specification and qualification of welding procedures for metallic materials -
Welding procedure test - Part 2: Arc welding of aluminium and its alloys (ISO 15614-2:2005)
EN ISO 15614-3:2008, Specification and qualification of welding procedures for metallic materials -
Welding procedure test - Part 3: Fusion welding of non-alloyed and low-alloyed cast irons (ISO 15614-
3:2008)
EN ISO 15614-4:2005, Specification and qualification of welding procedures for metallic materials -
Welding procedure test - Part 4: Finishing welding of aluminium castings (ISO 15614-4:2005)
EN ISO 15614-7:2019, Specification and qualification of welding procedures for metallic materials -
Welding procedure test - Part 7: Overlay welding (ISO 15614-7:2016)
EN ISO 15614-11:2002, Specification and qualification of welding procedures for metallic materials -
Welding procedure test - Part 11: Electron and laser beam welding (ISO 15614-11:2002)
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 15614-13:2021, Specification and qualification of welding procedures for metallic materials -
Welding procedure test - Part 13: Upset (resistance butt) and flash welding (ISO 15614-13:2021)
EN ISO 15620:2019, Welding - Friction welding of metallic materials (ISO 15620:2019)
EN ISO 17652-1:2003, Welding - Test for shop primers in relation to welding and allied processes - Part 1:
General requirements (ISO 17652-1:2003)
EN ISO 17652-2:2003, Welding - Test for shop primers in relation to welding and allied processes - Part 2:
Welding properties of shop primers (ISO 17652-2:2003)
EN ISO 25239-3:2020, Friction stir welding - Aluminium - Part 3: Qualification of welding operators (ISO
25239-3:2020)
EN ISO 25239-5:2020, Friction stir welding - Aluminium - Part 5: Quality and inspection requirements (ISO
25239-5:2020)
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 http://www.iso.org/obp
— IEC Electropedia: available at http://www.electropedia.org/
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
4 Preparation before welding
4.1 Welding planning documents
4.1.1 General
Welding planning documents shall be prepared by the manufacturer with the assistance of the
responsible welding coordinator.
When the technical specification requires approval of welding planning documents, these shall be
submitted prior to starting the welding activity. Welding planning documents may include working plans,
welding sequence plans, test planning documents, and welding procedure specifications.
Weld preparations defined in the drawing may be adapted for manufacturing under the supervision of
the responsible welding coordinator. However, the following changes shall not be made without
permission from the design department:
— weld type;
— reduction of the weld performance class;
— reduction of the weld inspection class;
— base material;
— minimum mechanical properties of welded joints;
— welding consumables specification;
— reduction of weld throat thickness;
— location of the weld;
— addition of welded joints;
— elimination of welded joints;
— addition of tack welds or temporary attachments outside of the joint preparation.
Any changes resulting from manufacturing adaptation shall be documented and included in the welding
planning documents.
4.1.2 Working plans
For the production of railway vehicles and components, a documented and controlled process of
manufacturing operations shall be available for the following sub-assemblies:
— bogie (sub-assemblies, assembly);
— underframe (with sub-assemblies);
— car body components (side wall, end wall, roof);
— car body assembly;
— further sub-assemblies with high safety relevance (e.g. cardan shafts, motor housing, hollow shaft
drive, drawbar coupling, bogie pivot pin).
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
4.1.3 Additional welding planning documents
For series production, in addition to the working plan, tacking and welding sequence plans may be used
to minimize weld shrinkage and distortion, to reduce residual stresses and to avoid missing welds, e.g.
for:
— bogie frames and their components, and
— underframes and their components.
Standardized welding sequence plans (that applies for different types of components) are also allowed.
Other welding planning documents may be necessary (e.g. repairing plans, documents for jigs and tools,
plans for cutting off damaged parts).
An inspection and test plan shall be prepared according to EN 15085-5:2023.
4.1.4 Welding procedure specification (WPS)
WPS according to the relevant part of EN ISO 15609:2019, EN ISO 14555:2017, EN ISO 15620:2019 or
EN ISO 25239:2020 are required for all weld performance classes except CP D. For weld performance
class CP D a welding instruction shall be prepared.
For all weld performance classes except CP D a welding procedure specification shall be supported by a
WPQR according to the relevant part of the following standards:
• EN ISO 15613:2004;
• EN ISO 15614 series (for EN ISO 15614 only level 2 is applicable);
• EN ISO 14555:2017;
• EN ISO 15620:2019;
• EN ISO 25239:2020.
