EN 15082 part 5

Railway applications welding of

railway vehicles and - vehicle parts
Part 5: Inspection, Testing
and Documentation

SCOPE
Defines the welds to be carried out in exams;
Shall carry out the destructive and non destructive tests
to determine;
Defines the necessary documentation for the release of
the product conformity

En 15085 contents

1 Scope
2 Normative references
3 Terms and definitions
4 Inspection and testing
4.1 General
4.2 Inspection and testing
4.3 Inspection and testing
4.4 Inspection and testing

of welded joints
before welding
during welding
after welding

5 Test planning and test criteria

5.1 Test planning
5.2 Test criteria

En 15085 contents
6 Documentation

7 Non-conformance and corrective
actions..
7.1General
7.2
Management of nonconformance
7.3
Additional tests
8 Sub-contractors
9 Declaration of conformity
10 Traceability

En 15085 contents
Annex A (normative) Inspection and testing of
welded joints
Tables

Table 1 Tests which have to be performed

during production
Table A.1 Relationship between essential
welding related tasks and the manufacturing
phases
to be performed

 4.1 General
The relationship between the welding-related tasks of
the responsible welding supervisor or his authorized
representative in the production phase is given in Table
A.1.
4.2 Checks before welding
In addition to Table A.1 the welding supervisor is
responsible for :
planning the preparation of the root and the support;
additional welding detail in the drawings.
The implementation of the design review in Table A.1
and the above tests must be documented

 The welder / operator has any type of welding the

following points to consider before beginning:
that the welding equipment in working order;
availability of work instructions;
the state of the weld preparation and the correct
specification of the welded seams works
pieces (purity and state of assembly of work pieces,
according to the drawing and / or WPS);
Identification of the welded work pieces;
that the welding consumables comply with the WPS.

 4.3 Test during welding

The welder or welding operator has the following items
for review during and
ensure:
the proper cleaning and the form of the compounds
during the Zwischenlagenschweiung;
compliance with the prescribed pre-heating and / or
intermediate layer temperatures;
compliance with the WPS and / or operating
procedures;
compliance with the order of operations, if in the
specific work instruction is required (such as welding
sequence diagram).

4.4 Testing after welding

4.4.1 Tests by the welder or operator

the welding, the welder or operator after check whether:

the weld is complete;
the weld is cleaned;
the shape and dimensions of the drawing correspond to the weld.

4.4.2 worker self-examination by the welder or operator

If a self-inspection system is employed, the self examination shall be done in an

appropriate manner with regard to the implementation of the visual inspection and the
requirements

EN 15085-3:2007, clause 5, by the responsible welding supervisor or a representative

(Representative of the welding supervisor or VT 2-examiner in accordance with EN
473).

The tests, the welder or operator of the need to be carried out in accordance with
Table 1 shall be clearly defined (acceptance criteria, dimensions, etc.) and are
recorded.

These records and calculations are of the welder or operator who has performed the
audit under review, and the test documents attached to another.

A copy of the personal signatures of names in publication is for the staff, the audit
documents to sign store, too. Alternatively, electronic systems are used

 4.4.3 Verification of the conformity of the welding

seams

After welding, the non-destructive tests carried out by qualified experts

weld Test class

CT1

Volumetric test
RT or UT
100%a

Surface examination
MT or PT
100%

CT2

10%a b

10%b

CT3

Not required

Not required

CT$

Not required

Not required

The percentages shown are based on the total length of all welds. This applies:
100% means: examination of all welds of all components;
10% means test for 10% of the welds of all components, or 100% testing
of a component of 10 components.
The test methods are shown in Table 1 Mindestprfanforderungen of welded
joints.

The percentages expressed refer to the total length to be examined for one given weld.
Thus:

100 % means: request for testing of the entire length of the weld and on all the pieces
built;

10 % means: testing of 10 % of the entire length of the weld on all the pieces built or
100 % testing on 1 of every 10 items built

The test methods indicated in Table 1 shall be the minimum capable of ensuring compliance
of the welded joints. Additional tests depending on the material, the design or customer
requirements may be necessary.

All NDT (RT, UT, MT or PT) shall be performed by personnel certified according to EN 473 and
shall be documented.

For inspection classes CT 1 and CT 2, the visual examination shall be performed by personnel
certified according to EN 473 and shall be documented.

For inspection class CT 3, the visual examination shall be performed as a minimum by

personnel qualified by the manufacturer and should be documented.

For inspection CT 4, the visual examination shall be performed as a minimum by welders

who are trained in visual examination and documentation is not required.

 Volumetric tests applicable only for butt welds and Twelds with full penetration.
b Where volumetric testing is not feasible for welds
of the weld performance class CP B in medium
safety category or CP C1, 100 % surface testing is
required. When five consecutive items are
acceptable, surface testing may be reduced to 25
%. A production weld test according to EN 15085-4
for every welder or operator of a robot who carries
out this weld before the start of the production is
necessary. The production weld test is valid for six
months and may be prolonged by the responsible
welding coordinator if the welder or operator is still
in the production (for information on weld
performance classes, see EN 15085-3:2007, Table 2).

 In the case of fully mechanised or

automatic welding procedures with
process monitoring for weld
performance class CP B and CP C1 the
extent of testing can be reduced in
agreement with the responsible welding
coordinator. If required, the agreement
of the customer shall be obtained.

5 test plan and test criteria

5.1 Inspection Planning

Production planning are the verification procedure, the verification time and the
necessary amount of tests in a test plan, depending on the weld test class , the
weld shape and the material set.
For simple welding components in the verification plan to work plan be
integrated.Particularly complex or important case of welded components is
recommended that a Test plan is created, the various phases of the tests clearly
describes.
5.2.1 weld grades
In accordance with the technical documentation (eg, drawing) specified weld
quality
classes are according to EN 15085-3, Section 5 of the specified evaluation for
imperfections
of standards EN ISO 5817 or EN ISO 10042 for steel aluminum and aluminum
alloys should be met with.
For the resistance welding method is EN 15085-3:2007, Annex F.
5.2.2 inspection stages and acceptance levels
EN 12062 is in the test stages and acceptable limits to the quality levels in terms of
applied non-destructive test methods referenced.
A CP is not completely contained in EN 12062 (see EN 15085-3:2007, clause 5).
In specific cases where a more accurate assessment of the extent and type of
irregularity
is needed to verify its compatibility mode, it may be necessary, that other as
contained in the EN tests are performed.

4.4.3 Conformity control of welds

After welding, the NDT (Non-Destructive Testing) is carried out by certified
personnel (except VT; see Table 1). Table 1 defines the type and frequency of
the testing to be carried out during series production. This is based
on the relationship between the weld performance class of the welded joint
assigned by the design engineer and the resulting inspection class (see EN
15085-3).

Testing at the beginning of production: shall be according to the inspection

class, 100 % testing of all welds on each initial item of the series if testing is
required in Table 1.

Testing during series production: the tests described in Table 1 shall be carried
out on products manufactured during series production in accordance with
the frequencies indicated therein and as per the weld performance class
indicated on the drawing by the design engineer.

In the case of detecting unacceptable defects during the tests indicated

in Table 1, the procedure for management of non-conformance shall be
applied, with the extension of the testing as indicated in Clause 7.