Mosifications: vison {santed to 210350 2.82 Rovision change fom SNZH0550(0 1802565/ 4 4.86 Revision 02.91 Revision 03.94 Revision 04.95, date o gina: das OPY 4. . Ty MASTER COP? 16 JUN 1997, Welding. N 027. 101e Fabrication Instructic for: Norm. . Steel Welded Constructions Scope This Norm stipulates the rules for welded joints-at the SIG factory. It is valid for all design and operations divisions. From the multitude of weld shapes which exist under ISO, DIN, or DVS, only 8 are |~ prescribed for preferred use. ‘The requirements for representation and dimensioning as well as for quality assurance have been compiled for these weld shapes. Generally valid basic rules. are referred to only in an abbreviated manner. Should further information regarding the detailed Norm be required, it may be requested from the Neuhausen SIG Norm Office. This Norm replaces the following SIG Norms: © N027 101/ 5th Edition March 94 * N027 102 / 2nd Edition April 86 + N035 365 February 85 © N 036.366 April 86 Normative reference: . EN 22553 03.97 Symbolic'representation on drawings ISO 2553 10.92 Symbolic representation on drawings EN 29692 04.94 Joint preparations for steel’ EN 287-1 04.92 Approval tésting of Welders; fusion welding of steel EN729-1 11.94 Fusion Welding of metallic materials; Guidelines for selection and use EN 729-2 11.94 Fusion welding of metallic materials; Comprehensive quality requirements, EN729-3 11.94 Fusion welding of metallic materials; Standard quality requirements EN729-4 11.94 Fusion welding of metallic materials; Elementary quality requirements EN719 08.94 Welding coordination - Tasks and responsibilities EN 970 03.97 _ Non-destructive examination of fusion welds - Visual examination EN 25 817 09.92 Guidance on quality levels for imperfections EN 288-1 04.92 Part 1.- General rules for fusion welding: EN 288-2 04.92.“ Part 2 - Welding procedures specification for arc welding ISO 13920 11.96 General tolerances for welded constructions; Dimensions for lerigths and angles; shape and position DVS 1610 08.88 Allg. Richtlinie, Schweisstechn. Fertigung im Schienen- ‘fahrzeugbau DVS 1612 01.84 Design and evaluation of butt and fillet welds in railway vehicle ‘construction DVS 1703 10.84 Recommendations for the selection of the workpiece temperature in the arc welding of steel structures of St52 ~ DS 95201 07.91 Schweissen metallischer Werkstoffe an Schienenfahrzeugen DS 95202 10.89 _Eignungsnachweis far Schweissbetriebe ausserhalb der DB Prepared 04.02 5TRM ‘Schweizerisché-Industrie-Gesolischait | N027 101e Authorized:11.04-956chn CH-8212 Neuhausen am Rheinfall page 11516 JUN 1997 Table of Contents Graphic representation and dimensioning __ MAST ER CO PY Principles ‘Symbolic representation Reference signs Peripheral weld Assembly weld : Dimensioning in the symbol Part dimensioning ‘Shrinkage data Main dimensions Permissible simplified indications Example of graphic representation and dimensioning Table 1: Peripheral welds 4.12 General tolerances for length and angle dimensions as well as shape and position POPErE ECE ErE ara CEN a3 2 Quality levels and influence on auatity 21 Quality level Table 2: Quality levels 2.2 Examination instructions 2.2.1 Normal cases 2.2.2 Prescribed examination 2.2.3. Data on the drawing 2.3 Design guidelines 2.3.1 Through welding 2.3.2 Example for the use of weld shapes from the-point of view of the stress analyst 2.3.3. Bending radii for welding in cold-worked zone i I 3. Weld shapes and weld preparation Table 3: Joint shapes and weld preparation 4, Welding procedure specification and welder qualifications 4.1. Welding procedure specification | 4.2 Assurance of the quality of welding work 4.3 Welder qualification 4.4 Approval of welding work 4.5 Existing drawings ' Prepared: OFOZSTRM | Schweizerische Industrie-Geselischart | N 027 10te ‘Authoriggd11,04.96/8chn CH-8242 Neuhausen am Rheinfall_ _| page 2/45146 JUN 1997 4. Graphic representation and dimensioning Abridgment from EN 22 553 - 08.94 / ISO 2553 - 10.92. 4.4 Principles MASTER COPY = The symbolic representation of welds gives all the information necessary for a clear interpretation of the welding. .Thus, the necessity for supplementary sections or views in the drawing is avoided. 