ENTWURF

ÖNORM
EN ISO 10042
Ausgabe: 2004-07-01

Normengruppe M

Ident (IDT) mit ISO/DIS 10042:2004

Ident (IDT) mit prEN ISO 10042:2004

Ersatz für ÖNORM EN 30042:1994-10

ICS 25.160.40 Welding – Arc-welded joints in aluminium and its

alloys
Quality levels for imperfections

Soudage – Assemblages en aluminium et alliages d'aluminium soudés à l'arc – Niveaux

de qualité par rapport aux défauts

Der Entwurf ÖNORM EN ISO 10042 besteht aus

• diesem nationalen Deckblatt
• dem offiziellen englischsprachigen Deckblatt der prEN ISO 10042:2004 sowie
• der offiziellen englischsprachigen Fassung der ISO/DIS 10042:2004.

Hinweis: Aufgrund von Stellungnahmen kann die endgültige Fassung

der ÖNORM vom vorliegenden Entwurf abweichen.
STELLUNGNAHMEN (SCHRIFTLICH) BIS 2004-08-31 AN DAS ON.

Fortsetzung
ENTWURF ÖNORM EN ISO 10042 Seite 2
prEN ISO 10042 Seiten 1 und 2 und
ISO/DIS 10042 Seiten i bis vi und 1 bis 19
Medieninhaber und Hersteller: Österreichisches Normungsinstitut, 1020 Wien Fachnormenausschuss 037
Copyright © ON - 2004. Alle Rechte vorbehalten; Schweißtechnik
Nachdruck oder Vervielfältigung, Aufnahme auf oder in sonstige Medien oder Datenträger
nur mit Zustimmung des ON gestattet!
Verkauf von in- und ausländischen Normen und technischen Regelwerken durch:
Österreichisches Normungsinstitut (ON), Heinestraße 38, A-1020 Wien
Tel.: (+43 1) 213 00-805, Fax: (+43 1) 213 00-818, E-Mail: sales@on-norm.at, lm/PU
Internet: http://www.on-norm.at
Seite 2
ENTWURF ÖNORM EN ISO 10042

Erläuterungen zum Entwurf

Der vom ISO/TC 44 in Zusammenarbeit mit dem CEN/TC 121 ausgearbeitete Entwurf zu einer Europäischen Norm
EN ISO 10042 wurde den CEN-Mitgliedern zur Abstimmung vorgelegt. Im Falle eines positiven Abstimmungsergebnisses
im Sinne der CEN/CENELEC-Regeln wird dieser Entwurf zu einer EN führen.
Wie alle Mitgliedsorganisationen des CEN ist das ON grundsätzlich verpflichtet, Europäische Normen in das nationale
Normenwerk zu übernehmen und entgegenstehende Normen zurückzuziehen.
Das ON legt hiermit diesen Entwurf eines europäischen Normungsdokumentes der Öffentlichkeit zur Information
und Stellungnahme als ÖNORM-Entwurf vor.
Da eine Übersetzung in die deutsche Sprache zu diesem Zeitpunkt noch nicht vorhanden ist, wird – um die von CEN
vorgegebene Einspruchsfrist einzuhalten – die englischsprachige Fassung der ISO/DIS 10042 zur Information und
Stellungnahme vorgelegt.

Hinweise zum Einspruchsverfahren

Einsprecher werden gebeten, ihre Stellungnahmen und Änderungsvorschläge in einer im Internet auf der ON-Homepage
verfügbaren Tabelle (download unter „http://www.on-norm.at/normungsarbeit/einspruch.htm“) zusammenzufassen,
um deren Behandlung im zuständigen Fachnormenausschuss bzw. deren Weitergabe an CEN und ISO zu vereinfachen.
Fachliche Einsprüche zu Europäischen Normen sollten in englischer Sprache erfolgen, da in den meisten Gremien die
Einspruchsbehandlung in der vereinbarten Arbeitssprache Englisch durchgeführt wird.
Redaktionelle Verbesserungsvorschläge zu deutschen Sprachfassungen sollten in Deutsch erfolgen.
Die ausgefüllte Tabelle sollte an den zuständigen Referenten des Österreichischen Normungsinstitutes als E-Mail
(martin.lorenz@on-norm.at) oder als Datei auf Diskette mit Angabe des verwendeten Programmes oder Formates
(WinWord, WordPerfect oder Rich Text Format) weitergeleitet werden.
Durch dieses Verfahren wird eine übersichtliche Zusammenstellung aller Einsprüche, geordnet nach den jeweiligen
Abschnitten, erleichtert.
Es wird gebeten, die Schriftart Arial (9 p) zu verwenden, die Formate nicht zu ändern und Kommentare zu den einzelnen
Abschnitten jeweils getrennt in eine Tabellenzeile einzutragen.
EUROPEAN STANDARD DRAFT
NORME EUROPÉENNE prEN ISO 10042
EUROPÄISCHE NORM
April 2004