For fillet welds a separate fillet weld qualification is necessary.
The manufacturer shall have a written procedure detailing how to manage the welding procedure
qualification process.
Each WPS shall be verified and authorized for use by the responsible welding coordinator or by the
welding coordinator in charge.
4.1.5 Training and qualification of welders and operators
The manufacturer shall have welders and welding operators qualified in accordance with EN ISO 9606
series, EN 287-6:2018, EN ISO 14555:2017, EN ISO 14732:2013 or EN ISO 25239-3:2020. Additionally,
all welding personnel should be trained for welding related tasks that are performed in the workshop
(e.g. grinding, flame cutting, tacking, etc.). The manufacturer shall maintain a list of the valid qualifications
of its welders and welding operators.
The manufacturer shall have an adequate number of qualified welders and welding operators. It is
recommended that at least two welders or welding operators, employed by the manufacturer, should be
qualified for each welding process and material type/grade.
For qualification according to the EN ISO 9606 series of standards the following rules shall be applied:
— For fillet welds a separate fillet weld qualification is necessary.
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
— The FW/BW – test sample according to EN ISO 9606-1:2017, Annex C is not permitted.
In addition, welders and operators should be trained about in the following as needed:
— checking the correct condition / operation of the welding equipment and its calibration status;
— use of and compliance with the relevant welding planning documents;
— checking of joint preparations;
— welding consumable designations;
— methods of cleaning, controlling preheating and inter-pass temperatures, and post weld heat
treatment;
— reading welding drawings and welding symbols;
— weld acceptance criteria;
— correct use and application of tack welds;
— content of this document, 5.2 (and applicable parts of EN 1011:2009);
— safety at work.
For welding of steel the revalidation of the qualification of welders shall be in accordance with
EN ISO 9606-1:2017, 9.3 option a or b.
4.2 Supplementary weld tests
4.2.1 General
4.2.1.1 Objectives of production weld tests
Due to the diversity of the welded joint types required in the manufacture of railway vehicles, the
responsible welding coordinator may decide to undertake production weld tests (supplementary weld
tests) to demonstrate that the required weld quality level can be, or has been, achieved.
The objectives of production weld tests are:
— to demonstrate the suitability of the design (see 4.2.2);
— to demonstrate the suitability of the welding procedure for specific joint types (see 4.2.3);
— to demonstrate the skill of the welders (see 4.2.4);
— to demonstrate the quality of the welded joint (see 4.2.5 to 4.2.10).
One production weld test may be used to demonstrate that the requirements indicated above have been
satisfied. With the exception of the production weld test to demonstrate the skill of the welder, the period
of validity of a production weld test is unlimited provided that the conditions are unchanged.
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SIST EN 15085-4:2023
EN 15085-4:2023 (E)
4.2.1.2 Realization and amount of producti
...
SLOVENSKI STANDARD
oSIST prEN 15085-4:2020
01-oktober-2020
Železniške naprave - Varjenje železniških vozil in elementov - 4. del: Zahteve za
proizvodnjo
Railway applications - Welding of railway vehicles and components - Part 4: Production
requirements
Bahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 4:
Fertigungsanforderungen
Applications ferroviaires - Soudage des véhicules et des composants ferroviaires - Partie
4: Exigences de production
Ta slovenski standard je istoveten z: prEN 15085-4
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
45.060.01 Železniška vozila na splošno Railway rolling stock in
general
oSIST prEN 15085-4:2020 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 15085-4:2020
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oSIST prEN 15085-4:2020
DRAFT
EUROPEAN STANDARD
prEN 15085-4
NORME EUROPÉENNE
EUROPÄISCHE NORM
August 2020
ICS 25.160.10; 45.060.01 Will supersede EN 15085-4:2007
English Version
Railway applications - Welding of railway vehicles and
components - Part 4: Production requirements
Applications ferroviaires - Soudage des véhicules et des Bahnanwendungen - Schweißen von
composants ferroviaires - Partie 4: Exigences de Schienenfahrzeugen und -fahrzeugteilen - Teil 4:
production Fertigungsanforderungen
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
© 2020 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 15085-4:2020 E
worldwide for CEN national Members.