7), Jf ugeln For multiple, varying welding dafa on one drawing, it is advantageous to indicate both representations - symbolic and detailed weld representation - together. (Standard SIG representation.) _ From the multitude of weld shapes, 8 shapes are prescribed at SIG as preferable for general use. Combinations of these shapes are possible. Deviations in weld shapes may be used only on the grounds of elevated stress demands or for reasons of production. (Only in collaboration with the welding engineer.) _ in dimensioning a part, it is specified that the production dimension - and net the nominal dimension, as previously was the case - must be used. (See Section 1.7.) - 4.2 Symbolic representation The symbolic data of a welded joint is composed of the following elements: - reference sign and reference lines, . ~ elementary and supplementary symbols. for the weld . dimensions, quality data, and welding procedure Only the necessary data should be given in each case. The information must be unambiguous, clear, and understandable. Elementary symbols with broad root face ‘Square butt weld | | “ap. : PSingleW butt weld Y Singie-V butt weld - Single-bevel butt weld with broad root face r Plug weld Fillet weld Slot weld Single-bevel butt Double-V butt weld weld Y with broad root face i _L _| Elementary and compound symbols may:be combined with supplementary symbols according to EN 22 553 / ISO 2553. ses Prepared: OAOESTRM | Schweizerische Industrie-Gesellschaft [N27 10te Authorizad1,04.95/8chn CH-8242 Neuhausen am Rheinfall page 3/4543 14 15 16 JUN 1997 Reference signs MASTER COPY (Position of the symbol in drawings) “The symbols included in these rules represent only a part of the complete method of representation (see Figure 1), which in addition to the symbol (3) includes: one arrow line (1) per joint, “a reference line, composed of two parallel lines: one continuous line (2a), and one dashed line (2b), (See Note 1.) . a certain number of dimensions and conventional signs, 2a fork (4). (See Note 2.) Note 4: The dashed line is generally drawn under the continuous lin The dashed line is omitted for symmetrical welds. ——_ Note 2: The fork is only to be drawn when the welding data of a weld deviates from the general data in the form.on the. drawing. ‘The objective of the followirig rules is to define the position of the weld by stipulating: - the position of the arrow line = the position of the reference line - the position of the symbol Figure 4: welding. joint 4 arrow tine. 3 symbol 2a" <“feferenés line: continuous line 4 fork 2b: ‘referenca'line! dashed line Peripheral weld * - Data regarding welds which extend : without interruption all around a part. (Applies only to round parts.) (Example, see Table 1.) Assembly weld Welding is carried out during assembly. Prepared: O40257RM | Schweizerische Industrie-Geselischaft | N 027 101e Authorized:11,04.98/Schn CH-8212 Neuhausen am Rheinfall page 4/1516 17 18 Dimensioning in the symbol The necessary data for a weld is given in the following order: (Example) Number of welds per pie ‘Weld thickness = 4 ram (filet welds = 2) ‘Symbol Number of intermittent weld positions = 16 Length of welding positions = 50 mm Distance between welding positions for * intermittent welds = 200 mn {or deviations from general data _ Supplementary data (os ¥_ 10x50 cme, ‘ven in the for on the drawing, (See Section 4) Part dimensioning Dimensioning of a part is carriéd out according to the weld shape; that Is: Single part / detail drawi Single-bevel butt weld, single-V butt weld, ing: “= face, single-V butt weld with broad root face (Figure 2): ‘Dimension fag length (c) and angle (a). (Consider distance botweer legs for singlo-bovel . bul welds and singlo-V butt welds. ) single-bevel butt weld with broad root ‘Anglo a = 48° for singlo-bevel butt wolds and single-bevel ol Dutt welds with broad root face = 30° for single-V butt welds and single-V butt welds with broad root face Baz Weld drawing: . Single-bevel butt weld ‘Single-bevel butt weld with broad root face Figure 3: . Figure 4: Dimension distance between legs (b) 7 -@Wfeld cross section = material thickness minus leg length) Single-V butt weld Figure $: Dimension distance between legs (b) ross section = material thickness) Single-V butt weld with broad root face Figure é: (Weld cross section = material thickness) «..y° te as Shrinkage data Allowances for shrinkage by Process Planning. (Weld cross section = material thickness minus fog length) are not to be dimensioned by Design; they will be determined Prepared: 0802.5TRM ‘Authorized:11.04.951Senn ‘Schweizerische Industrie-Geselischaft CH-8212.Neuhausen am Rheinfall N 027 101e page 5/15{ sretewee 16 JUN 1997 4.9 Main dimensions Designation, definition, and indication on the symbol;see in detail EN 22653 / ISO 2553. + The length of the weld is generally given to the right of the symbol. (Description, see Section 1.6.) « For fillet welds, the letter "a" is placed before the corresponding dimension of the weld thickness. ‘ Dimension data for filet welds ‘weld height. For round or slot welds with beveled edges, the dimension at the bottom of the hole applies. 