ICS

English version

Welding - Arc-welded joints in aluminium and its alloys - Quality

levels for imperfections

Soudage - Assemblages en aluminium et alliages

d'aluminium soudés à l'arc - Niveaux de qualité par rapport
aux défauts

This draft European Standard is submitted to CEN members for parallel enquiry. It has been drawn up by the Technical Committee
CEN/TC 121.

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 Management Centre has the same
status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,
Slovenia, Spain, Sweden, Switzerland and United Kingdom.

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

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2004 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN ISO 10042:2004: E
worldwide for CEN national Members.
prEN ISO 10042:2004 (E)

Foreword

This document (prEN ISO 10042:2004) has been prepared by Technical Committee ISO/TC 44
"Welding and allied processes" in collaboration with Technical Committee CEN/TC 121
"Welding", the secretariat of which is held by DIN.

This document is currently submitted to the parallel Enquiry.

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).

Endorsement notice

The text of ISO/DIS 10042:2004 has been approved by CEN as prEN ISO 10042:2004 without
any modifications.

2
 DRAFT INTERNATIONAL STANDARD ISO/DIS 10042

ISO/TC 44/SC 10 Secretariat: DIN

Voting begins on: Voting terminates on:

2004-04-22 2004-09-22
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION • МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ • ORGANISATION INTERNATIONALE DE NORMALISATION

Welding — Arc-welded joints in aluminium and its alloys —

Quality levels for imperfections
Soudage — Assemblages en aluminium et alliages d'aluminium soudés à l'arc — Niveaux de qualité par
rapport aux défauts

[Revision of first edition (ISO 10042:1992)]

ICS 25.160.40

ISO/CEN PARALLEL ENQUIRY

The CEN Secretary-General has advised the ISO Secretary-General that this ISO/DIS covers a subject
of interest to European standardization. In accordance with the ISO-lead mode of collaboration as
defined in the Vienna Agreement, consultation on this ISO/DIS has the same effect for CEN
members as would a CEN enquiry on a draft European Standard. Should this draft be accepted, a
final draft, established on the basis of comments received, will be submitted to a parallel two-month FDIS
vote in ISO and formal vote in CEN.

To expedite distribution, this document is circulated as received from the committee secretariat.
ISO Central Secretariat work of editing and text composition will be undertaken at publication
stage.

Pour accélérer la distribution, le présent document est distribué tel qu'il est parvenu du
secrétariat du comité. Le travail de rédaction et de composition de texte sera effectué au
Secrétariat central de l'ISO au stade de publication.

THIS DOCUMENT IS A DRAFT CIRCULATED FOR COMMENT AND APPROVAL. IT IS THEREFORE SUBJECT TO CHANGE AND MAY NOT BE
REFERRED TO AS AN INTERNATIONAL STANDARD UNTIL PUBLISHED AS SUCH.
IN ADDITION TO THEIR EVALUATION AS BEING ACCEPTABLE FOR INDUSTRIAL, TECHNOLOGICAL, COMMERCIAL AND USER PURPOSES, DRAFT
INTERNATIONAL STANDARDS MAY ON OCCASION HAVE TO BE CONSIDERED IN THE LIGHT OF THEIR POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN NATIONAL REGULATIONS.

© International Organization for Standardization, 2004

ISO/DIS 10042

PDF disclaimer
This PDF file may contain embedded typefaces. In accordance with Adobe's licensing policy, this file may be printed or viewed but shall
not be edited unless the typefaces which are embedded are licensed to and installed on the computer performing the editing. In
downloading this file, parties accept therein the responsibility of not infringing Adobe's licensing policy. The ISO Central Secretariat
accepts no liability in this area.

Adobe is a trademark of Adobe Systems Incorporated.