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oSIST prEN 15085-4:2020
prEN 15085-4:2020 (E)
Contents Page
European foreword . 3
Introduction . 4
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 6
4 Preparation before welding . 6
4.1 Welding planning documents . 6
4.2 Production weld tests . 9
5 Requirements for welding . 12
5.1 General . 12
5.2 General requirements . 12
5.3 Welding consumables . 15
5.4 Parent metals . 15
5.5 Welding processes . 17
Annex A (informative) Guidance to choose welding consumables . 19
Annex ZA (informative) Relationship between this European Standard and the Essential
Requirements of EU Directive 2016/797/EU aimed to be covered . 23
Bibliography . 25
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oSIST prEN 15085-4:2020
prEN 15085-4:2020 (E)
European foreword
This document (prEN 15085-4:2020) 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 CEN Enquiry.
This document will supersede EN 15085-4:2007.
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 for welding manufacturers;
— Part 3: Design requirements;
— Part 4: Production requirements;
— Part 5: Inspection, testing and documentation;
— Part 6: Maintenance welding requirements.
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, B, C or D, 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 are the basic technical welding standards in respect of the special requirements for the
construction of railway vehicles.
This document is aimed at defining the terms of enforcement applicable to European Standards, it should
not be construed as a substitute to these standards.
This document can also be used by internal and external parties to assess the organization's ability to
meet customer, regulatory, and the organization's own requirements.
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1 Scope
This document describes the production requirements (i.e. preparation and execution) of the welding
work.
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 (all parts), Welding — Recommendations for welding of metallic material
EN 287-6, Qualification test of welders - Fusion welding - Part 6: Cast irons
EN 10204, Metallic products - Types of inspection documents
EN 13479, Welding consumables - General product standard for filler metals and fluxes for fusion welding
of metallic materials
EN 14532-1, Welding consumables - Test methods and quality requirements - Part 1: Primary methods and
conformity assessment of consumables for steel, nickel and nickel alloys
EN 14532-2, Welding consumables - Test methods and quality requirements - Part 2: Supplementary
methods and conformity assessment of consumables for steel, nickel and nickel alloys
EN 15085-1, Railway applications — Welding of railway vehicles and components — Part 1: General
EN 15085-3:2007, Railway applications — Welding of railway vehicles and components — Part 3: Design
requirements
EN 15085-5, Railway applications - Welding of railway vehicles and components - Part 5: Inspection, testing
and documentation
EN ISO 544, Welding consumables - Technical delivery conditions for filler materials and fluxes - Type of
product, dimensions, tolerances and markings (ISO 544:2017)
EN ISO 4063:2010, Welding and allied processes — Nomenclature of processes and reference numbers
EN ISO 9606 (all parts), Qualification test of welders — Fusion welding
EN ISO 14555, Welding - Arc stud welding of metallic materials (ISO 14555)
EN ISO 14732, Welding personnel - Qualification testing of welding operators and weld setters for
mechanized and automatic welding of metallic materials (ISO 14732)
EN ISO 15609 (all parts), Specification and qualification of welding procedures for metallic materials —
Welding procedure specification
EN ISO 15613, Specification and qualification of welding procedures for metallic materials - Qualification
based on pre-production welding test (ISO 15613)
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EN ISO 15614-(all parts), Specification and qualification of welding procedures for metallic materials —
Welding procedure test
EN ISO 15620, Welding - Friction welding of metallic materials (ISO 15620)
EN ISO 17652-1, Welding - Test for shop primers in relation to welding and allied processes - Part 1: General
requirements (ISO 17652-1)
EN ISO 17652-2, Welding - Test for shop primers in relation to welding and allied processes - Part 2: Welding
properties of shop primers (ISO 17652-2)
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 http://www.iso.org/obp
— IEC Electropedia: available at http://www.electropedia.org/
4 Preparation before welding
4.1 Welding planning documents
4.1.1 General
Welding planning documents shall be prepared by the manufacturer with the assistance of the
responsible welding coordinator. Type, scope and time of the submission and inspection should be
defined in the technical specification.
Welding planning documents may include working plans, welding sequence plans, test planning
documents, and welding procedure specifications.
Design documents of welded components shall be checked by the responsible welding coordinator or one
of his deputies about their suitability. If necessary – the design documents can be adapted for the
manufacturing under the supervision of the responsible welding coordinator, e.g. by changing chamfer
angle of the weld preparation to achieve the required weld quality.
The following changes shall not be done without a permission of the design office:
— weld type;
— weld performance class;
— weld inspection class;
— base material;
— properties of the weld metal;
— reduction of weld throat thickness;
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For railway applications, only EN ISO 15614-1, EN ISO 15614-2, EN ISO 15614-3, EN ISO 15614-4,
EN ISO 15614-7, EN ISO 15614-11, EN ISO 15614-12, and EN ISO 15614-13 are relevant.