410 Permissible simplified indications | For fillet welds of equal thickness "a" and length, the dimensioning may be correspondingly simplified. That is, the dimensioning of one weld suffices for identical welds. Further, according to the following case (Figure 7), one dimensioning suffices when given the number of identical welds of the same thickness and length. (Only for plotted welds.) 0 19 0-290 40 S80 20 . eh 3 JIE 1.41 Example of graphic representation and dimensioning Fillet welds, intermittent, staggered with end distance and equal weld thicknesses Graphic representation Figwee Explanation Figue : ae I Jee? | A: . rag a Patton 4 of fetal "a" in is tobe avoided in graphic representation. due to confusion with ealier dimension data, Prepared: CAOZSTRM | Schwelzerigche industrie-Gesellschaft [N 027 101e Authorized: 11,04.96/Schn (CH-2212 Néithausen am Rheinfall | page 6/15 . L eowunawaea ene pasaPlug welds Slot Peripheral welds ‘ne numbor ofweld «| a dagtregnae YL with ofa elements ‘ Welds which extend without interruption over the entire length of the joint, and thereby change their direction (e.g., developed), are designated according to the examples in Table 1, in addition to the supplementary reference sign for peripheral welds. ‘Table 1 / Peripheral welds Mlustration Drawing data | Mustration Drawing data &Y The symbol data (Seo, 1.4) is not necessary; the’ Weld extends around the ‘enire circumference, 7 oS iA cs Prepared: 04.02.97RM | Schweizerische Industrie-Gesellschal | N 027 401e Authorized:t 4.04.96/Schn CH-8212 Neuhausen am Rheinfall page 7/15MASTER COPY General tolerances for length and angie dimensions as well as shape and position If the drawings for welded constructions includé no data regarding permissible tolerances, the general tolerances according to SIG Norm N 041 001 apply (Tables 8, i i | i f 9, 10). i These norms contain: ' - For length and angle dimensions, DIN-8570 Part 1: Degree of Accuracy "A" ~ | (Draft EN 33 920-1). . j - For shape and position, DIN 8570 Part 3: Degree of Accuracy "E’ : i : (Draft EN 33 920-2). . | 5 ; ' = 2, Quality levels and influence on quality ‘ : Li - 24 Quality levels t ‘The quality levels are determined by Engineering on the basis of demands and Ae 4 requirements of each welded joint. f e “The requirements of each weld thus'determine the input from Production and Quality i : Control. The fabrication of welds is classified in quality levels Q1 to Q4, with the i ' following definitions and fabrication instructions: | z | “able 2 1 Qualty lovels nei , SIG ~ | Definition Requremonis ‘Quality groupe (evaluation groups) Beans Weld according to: foruse” uatty Trey val Level (OIN 886373 bvs16%2 N25 617 | 0s 95204 | butt/Toints) OF | aaatiy evel Gt Twa examination AS and an) ( ! applies towelded | - welds worked e 1 usable only as | 2 jeints whose faire | > 400% zip® » | exceptions ‘would ruin the + cortifed and minutes | © 3 8:34] < 3 entie constuction, Availabilty cannot be [visual examination restores + welds uaworked |B). | lle “100% Zip® erties and minutes | ous GE | Caaly vet GE Visual examination ‘Sige i applies towelded | - welds unworked | (C) | tb Bsandak — | ential joints whose fai 100% Zip partsin Would ead to failure | = ceriied and minutes bogie tthe main function of the enti : construction. ‘allay can be en tet ae restore. (continuation on next page) Prepared: 0402. 