Details of the software products used to create this PDF file can be found in the General Info relative to the file; the PDF-creation
parameters were optimized for printing. Every care has been taken to ensure that the file is suitable for use by ISO member bodies. In the
unlikely event that a problem relating to it is found, please inform the Central Secretariat at the address given below.

Copyright notice
This ISO document is a Draft International Standard and is copyright-protected by ISO. Except as permitted
under the applicable laws of the user's country, neither this ISO draft nor any extract from it may be
reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, photocopying,
recording or otherwise, without prior written permission being secured.

Requests for permission to reproduce should be addressed to either ISO at the address below or ISO's
member body in the country of the requester.

ISO copyright office

Case postale 56 • CH-1211 Geneva 20
Tel. + 41 22 749 01 11
Fax + 41 22 749 09 47
E-mail copyright@iso.org
Web www.iso.org

Reproduction may be subject to royalty payments or a licensing agreement.

Violators may be prosecuted.

ii © ISO 2004 – All rights reserved

 ISO/DIS 10042

Contents Page

Foreword............................................................................................................................................................ iv
Introduction ........................................................................................................................................................ v
1 Scope ..................................................................................................................................................... 1
2 Normative references ........................................................................................................................... 1
3 Terms and definitions........................................................................................................................... 2
4 Symbols ................................................................................................................................................. 3
5 Assessment of imperfections.............................................................................................................. 4
Annex A (informative) Examples for determination of percent (%) of porosity ....................................... 16
Annex B (informative) Additional information and guidelines for use of this International Standard .... 18
Bibliography ..................................................................................................................................................... 19

Table 1 — Limits for imperfections ...................................................................................................................... 5

© ISO 2004 – All rights reserved iii

ISO/DIS 10042

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.

International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.

The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. ISO shall not be held responsible for identifying any or all such patent rights.

ISO 10042 was prepared by Technical Committee ISO/TC 44, Welding and allied processes, Subcommittee
SC 10, WG 1.

This second edition cancels and replaces the first edition (ISO 10042:1992), which has been technically
revised.

iv © ISO 2004 – All rights reserved

 ISO/DIS 10042

Introduction
This International Standard should be used as a reference in drafting of application codes and/or other
application standards. It contains a simplified selection of arc welding imperfections based on the designations
given in ISO 6520-1.

Some imperfections described in ISO 6520-1 have been used directly and some have been grouped together.
The basic numerical referencing system from ISO 6520-1 has been used.

The purpose of this International Standard is to define dimensions of typical imperfections which might be
expected in normal fabrication. It may be used within a quality system for the production of welded joints. It
provides three sets of dimensional values from which a selection can be made for a particular application. The
quality level necessary in each case should be defined by the application standard or the responsible designer
in conjunction with the manufacturer, user and/or other parties concerned. The quality level shall be
prescribed before the start of production, preferably at the enquiry or order stage. For special purposes,
additional details may to be prescribed.

The quality levels given in this International Standard provide basic reference data and are not specifically
related to any particular application. They refer to the types of welded joints in fabrication and not to the
complete product or component itself. It is possible, therefore, that different quality levels are applied to
individual welded joints in the same product or component.

It would normally be expected that for a particular welded joint the dimensional limits for imperfections could
all be covered by specifying one quality level. In some cases, it may be necessary to specify different quality
levels for different imperfections in the same welded joint.

The choice of quality level for any application should take account of design considerations, subsequent
processing (e. g. surfacing), mode of stressing (e. g. static, dynamic), service conditions (e. g. temperature,
environment) and consequences of failure. Economic factors are also important and should include not only
the cost of welding but also of inspection, test and repair.

Although this International Standard includes types of imperfections relevant to the arc welding processes
given in clause 1, only those which are applicable to the process and application in question need to be
considered.

Imperfections are quoted in terms of their actual dimensions, and their detection and evaluation may require
the use of one or more methods of non-destructive testing. The detection and sizing of imperfections is
dependent on the inspection methods and the extent of testing specified in the application standard or
contract.

This International Standard doesn't address the methods used for the detection of imperfections. However,
ISO/DIS 17635 contains a correlation between the quality level and acceptance level for different NDT
methods.

This International Standard is directly applicable to visual examination of welds and does not include details of
recommended methods of detection or sizing by non-destructive means. It should be considered that there
are difficulties in using these limits to establish appropriate criteria applicable to non-destructive testing
methods such as ultrasonic, radiographic, penetrant testing and may need to be supplemented by
requirements for inspection, examining and testing.

