EN 15082 – part 5Railway applications – welding of railway vehicles and - vehicle parts – Part 5: Inspection, Testing and Documentation • Defines the necessary documentation for the release of the product conformity .SCOPE • Defines the welds to be carried out in exams. • Shall carry out the destructive and non destructive tests to determine. 3 Inspection and testing 4.En 15085 contents • • • • • • • • 1 Scope 2 Normative references 3 Terms and definitions 4 Inspection and testing 4.1 General 4.2 Inspection and testing 4.1 Test planning • 5.2 Test criteria .4 Inspection and testing of welded joints before welding during welding after welding • 5 Test planning and test criteria • 5. . • 7.3 Additional tests • 8 Sub-contractors • 9 Declaration of conformity • 10 Traceability .2 Management of nonconformance • 7.1General • 7.En 15085 contents • 6 Documentation • • 7 Non-conformance and corrective actions. 1 — Relationship between essential welding related tasks and the manufacturing phases • to be performed .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. • ⎯ additional welding detail in the drawings.• 4.1 the welding supervisor is responsible for : • ⎯ planning the preparation of the root and the support.1 and the above tests must be documented . • 4. • The implementation of the design review in Table A.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.2 Checks before welding • In addition to Table A.1. according to the drawing and / or WPS). • ⎯ the state of the weld preparation and the correct specification of the welded seams works • pieces (purity and state of assembly of work pieces. • ⎯ availability of work instructions. • ⎯ that the welding consumables comply with the WPS. . • ⎯ Identification of the welded work pieces.• The welder / operator has any type of welding the following points to consider before beginning: • ⎯ that the welding equipment in working order. 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 Zwischenlagenschweißung. • ⎯ compliance with the prescribed pre-heating and / or intermediate layer temperatures. • ⎯ compliance with the order of operations.• 4. if in the specific work instruction is required (such as welding sequence diagram). . • ⎯ compliance with the WPS and / or operating procedures. clause 5. • 4. 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. by the responsible welding supervisor or a representative (Representative of the welding supervisor or VT 2-examiner in accordance with EN 473).4. the welder or operator after check whether: ⎯ the weld is complete. ⎯ the shape and dimensions of the drawing correspond to the weld.2 worker self-examination by the welder or operator • If a self-inspection system is employed.4 Testing after welding • 4. ⎯ the weld is cleaned.1 Tests by the welder or operator • • • • the welding.4.• 4. . the welder or operator of the need to be carried out in accordance with Table 1 shall be clearly defined (acceptance criteria.• The tests. dimensions. . Alternatively. and the test documents attached to another.) and are recorded. • These records and calculations are of the welder or operator who has performed the audit under review. • A copy of the personal signatures of names in publication is for the staff. too. etc. the audit documents to sign store. electronic systems are used . This applies: ⎯ 100% means: examination of all welds of all components.3 Verification of the conformity of the welding seams • After welding. or 100% testing of a component of 10 components.4. The test methods are shown in Table 1 Mindestprüfanforderungen of welded joints. 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. ⎯ 10% means test for 10% of the welds of all components. .• 4. All NDT (RT. .• • • • • • • • • • • • • • • The percentages expressed refer to the total length to be examined for one given weld. 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. For inspection CT 4. Additional tests depending on the material. UT. Thus: 100 % means: request for testing of the entire length of the weld and on all the pieces built. the visual examination shall be performed as a minimum by personnel qualified by the manufacturer and should be documented. the visual examination shall be performed by personnel certified according to EN 473 and shall be documented. 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. For inspection class CT 3. the design or customer requirements may be necessary. the visual examination shall be performed as a minimum by welders who are trained in visual examination and documentation is not required. When five consecutive items are acceptable. 100 % surface testing is required.• Volumetric tests applicable only for butt welds and Twelds with full penetration. surface testing may be reduced to 25 %. 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. 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. Table 2). . see EN 15085-3:2007. • b Where volumetric testing is not feasible for welds of the weld performance class CP B in medium safety category or CP C1. • .• 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. depending on the weld test class . Annex F. Particularly complex or important case of welded components is recommended that a Test plan is created.2. 5. it may be necessary. that other as contained in the EN tests are performed.1 Inspection Planning Production planning are the verification procedure. the verification time and the necessary amount of tests in a test plan. the weld shape and the material set. clause 5). 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. A CP is not completely contained in EN 12062 (see EN 15085-3:2007.2 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. the various phases of the tests clearly describes.1 weld grades In accordance with the technical documentation (eg. • • • • • • • • . For the resistance welding method is EN 15085-3:2007. For simple welding components in the verification plan to work plan be integrated. drawing) specified weld quality classes are according to EN 15085-3.2. In specific cases where a more accurate assessment of the extent and type of irregularity is needed to verify its compatibility mode.• 5 test plan and test criteria • • 5. In the case of detecting unacceptable defects during the tests indicated in Table 1. with the extension of the testing as indicated in Clause 7. 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). see Table 1). Testing at the beginning of production: shall be according to the inspection class. . Table 1 defines the type and frequency of the testing to be carried out during series production.• • • • • • • • • 4.4. the procedure for management of non-conformance shall be applied.3 Conformity control of welds After welding. the NDT (Non-Destructive Testing) is carried out by certified personnel (except VT. 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.