97mM_ | ~ Schweizerische Industrie-Geselischaft_) N027 1016 Authorized:11.04,05/Schn CH-8212 Neuhausen am Rheinfall page 8/15 tGuay Tevel 3 ~ visual examination Bogie applies towelded | - weldsunworked |. (0) ta cS and BK frames joints whose failure | - certifed (where ‘would impair the + SFI/SFM? required) Lusabilly ofthe entire construction, but ‘would not lead to failure ofthe main ‘Quality ievel OF 7 Vistar examination Seandard applies towelded | = wek’sunworked | © (D) m DS and cK ‘construc: pints whose failure tion would affect the Uusabiity ofthe entice construction only negligibly. Availabilty. snot impeired. i) Applies as an example; the technical layout ofthe design Grawihig remains vald In any cave, 2) Certified and minutes 3) Welding engineer welding specatst 4) A,B,C, = evaluation groupe: S = but wold: K = filot wold 2.2 Examination instructions }224 Normal cases In normal cases, a visual examination is carried out in Production according to the stipulations of the evaluation group under EN 25°87 atid the assignment to a quality level according to Table 2. ee ~ An assessment relative to an internal imperfection is not possible here. - Visual examination according to Work and Inspection Instruction 49 980 451 (prEN 970). 22.2 Prescribed examination 22.3 If visual examination is not sufficient, other examination procedures are to be stipulated in cooperation with Stress Analysis and the welding engineer. One of the examination procedures is to be stipulated: Quter imperfection - dye penetrant test ionerimperfection - ultrasonic test ~ magnetic crack test . ‘ ~ radiography test ‘A technical specification for testing procedure, frequency of testing, and documentation is to be prepared. Data on the drawing The form must be applied to every drawing with welding data. (Figure 10) Quality levels Q1 to Q4 are generally entered on-all welding drawings. The welding quality level which generally applies for the welds:on the drawing is always given above the drawing heading. Prepared: 02 02.971RM | ~ Schweizerische Industrie-Gesellschaft | N027 1016 Authorized:11.04.95/8chn ‘CH-8212 Neuhausen am Rheinfall__| page 9/1516 JUN 1997 MASTER Copy Q2 Q3: [04 7 x Figure 10 WELD QUALITY SIG NORM N 127 101 If Note: All quality levels which deviate from those generally given are to be entered on the drawing on the weld. (Figure 11) ~ In addition, they must be entereid in'tve form in parentheses next to the generally applicable quality level. (Figure 12) . sv w/o, Se WELD QUALITY: Q1 [Q2 Tas Tas I SIG NORM-N 127 401 TX Quality level for this weld Figure 12 “ Design guidelines (Stress Analysis, Design, Production) 923.1 Through welding 5 Both Design and Production influence the quality of the welding? E When through welding is required, singléV butt welds and single-bevel butt welds must be selected. Ensured through welding ig provid only with welding on both sides. Through welding is not guaranteed for single-V buttwelds with broad root face or single-bevel butt welds with broad root face.; : - The through welding imperfections shown in Table 3 (Fs-+ Fk) can be compensated for with an additional fillet weld, Figure 13 Filet weld Fesés Fk = dimensioned leg length Fs = welding imperfection in production ‘3.2 Example for the use of weld shapes from the point of view of the stress analyst Under dynamic load, the welds or flaws in rigidity are the fundamental weak parts of the construction, ae ° This is of particular importance when the weld is stressed transversely to the direction Of force or in bending. The following are'a few exartples of which weld shapes are appropriate, or not appropriate, under which types of stress." Prepared: 0402.077RM ‘Schweizerische Industrie-Gesellachait | N O27 101e | Authorized:11.04.95/Schn CH-8212 Neuhausen am Rheinfall page 10/45 poe ee. : 16 JUN 1997 MASTER Copy Only usable under light static stress. Af gj Bis 27 i 28 Also appropriate: All weld forms under longitudinal weld stress,-6. Figure 20 oo From the above examples, it follows th: Aulhoneads toe, | Schwelzerische industie-Gosalscha TW 027 10te - Authorizedt1.04.95/Scha CH-8212 Newhausén am Rheinfali’ page 11/15The thickness (a) should correspond to the calculation. ‘The most economical limit is from a > 3 to< 6mm, For single-sided fillet welds, a= 0.7 § min., and for double-sided fillet welds, a= 0.4 S min., should not be eo exceeded, ome, In addition, it must be ensured that S : $ min, Extreme case: Example - box girder with fillet weld ‘Bend on the X-axis amt = 6m Som = . sme =s8mm Distance tom edge (5x0 + 2mm) gure 31 For thicker plates, single-bevel butt welds or single-bevel butt welds with broad root face with fillet weld must be seleeted, | Example - box girder with single-bevél butt weld with broad root