The values given for imperfections are for welds produced using normal welding practice. Requirements for
smaller (more stringent) values as stated in quality level B may include additional manufacturing processes,
e. g. grinding, TIG dressing.

© ISO 2004 – All rights reserved v

ISO/DIS 10042

Request for an official interpretation of technical aspects of this International Standard should be directed to
the relevant secretariat of ISO/TC 44/SC 10 "Unification of requirements in the field of metal welding" via the
user's national standardization body; a listing of these bodies can be found at www.iso.org.

vi © ISO 2004 – All rights reserved

 ISO/DIS 10042

Welding — Arc-welded joints in aluminium and its alloys —

Quality levels for imperfections

1 Scope
This International Standard provides quality levels of imperfections in arc-welded joints in aluminium and its
alloys. It applies to material thickness above 0,5 mm.

Quality levels for beam welded joints are presented in ISO 13919-2.

Three quality levels are given in order to permit application for a wide range of welded fabrication. They are
designated by symbols B, C and D. Quality level B corresponds to the highest requirement on the finished
weld. The quality levels refer to production quality and not to the fitness-for-purpose (see 3.2) of the product
manufactured.

This International Standard applies to:

 all types of welds, e. g. butt welds, fillet welds and branch connections;

 the following welding processes and their defined sub-processes in accordance with ISO 4063:

 131 metal inert gas welding (MIG welding); gas metal arc welding /USA/;

 141 tungsten inert gas welding (TIG welding); gas tungsten arc welding /USA/;

 15 plasma arc welding;

 manual, mechanised and automatic welding;

 all welding positions.

Metallurgical aspects, e.g. grain size, hardness, are not covered by this International Standard.

For the purposes of this International Standard the term aluminium covers aluminium and its alloys.

2 Normative references
The following referenced documents are indispensable for the application 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.

ISO 2553:1992, Welded, brazed and soldered joints — Symbolic representation on drawings.

ISO 4063:1998, Welding and allied processes — Nomenclature of processes and reference numbers.

ISO 6520-1:1998, Welding and allied processes — Classification of geometric imperfections in metallic
materials.

ISO 13919-2, Welding — Electron and laser beam welded joints — Guidance on quality levels for
imperfections — Part 2: Aluminium and its weldable alloys.

© ISO 2004 – All rights reserved 1

ISO/DIS 10042

3 Terms and definitions

For the purposes of this International Standard, the following terms and definitions apply.

3.1
quality level
description of the qualities of a weld on the basis of type, size and amount of selected imperfections

3.2
fitness-for-purpose
ability of a product, process or service to serve a defined purpose under specific conditions

3.3
short imperfection
one or more imperfections of total length not greater than 25 mm in any 100 mm length of the weld or a
maximum of 25 % of the weld length for a weld shorter than 100 mm. The range with most imperfections shall
apply

3.4
systematic imperfection
imperfections that are repeatedly distributed in the weld over the weld lengths to be examined; the sizes of the
single imperfections being within the limits of the imperfections given in table 1

3.5
cross section area
area to be considered after fracture or sectioning

3.6
projected area
area where imperfections distributed along the volume of the weld under consideration are imaged two-
dimensionally

In contrast to the cross section area the occurrence of imperfections is dependent on the weld thickness when
exposed radiographically (see figure 1).

2 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Key

1 X-ray 3 6-fold thickness 5 2-fold thickness

2 4 pores per volume unit 4 3-fold thickness 6 1-fold thickness

Figure 1 — Radiographic films of specimens with identical occurrence of pores per volume unit

4 Symbols
The following symbols are used in table 1:

A area surrounding the gas pores;

a nominal throat thickness of the fillet weld (see also ISO 2553);

b width of weld reinforcement;

d diameter of gas pore;

dA diameter of area surrounding the gas pores;

h height or width of imperfection;

l length of imperfection in longitudinal direction of the weld;

lp length of projected or cross section area;

s nominal butt weld thickness (see also ISO 2553);

t wall or plate thickness (nominal size);

wp width of the weld or width or height of the cross section area;

z leg length of a fillet weld (see also ISO 2553).

© ISO 2004 – All rights reserved 3

ISO/DIS 10042

5 Assessment of imperfections
Limits for imperfections are given in table 1.

If for the detection of imperfections micro-examination is used, only those imperfections shall be considered
which can be detected with a maximum tenfold magnification.