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— location of the weld;
— addition of welded joints;
— elimination of welded joints.
After a successful check and possible adaptation, the design documents can be included in the welding
planning documents. The weld preparation should be finally defined during design review and this
definition shall be documented.
4.1.2 Working plans
For the production of railway vehicles, it is necessary to have working plans for the following sub-
assemblies:
— bogie (sub-assemblies, assembly);
— underframe (with sub-assemblies);
— car body components (side wall, end wall, roof);
— car body assembly;
— further sub-assemblies with high safety and functional requirements (e.g. cardan shafts, brake cross
members, motor housing, hollow shaft drive, drawbar coupling, bogie pivot pin, cross bearer).
4.1.3 Other welding planning documents
For more complicated assemblies welding sequence plans may be necessary to reduce residual stresses
or deformation and shrinkage or to avoid missing welds e.g. for:
— bogie frames and their components, and
— underframes and their components.
Standardized welding sequence plans (that applies for different types of components) are also allowed.
Furthermore, other welding planning documents may be necessary (e.g. tacking sequence plans,
repairing plans, documents for jigs and tools, plans for separating of damaged parts, special instructions
for electronic parts). These details shall be determined by the responsible welding coordinator and/or
the customer.
The test plan shall be done in accordance with EN 15085-5:2007, Clause 6.
4.1.4 Welding procedure specification
For weld performance classes CP B1, CP B2, CP C1, CP C2 or CP C3 each weld shall be covered by WPS
according to the relevant part of EN ISO 15609, EN ISO 14555 or EN ISO 15620.
For weld performance class CP D a welding instruction shall exist.
For weld performance classes CP B1, CP B2, CP C1 or CP C2 an evidence by WPQR according to
EN ISO 15613, to EN ISO 15614 series, for EN ISO 15614-1 only level 2 is applicable, to EN ISO 14555 or
to EN ISO 15620 shall be given. When tests as described in the mentioned standards do not provide
information on the mechanical properties of the joint, and these properties are relevant to the
application, an additional qualification shall be carried out on a butt weld.
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If changes in EN ISO 15614 series appear regarding range of validity and testing, the requirements of the
level should apply, which is comparable the requirements of the latest version of EN ISO 15614 in use in
2018.
For weld performance class CP C3 all standards for the qualification of welding procedure according to
EN ISO 15607 and EN ISO 14555 are permitted.
For fillet welds a separate fillet weld qualification is necessary.
The manufacturer shall have a written procedure detailing how to manage the welding procedure
qualification process.
All WPS shall be verified and authorized for use by the responsible welding coordinator or by the welding
coordinator in charge.
4.1.5 Training and qualification of welders and operators
The manufacturer shall have welders and welding operators with qualification in accordance with series
of standard EN ISO 9606, with EN 287-6, with EN ISO 14555 or with EN ISO 14732. Additionally they
should be trained for tasks, which they do in the workshop.
The manufacturer shall have a list of the valid qualification of its welders and welding operators.
The welders and operators shall follow the instructions of the welding coordinators of the manufacturer.
The manufacturer shall have an adequate number of qualified welders and operators. At least two
welders or operators, who are employees of the manufacturer, for each welding process and welded
material type are recommended.
For the application of EN ISO 9606 (series) in the production of railway vehicles the following rules shall
be considered:
— For fillet welds a separate fillet weld qualification is necessary.
— The FW/BW – test sample according to EN ISO 9606-1:2017, Annex C isn’t accepted.
In addition, welders and operators should be trained about the following issues:
— correct state of the welding equipment;
— availability and compliance of the welding planning documents with the welded component;
— conformity of joint preparations;
— conformity of welding consumables;
— if necessary: cleaning, preheating temperature, inter-pass temperatures, and post weld heat
treatment;
— conformity of the weld relating to the drawing;
— ability to check the weld quality, which is required in accordance with the weld performance class;
— correct tack welding;
— content of 5.2 (see also applicable parts of EN 1011);
— working safety.
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For welding of steel the validity of the qualification of welders shall be in accordance with
EN ISO 9606-1:2017, 9.3 option a or b.
The manufacturer shall have a written procedure detailing how to manage the welder and operator
qualification process.
All welders and operators shall be authorized to weld by a welding coordinator.
4.2 Production weld tests
4.2.1 General
4.2.1.1 Aims and objectives of production weld tests
Due to the complexity of many welded joints in railway vehicles, the responsible welding coordinator
may decide carry out production weld tests to demonstrate that the required quality level can be, or has
been, achieved.
