Texmaco Limited

WPI/BOX/001/11 (page28/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Under Frame Details

Bolster Top Flange to Web Plate
& Bottom Flange to Web Plate
 Material : IRSM 44

 Welding Type & Size : Double Fillet – 5 mm

& Single Bevel Butt with Fillet – 5mm
 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

 Texmaco Limited
WPI/BOX/002/11 (page 22/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Typical Floor Joint

 Material : IRSM 44

 Welding Type & Size : 1) Double Fillet - 3 mm &

2) Square Butt
 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

 Texmaco Limited
WPI/BOX/003/11(page 23/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Under Frame Arrangement

Centre Sill to Floor Plate

 Material : IRSM 44

 Welding Type & Size : Fill with weld

 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Voltage : 28 – 31 Volt
 Texmaco Limited
 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/004/11(page 26/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Under Frame Details

Bolster Bottom Flange to Soleber
 Material : IRSM 44

 Welding Type & Size : Single Bevel Butt

 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Voltage : 28 – 31 Volt
 Texmaco Limited
 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/005/11(Page 26/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Under Frame Details

Centre Sill to Bolster Top Flange
 Material : IRSM 44

 Welding Type & Size : Gap to Fill

 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Voltage : 28 – 31 Volt
 Texmaco Limited

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/006/11(page 27/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Under Frame Details

Cross Bar Flange to Cross Bar Web
 Material : IRSM 44

 Welding Type & Size : Double Fillet – 3 mm

 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Texmaco Limited
 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/007/11(page 30/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Body Side Arrangement

Side Stanchion Back Plate to Side Top Coping

 Material : IRSM 44

 Welding Type & Size : Single Bevel Butt &Fillet – 5 mm

 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Texmaco Limited

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/008/11(page 29/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Body Side Arrangement

Side Top Coping Plate to Side Top Coping CRF
 Material : IRSM 44

 Welding Type & Size : Single Bevel Butt

 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Texmaco Limited
 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/009/11(page 29/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Body Side Arrangement

Body Side Plate to Side Top Coping CRF

 Material : IRSM 44

 Welding Type & Size : Fillet – 3 mm

 Welding Process : GMAW

 Electrode / Wire Dia. : 1.2 mm

 Electrode / Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Texmaco Limited

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/010/11(page 32/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Body Side Arrangement

Side Stanchion Base Plate to Body Side Plate

 Material : IRSM 44

 Welding Type & Size : Fillet – 3 mm

 Welding Process : GMAW

 Electrode/Wire Dia. : 1.2 mm

 Electrode/Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Texmaco Limited

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/011/11(page 32/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Body Side Arrangement

Side Stanchion Base Plate to Side Stanchion

 Material : IRSM 44

 Welding Type & Size : Single Bevel Butt & Fillet – 5 mm

 Welding Process : GMAW

 Electrode/Wire Dia. : 1.2 mm

 Electrode/Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Texmaco Limited

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/012/11(page 33 /35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Flap Door Arrangement

 Material : IRSM 44

 Welding Type & Size : Fillet – 3 mm

 Welding Process : GMAW

 Electrode/Wire Dia. : 1.2 mm

 Electrode/Wire Spec. : IRS VI

 Current Range : 200-250 Amp

 Texmaco Limited

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/013/11(page 34 /35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Body End Arrangement

End Top Coping to RIB
 Material : IRSM 44

 Welding Type & Size : Fillet - 3 mm

 Welding Process : GMAW

 Electrode/Wire Dia : 1.2 mm

 Electrode/Wire Spec. : IRS VI

 Texmaco Limited
 Current Range : 200-250 Amp

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm

WPI/BOX/014/11(page 34/35)
WELDING PROCESS INSTRUCTION

 Type of Wagon. : BOXNHL

 Stage : Body End arrangement

End Stanchion to Ladder Pipe
 Material : IRSM 44

 Welding Type & Size : Fillet – 3 mm

 Welding Process : GMAW

 Electrode/Wire Dia : 1.2 mm

 Electrode/Wire Spec. : IRS VI

 Texmaco Limited
 Current Range : 200-250 Amp

 Voltage : 28 – 31 Volt

 Gas Flow Rate : 12 – 15 Lpm