Except from this are micro cracks.

A welded joint should usually be assessed separately for each individual type of imperfection (see table 1, 1.1
to 3.2).

Different types of imperfection occurring at any cross-section of the joint can possibly need special
consideration (see table 1, No. 4.1).

The limits for multiple imperfections (see table 1) are only applicable for cases, where the requirements for a
single imperfection are not exceeded.

Any two adjacent imperfections separated by a distance smaller than the major dimension of the smaller
imperfection shall be considered as a single imperfection.

4 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Table 1 — Limits for imperfections

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B
1 Surface imperfections
1.1 100 Crack — ≥ 0,5 Not permitted Not permitted Not permitted
h ≤ 0,4 s or 0,4 a
1.2 104 Crater crack h = height or width ≥ 0,5 Not permitted Not permitted
l ≤ 0,4 s or 0,4 a
Uniformly For the evaluation of the porosity see examples
1.3 2012 ≥ 0,5 ≤2% ≤1% ≤ 0,5 %
distributed porosity given in Annex A.

© ISO 2004 – All rights reserved 5

ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

1.4 2013 Clustered

(localized) porosity

The total gas pore area within the cluster should be ≥ 0,5 dA ≤ 25 mm or Not permitted Not permitted
summed by a circle with the diameter dA surrounding all dA,max ≤ b
gas pores.
The requirements for a single gas pore shall be fulfilled
by the gas pores within the envelope.
The permitted porous area should be local. The
possibility of masking of other imperfections should be
taken into consideration.
If D is less than dA1 or dA2, whatever is smaller, a circle
with a summarized diameter of dA1 + dA2 + D shall be
considered as one area of imperfection.
Systematic clustered porosity is not permitted.

6 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

1.5 2014 Linear porosity — ≥ 0,5 Not permitted Not permitted Not permitted
1.6 2017 Surface pore 0,5 to 3 d ≤ 0,3 s or 0,3 a d ≤ 0,2 s or 0,2 a d ≤ 0,1 s or 0,1 a
Maximum dimension of a single gas pore.
>3 d ≤ 0,4 s or 0,4 a d ≤ 0,3 s or 0,3 a d ≤ 0,2 s or 0,2 a
max. 3 mm max. 1,5 mm max. 1 mm
1.7 2025 End crater pipe h ≤ 0,4 t h ≤ 0,2 t
— ≥ 0,5 not permitted
max. 3 mm max. 1,5 mm
1.8 401 Lack of fusion
(incomplete fusion) Short imperfections
≥ 0,5
h ≤ 0,1 s or 0,1 a
Not permitted Not permitted
max. 3 mm

1.9 4021 Incomplete root Short imperfections, but no systematic

penetration imperfections.
≥ 0,5 Not permitted
h ≤ 0,2 s
Not permitted
max. 2 mm

1.10 5011 Continuos undercut

h ≤ 0,2 t h ≤ 0,1 t Not permitted
0,5 to 3
h ≤ 0,2 t h ≤ 0,1 t Not permitted
>3
but max. 1 mm but max. 0,5 mm

5012 Intermittent
undercut (Short
imperfection) 0,5 to 3 h ≤ 0,2 t h ≤ 0,1 t h ≤ 0,1 t

>3 h ≤ 0,2 t h ≤ 0,1 t h ≤ 0,1 t

but max. 1,5 mm but max. 1 mm but max. 0,5 mm
Smooth transition is required. 5012 is not regarded as a
systematic imperfection.

© ISO 2004 – All rights reserved 7

ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

1.11 502 Excess weld metal Smooth transition is required.

h ≤ 1,5 mm + 0,2 b h ≤ 1,5 mm + 0,15 b h ≤ 1,5 mm + 0,1 b

≥ 0,5
max. 10 mm max. 8 mm max. 6 mm

h ≤ 1,5 mm + 0,3 b h ≤ 1,5 mm + 0,15 b h ≤ 1,5 mm + 0,1 b

1.12 503 Excessive convexity ≥ 0,5
max. 5 mm max. 4 mm max. 3 mm

1.13 5213 Insufficient throat Not applicable to processes with proof of greater depth
thickness of penetration.