The aims and objectives of (pre-) production weld tests are:
— to check and ensure that the design is suitable as specified in EN 15085-3 (see 4.2.2);
— to prove the welding procedure (see 4.2.3) for welded joints, which are not covered by the usual
welding standards for the welding procedures qualification;
— to demonstrate the skill of the welders (see 4.2.4) for welded joints, which are not covered by the
usual welding standards for the welder qualification;
— to ensure the integrity of the welded joint (see 4.2.5 to 4.2.10).
One production weld test can be used for several tasks indicated above.
4.2.1.2 Realization and amount of testing of production weld test
The production weld tests and the amount of testing shall be specified by the welding coordinator e.g.
during design review or during manufacturing phase.
The production weld test shall be carried out under the same manufacturing conditions as the real
product. They shall be carried out under the supervision of the responsible welding coordinator and they
shall be documented.
The production weld tests may be welded separately as test plates, as sample sub-assemblies (mock-ups)
or together with sub-assembly, for example, as an extension of the weld.
The production weld tests and the amount of testing should be listed in the test plan or specified by the
welding coordinator.
The manufacturer shall have a written procedure detailing how to manage the execution of production
weld tests.
All production weld test results shall be accepted by a welding coordinator.
The results of every production weld test shall be documented.
4.2.2 Production weld tests to check and ensure the design
Test specimens to demonstrate the weldability of the design should be welded as a sample sub-assembly
during the design phase. They are necessary to demonstrate:
— practicability (design which is convenient for welding);
— selection of the material;
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— possibility of testing;
— quality requirements;
— mechanical property data (e.g. strength, ductility).
If no details for the testing of the production weld tests are defined in the test plan, EN ISO 15613 applies.
These production weld test results can be applied to different projects as long as the conditions are the
same; its validity is unlimited in this case.
4.2.3 Production weld tests to prove the welding conditions
For special welds where no proof is possible in accordance with EN ISO 15614, production weld tests are
necessary for proving these welds to ensure the fusion of the weld. The responsible welding coordinator
shall decide which production weld tests are necessary, those can be, for example:
— welds without full penetration on butt and T joints;
— for welds with several degrees of difficulty, e.g. three plate butt welds, plug welds, lap joints,
complicated welds on extrusion profiles;
— to avoid irregularities in production that may be caused by the use of new equipment, jigs, fixtures
or new material;
— HV welds on T joints with single side access.
The production weld tests serve to demonstrate that the specified weld performance class has been
achieved. If no details for the destructive testing of the production weld tests are defined in a test plan,
EN ISO 15613 applies.
4.2.4 Production weld tests to demonstrate the skill of the welder
For welds which require a special skill in welding and are not specified in standards EN ISO 9606-1 or
EN ISO 9606-2 to EN ISO 9606-5, production weld tests are necessary to complete the welders
qualification in relation to the necessary skill required in production. The testing of the production weld
tests shall be carried out as specified in EN ISO 9606-1 to EN ISO 9606-5. If the testing cannot be carried
out according to these standards the responsible welding coordinator should specify the testing.
EN ISO 9606-1 to EN ISO 9606-5 applies to the range of the validity. For the duration of the validity and
the prolongation 4.1.5 applies.
The responsible welding coordinator shall decide about the production weld tests for the qualification of
welders (depending on their specific tasks). It may be necessary for example:
— for HV or HY welds on T joints;
— for welds with several degrees of difficulty, e.g. three plate butt welds, plug welds, cross weld,
complicated welds on extrusion profiles;
— for welds under complicated conditions, e.g. repairing;
— for poor accessibility;
— for welds with backing;
— for materials with poor weldability;
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— for pipe branches and pipe collars;
— for lap joints and corner welds in thin sheets (t ≤ 3 mm);
— for especially high quality requirements, e.g. weld performance class CP A and CP B1 as specified in
EN 15085-3;
— when taking on new welders or welding operators, e.g. staff on loan.
The production weld tests should be listed in the planning documents or specified by the welding
coordinator.
4.2.5 Production weld tests to demonstrate the integrity of the welded joint
The weld quality may be demonstrated with production weld tests, e.g. to ensure the weld quality for
inspection class CT 2 (see EN 15085-5:2007, Table 1), production weld tests are necessary if neither X-
ray nor ultrasonic inspection is possible.
For example, the following conditions should be considered:
— kind of the production weld test and the frequency should be given in the test plan by the welding
coordinator;
— production weld tests shall be taken from the assembly or from an extension of the work piece (e.g.
run-on or run-off plates) or from a similar work piece;
— production weld tests should be checked by a fracture test or macro-section to demonstrate that
their requirements of the demanded weld performance class are fulfilled.