face with fillet weld: ~ Figure 32 x14. Distance from edge The distance from the edge is given through the dimension "a" of the fillet weld as well as from the welding position in Production. It must be determined on a case-by- case basis by the welding engineer, Distance from edge Figure 33 (welding position: ¢, PB) Figure 34 (welding positon: h, PA) {tis to be ensured that with the introdiictién of force, no bending stress occurs in the single-bevel weld with broad root face or the filet weld. Prepared: O02 SRM ‘Schweizerische Industrie-Gesellechaft[N027 1010 ‘Authorized:t1.04,95/Schn, CH-8212 Neuhatisen am Rheinfall__| page 1215i 2:3.3. Bending radii for welding in cold-worked zone According to DS 952, welding in the area of cold-worked zones is to be avoided. In cold-worked zones, welding may occur only when the bends dependent on the relationship of “inner radius : plate thickness" or on the related elongation are maintained. (Minimum bending radius, see N 031.512.) 3. Weld shapes and weld preparation . Joint shapes are based on EN 22 553 / ISO 2553. Joint shapes which are preferred for use aré described in Table 3. Table 3 / Joint shapes and weld preparation ‘Sym ] Desig | dont shape Fabia [wal [orstance [Log] RV] Guatine for use and bot” | nation | (section) cation fick | fength [value | fabrication * ness [o_o ‘one 42 o | | Eeonomical buit weld joint, joy fase ess Only for secondary joins. I] save | exami 334_| 15 0.88 but wold | bah [sas [1 ‘quali tvel cannot be “ate side” [7358 [ 15 assigned. 36a [2 ow a Re a ‘irengih jor, as thaweld cross ve section can closely correspond o sroey | eX Bart Sn is. utes | CEN AAV} ee od 42 = Use ofthe shims to be determined in coordination with ‘Single-V_ I! Production. butt weld y ‘must be drawn on the wel, with shim 9 ness § |b“): je Sao] a aera butt weld oP 4 og rath 3x8 2 a The weld cross section is to be “ one 3 + [gumente soa, Gus broad side Jeg length) ratte idan] [| |SRS nprtctn ple ° _ ‘+Fs (according to Section 2.3.1) Single Weld enereacia 5 $<8=2mm/28=3.5mm- IX, | bevet adel a8 10 ~ Dimension a on the fillet wold butt weld ee one 0 1 depends on requirements from y |e a : catator nd he wl broad ‘28:20 ¥ we ‘position, en fH PP Bt: anarowee ot fie ‘ sy eae BP] Ts ea bata tis wee aud yal an | mma eed, Done ion wottce on cover! sides ne Tae KX Most econ welded on. resi ss 2 mars 02.82) mom : ~ — 1) Distance dimension "b*- for square but weld = face sida distance + forall prepared joint shapes = distance between logs + the tolerance is not to be given in the drawing oe 2) Cost comparison value ° : 3) Data forthe through weld imperfections have value a8 experience; and are-verfied through tials, 4." Welding procedure specificationiand-welder qualifications 41 Welding procedure specification | : Every weld requires a welding procedure specification according to EN 288. This is Prepared by a welding engineer / welding specialist and must be mentioned in the Production contract (Process Planning). 4.2 Assurance of the quality of welding work The requirements according to EN 26 817 are fulflled. (The corresponding quality level is determined by Stress Analysis.) pupored: C402 9RMT Schweizerische industrie-Gesellschat | NO27 1016 Authorized: 1,04,96/Schn CH-8212.Neuhausen am Rheinfall page 1415 Ve7 4.3 Welder qualification q Welding personnel are trained internally at SIG. For quality levels 1 to 3, the welding personnel are examined according to EN 287. sys a 4.4 Approval of welding work : ‘The methodical carrying out of welding work is executed and confirmed by the a employee by self-checking. . 4 This is generally limited to a visttal appraisal of the weld, as well as the checking of true measurement with respect to the required quality level. y In appraising weld preparation, the examiner may require that individual parts or assemblies be submitted to him before welding or in bound form, but without any noticeable interference to the production procedure. a 48 Existing drawings {abe E * For drawings which do not cotfespond tothe valid Norm, the present valid Norm is to q be used. * q In cases of uncertainty, the exact procedure is to be prescribed by Process Planning (quality level, weld preparation according to Table 3, weld signs). hy Prepared: ORDLOTRM | Schweizerische industrie-Geselischaft [N027 1016 9 ‘Authorized 1,04.96/Schn CH-8212 Neuhausen am Rheinfall page 15/15