Short imperfection
≥ 0,5
h ≤ 0,3 a h ≤ 0,2 a h ≤ 0,1 a
max. 2 mm max. 1,5 mm max. 1 mm

1.14 504 Excess penetration

≥ 0,5 h ≤ 5 mm h ≤ 4 mm h ≤ 3 mm

1.15 506 Overlap

short imperfections:
≥ 0,5 Not permitted Not permitted
h ≤ 0,2 b

8 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B
1.16 509 Sagging Smooth transition is required.
Short imperfections
511 Incompletely filled
groove ≥ 0,5 h ≤ 0,2 t h ≤ 0,1 t h ≤ 0,05 t
max. 2 mm max. 1 mm max. 0,5 mm

1.17 512 Excessive It is assumed that an asymmetric fillet weld has not
asymmetry of fillet been expressly prescribed.
weld (excessive
unequal leg length)

≥ 0,5 h ≤ 3 mm + 0,3 a h ≤ 2 mm + 0,25 a h ≤ 1,5 mm + 0,2 a

1.18 515 Root concavity Smooth transition is required.

Short imperfections
≥ 0,5
h ≤ 0,2 t h ≤ 0,1 t h ≤ 0,05 t
5013 Shrinkage groove max. 1,5 mm max. 1 mm max. 0,5 mm

© ISO 2004 – All rights reserved 9

ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

2 Internal imperfections
2.1 100 Crack All types of cracks except microcracks and crater
≥ 0,5 Not permitted Not permitted Not permitted
cracks.
2.2 1001 Micro-crack Acceptance depends on type of parent metal with
A crack usually only visible under the microscope (50×) ≥ 0,5 Permitted
particular reference to crack sensitivity
2.3 2011 Gas pore d ≤ 0,4 s or 0,4 a d ≤ 0,3 s or 0,3 a d ≤ 0,2 s or 0,2 a
Maximum dimension of a single gas pore. ≥ 0,5
but max. 6 mm but max. 5 mm but max. 4 mm
2.4 2012 Uniformly The evaluation of porosity refers to the cross section
≥ 0,5 ≤6% ≤2% ≤1%
distributed porosity area. See examples given in annex A .

0,5 to 3 ≤6% ≤2% ≤1%

The evaluation of imperfections refers to the projected > 3 to 12 ≤ 10 % ≤4% ≤2%

area. See examples given in annex A and 3.7. > 12 to 30 ≤ 15 % ≤6% ≤3%
> 30 ≤ 20 % ≤8% ≤4%

10 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

2.5 2013 Clustered

(localised) porosity

The total gas pore area within the cluster should be ≥ 0,5 dA ≤ 25 mm or dA ≤ 20 mm or dA ≤ 15 mm or
summed by a circle with the diameter dA surrounding all dA,max ≤ b dA,max ≤ b dA,max ≤ b/2
gas pores.
The requirements for a single gas pore shall be fulfilled
by the gas pores within the envelope.
The permitted porous area should be local. The
possibility of masking of other imperfections should be
taken into consideration.
If D is less than dA1 or dA2, whatever is smaller, a circle
with a summarized diameter of dA1 + dA2 + D shall be
considered as one area of imperfection.
Systematic clustered porosity is not permitted.

© ISO 2004 – All rights reserved 11

ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

Short imperfections
2.6 2014 Linear porosity — ≥ 0,5 Not permitted
permitted

2015 Elongated cavity l ≤ 0,4 s or 0,4 a l ≤ 0,3 s or 0,3 a l ≤ 0,2 s or 0,2 a

2.7 — ≥ 0,5
2016 Worm-hole but max. 6 mm but max. 4 mm but max. 3 mm

2.8 303 Oxide inclusion If several oxide inclusions l1, l2, l3... exist in one cross Short imperfections
section, the summation is l = l1 + l2 + l3 ... ≥ 0,5 l ≤ s or a l ≤ 0,5 s or 0,5 a l ≤ 0,2 s or 0,2 a
max. 10 mm max. 5 mm max. 3 mm
l ≤ 0,4 s or 0,4 a l ≤ 0,3 s or 0,3 a l ≤ 0,2 s or 0,2 a
2.9 3041 Tungsten inclusion — ≥ 0,5
but max. 6 mm but max. 4 mm but max. 3 mm
2.10 401 Lack of fusion
(incomplete fusion)

h ≤ 0,3 s or 0,3 a
≥ 0,5 Not permitted Not permitted
but max. 3 mm

12 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B
2.11 402 Lack of penetration
(incomplete
penetration)