4.2.6 Production weld tests to check electron beam and laser beam welding
Before the start of the fabrication, production weld tests shall be produced and assessed in accordance
with EN ISO 15614-11 (e.g. bending or tensile test). For a change of the design, of the material, in the way
of fabrication or in the production other production weld tests could also be necessary, if the changes can
influence the quality of the weld.
4.2.7 Production weld tests to check resistance spot, roll seam and projection welds
With resistance spot, resistance seam and projection welding, production weld tests shall be produced
according to EN 15085-3:2007, Table F.2. Simplified weld production tests (e.g. bending or tensile shear
test) shall be done before the daily start of the fabrication. Normal weld production tests shall be done to
prove the quality in the production at regular intervals depending on weld volume, weld equipment, and
weld performance class.
4.2.8 Production weld tests to check flash butt welding
For flash butt welds at the beginning of a new production run or when changing the manufacturing
conditions (e.g. materials etc.) it is necessary to demonstrate the quality of the weld by production weld
tests according to EN ISO 15614-13 and testing with a notch bending test, a fracture surface assessment
or a non-destructive testing that the mechanical and technical quality values of the weld are in accordance
with the specification.
4.2.9 Production weld tests to check stud welding
For stud welding, simplified production tests according to EN ISO 14555 shall be done before starting
production or when changing the manufacturing conditions and shall be recorded in a log book.
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4.2.10 Production weld tests to check friction stir welding
For friction stir welding, production weld tests shall be done according to EN ISO 25239-5.
5 Requirements for welding
5.1 General
Listed below are the technical requirements for the welding of railway vehicles and their components. In
addition, the recommendations of series of standards EN 1011 should be observed for welding.
The welding work shall be done in accordance with the relevant welding planning documents.
5.2 General requirements
5.2.1 Weld preparation and other requirements
1) The weld preparation shall be done as specified on the drawing or in other work documents. The
requirements specified in EN 15085-3 should be considered.
2) If there are no specified requirements, the quality of cut edges should be a minimum of class 33
according to EN ISO 9013.
3) The cut surface of sheared cuts or stamped jogs shall be free of notches and cracks. If necessary, these
imperfections shall be ground out.
4) Run-on and run-off plates shall be used according to EN 15085-3:2007, 7.3.11. For thickness
t ≥ 8 mm they shall have the same joint preparation as the actual weld. The run-on and run-off plates
shall be made so as to enable the welding to be started or stopped beyond its necessary length. The
parts to be assembled and the plates, which are “integrated” into the design or implanted as small
plates on the parts to be welded, shall be homogenous. The preparation of these plates shall be the
same as that used on the joints to be made. The plates shall be fixed by mechanical or magnetic means
and can be welded. After having completed the joint, the plates can either be mechanically removed
or cut using a blowpipe or plasma. A longitudinal grinding shall be made after the removal of the
plates. Any rupture caused by shock or breaking is prohibited.
5) All additional weld seams (see 4.1.1), which are not defined in the design documents shall be
accepted and documented by the design department.
6) The surfaces in the weld shall be free from damp and contamination such as dirt, rust, scale, slag, oil,
and paint. For multi-run welding the surface of the previous run shall be prepared so that a
satisfactory welding of the next run is possible. Dirt, slag, and unacceptable imperfections shall be
removed.
7) For corrosion protection on overlap joints and other areas that are no longer accessible after welding,
the application of shop primer paint or coating is acceptable if the following conditions are met:
i) using these primers or coatings is accepted by the customer, if required;
ii) the requirement is included in the design;
iii) the WPQR has been qualified with the primer being applied;
iv) the requirements of EN ISO 17652-1 and EN ISO 17652-2 are met.
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8) The weld joints shall be visible and the accessibility should be optimized for the welder (see 4.2.4).
9) Before welding, any irregularities shall be advised to the welding coordinator, e.g. incorrect weld
preparation, faulty or unsuitable filler metals or unsuitable welding machines.
5.2.2 Execution of the welding
1) Weld layers, weld direction and weld sequence should be chosen so that the welding produces
minimized residual stresses and distortion, so that the weld quality and the required mechanical
properties are achieved.
2) At the end of gussets or stiffeners, the weld return without interruption should be made in
accordance with EN 15085-3.
3) If possible, the welding should be done in position PA or PB. If possible, rotating equipment should
be used.
4) The
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