Short imperfections, but no systematic

imperfections.
≥ 0,5 Not permitted
h ≤ 0,4 s h ≤ 0,2 s
max. 3 mm max. 2 mm

2.12 — Lack of penetration

(incomplete
penetration)
fillet weld
Short imperfections
≥ 0,5
h ≤ 0,3 a h ≤ 0,2 a h ≤ 0,1 a
max. 2 mm max. 1,5 mm max. 1 mm

© ISO 2004 – All rights reserved 13

ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

3 Imperfections in joint geometry

3.1 507 Linear misalignment The limits relate to deviations from the correct position.
Unless otherwise specified, the correct position is that
when the centrelines coincide (see also clause 1).
t refers to the smaller thickness.

h ≤ 0,4 t h ≤ 0,3 t h ≤ 0,2 t

≥ 0,5
max. 8 mm max. 4 mm max. 2 mm

Plates and longitudinal welds

h ≤ 0,4 t h ≤ 0,3 t h ≤ 0,2 t

≥ 0,5
max. 10 mm max. 6 mm max. 4 mm

Circumferential welds

14 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Table 1 (continued)

ISO 6520-1 Imperfection Limits for imperfections for quality levels

No. Remarks t in mm
reference Designation D C B

3.2 617 Incorrect root gap An excessive or insufficient gap between the parts to
for fillet welds be joined.

h ≤ 1 mm + 0,2 a h ≤ 0,5 mm + 0,15 a h ≤ 0,5 mm + 0,1 a

≥ 0,5
max. 4 mm max. 3 mm max. 2 mm

Gaps exceeding the appropriate limit may in certain

cases be compensated for by a corresponding increase
in the throat.
4 Multiple imperfections
4.1 — Multiple
imperfections in any
cross section

The sum of acceptable individual imperfections in any cross section shall not
exceed
≥ 0,5
0,4 t or 0,4 a 0,3 t or 0,3 a 0,2 t or 0,2 a

© ISO 2004 – All rights reserved 15

ISO/DIS 10042

Annex A
(informative)

Examples for determination of percent (%) of porosity

The figures A.1 to A.10 give a presentation of different percent (%) of porosity. This should assist the
assessment of porosity on projected areas (radiographs) or cross section areas.

Figure A.1 — 0,5 %

Figure A.2 — 1 %

Figure A.3 — 2 %

Figure A.4 — 3 %

Figure A.5 — 4 %

16 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Figure A.6 — 6 %

Figure A.7 — 8 %

Figure A.8 — 10 %

Figure A.9 — 15 %

Figure A.10 — 20 %

© ISO 2004 – All rights reserved 17

ISO/DIS 10042

Annex B
(informative)

Additional information and guidelines for use of this International

Standard

This International Standard specifies requirements for three quality levels for imperfections in welded joints of
aluminium and its alloys for arc welding processes (beam welding excluded) according to the scope and for
weld thickness ≥ 0,5 mm. It may be used, where applicable, for other arc welding processes or weld
thickness.

Different components are very often produced for different applications, but to similar requirements. The same
requirements should, however, apply to identical components produced in different workshops to ensure that
work is carried out using the same criteria. The consistent application of this International Standard is one of
the fundamental cornerstones of a quality assurance system for use in the production of welded structures.

The summary of multiple imperfections shows a theoretical possibility of superimposed individual

imperfections. In such a case, the total summation of all permitted deviations shall be restricted by the
stipulated values for the different imperfections, i.e. the limit value of a single imperfection ≤ h, e. g. for a
single pore, shall not be exceeded.

This International Standard may be used in conjunction with a catalogue of realistic illustrations showing the
size of the permissible imperfections for the various quality levels by means of photographs showing the face
and root side and/or reproductions of radiographs and of photomacrographs showing the cross-section of the
weld. An example of such a catalogue is given with "Reference radiographs for the assessment of weld
imperfections according to ISO 5817", published by International Institute of Welding (IIW) and Deutscher
Verlag für Schweißen und verwandte Verfahren, Düsseldorf. This catalogue may be used with reference cards
to assess the various imperfections and may be employed when opinions differ as to the permissible size of
imperfections.

18 © ISO 2004 – All rights reserved

 ISO/DIS 10042

Bibliography

ISO 17635, Non-destructive testing of welds — General rules for fusion welds in metallic materials.

© ISO 2004 – All rights reserved 19