Engineering Apparatus Instructions: N. F. Bratkovich 1651

________________________________________________________________________________________________________________________
ISSUED BY NUMBER
N. F. Bratkovich 1651
ENGINEERING FIRST ISSUED
APPROVED BY
December 31, 1948
G. W. Brownell APPARATUS INSTRUCTIONS
SUPERSEDES
ELECTRO-MOTIVE DIESEL
LaGrange, Illinois
SUBJECT EMD WELDING, BRAZING AND SOLDERING SPECIFICATION

AFFECTS MODELS All
PART NOS. AFFECTED
REF DRAWINGS See Applicable References

SCOPE
The purpose of this A.I. is to provide Electro-Motive Diesel and its suppliers with mandatory practices and
procedures for all arc welding, brazing, and soldering applied to EMD products. American Welding Society
(AWS) D1.1/D1.1M & D15.1, American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel
Code, European Norm Standards (EN), Canadian Welding Bureau (CWB) W59, and others were used as a
guide, rather than a rule, in the formulation of EMD welding standards.
APPLICABLE REFERENCES
The following A.I.'s are or may be incorporated by reference into this A.I. as applicable. A.I 1046 and A.I
2208 shall also be provided to EMD personnel and suppliers using this A.I:
1046 Electro-Motive Standard Welding Symbols
1576 Application of Welded Pipe Clamps
1609 Soldered Joints
1970 Qualification of Welded Studs
2009 Welding Specification for Joining Pipe to Pipe Fittings and Welding of Flanges
2208 Qualification of Welders
2220 Main Res. & Air Tank Qual. of Automatic Machine, Procedure, Operator & Welder Performance Qualification
2296 Acceptance Criteria & Repair Procedures Concerning Internal Discontinuities (Lamination) in Structural Steel
Shapes & Plates
2440 Welding of Stud Plates and Brackets
2491 Long Hood, Cab & Short Hood Special Quality Requirements
2514 Reinf. Pads for Pipe Clamps, Stud Plates, Cable Supports and Attachments Welded to Vessels or Tank Shells
2525 Needle Peening of Weldments
2572 Skip Weld Sealant Apl
2606 Application of Welded Electrical Tie rods
2630 Projection Weld Nut Application
REV DATE CR PAGES AFFECTED CHANGED BY APPROVED BY

V 10/10/15 D725771 ALL PAGES REVISED Oddie/Spry J. L. Buchman
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© 2015 Electro-Motive. All Rights Reserved. The information hereon is the property of Electro-Motive Diesel, Inc. and/or its subsidiaries.
Without written permission, any copying, transmittal to others, and any use except for which it is specifically provided, is prohibited.
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EMD Welding, Brazing and Soldering Specification
Table of Contents
A.I. 1651 check list
1. Welding Procedures
1.A. Procedure Qualification

1.B. Welding Qualification & Certification
1.C. Welding Requirements
2. Class, Inspection and Acceptance
2.A. Weld Classes

2.B. Inspection
2.C. Acceptance Standards
2.D. Preparation of Base Metal
3. Arc Welding Processes and Electrodes
3.A. Gas Metal Arc Welding

3.B. Shielded Metal Arc Welding
3.C. Gas Tungsten Arc Welding
3.D. Flux-Cored Arc Welding
3.E. Submerged Arc Welding
3.F Resistance Welding
3.G. Arc Stud Welding
3.H. Electroslag Welding
4. Fabrication
4.A. Technical Review (Manufacturing Control)

4.B. Reworking Welded Assemblies
4.C. Heat Treating After Welding
4.D. Peening of Welds
4.E. Materials
5. Brazing of Ferrous and Non-Ferrous Metals
6. Soldering of Ferrous and Non-Ferrous Metals
7. Weldment Design
8. Terms Definitions & Acronyms

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A.I. 1651 Check List
For supplier approval process, and when a new welding process is required or essential
variables are changed.
Actual WPQR's that will be used on EMD products, see Section 1.A. Indicate all
essential variables listed in AWS, ASME or ISO weld codes and include the following
additional information
a. One macro cross section photo showing joint fusion and weld profile.
Actual WPS's that will be used on EMD products, see Section 1.A. Indicate all essential
variables listed in AWS, ASME or ISO weld codes and include the following additional
information.
a. Must reference the qualifying WPQR or a pre-qualified AWS joint.
b. Indicate weave or stringer bead.
c. Indicate multi pass bead sequence by the use of a sketch.
Welder qualification documents, see Section 1.B
Visual, NDT and/or pressure testing inspection documents showing conformance to
Section 2.B
Other additional elements that must be reviewed before and during welding
Parent metal condition for each weld process used, see Section 2.D
Welding consumables, see Section 1.A.4 & Section 3
Equipment maintenance, see Section 1.B.2.4 & Section 4.A.2
Technical review, see Section 4.A
Non-conformance and corrective action, see Section 4.B

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1. Welding Procedures
For the purpose of this document the following names will be used to define groups and the groups'
functions at EMD as they relate to welding. The Manufacturing group at EMD that develops the
welding manufacturing procedures, monitors welding manufacturing processes, and trains and tests
welders is called "Weld Manufacturing Engineering". The Engineering group that defines the
welding standards, interprets the weld standards and develops the engineering weld requirements is
called "Welding Engineering". See “Terms, Definitions, & Acronyms” Section 8 of this document.
1.A. Procedure Qualification

EMD Weld Manufacturing Engineering (in-house) and the supplier (for purchased components) are
responsible for developing and implementing Welding Procedure Qualification Records (WPQR)
and Welding Procedures Specifications (WPS) that are used in the production of EMD products.
Welding procedures are to be developed to meet all Engineering requirements of the design as well
as assist in the ease of manufacturing. Procedures may be general, such as covering the normal
application of the Gas Metal Arc Welding process, or specific, such as the detailed welding
procedure for welding the SD70ACe pivot pin. All procedures must be tested and evaluated before
implementation. Testing can be done on actual or a simulation of production parts. Evaluation may
include destructive as well as non-destructive tests to assure the soundness of the welded structure.
Welding Engineering will approve each welding procedure, verifying that the procedure meets the
engineering requirements prior to production. Welders must have access to and understand the
WPS prior to welding.
1.A.2. Welding Procedure Qualification

WPQRs for the various welding processes and weld joints that will be used on EMD products must
be developed and qualified prior to starting production. A unique stand-alone WPQR must be
developed and qualified for all weld joints that are designated class C1 (see "Section 2.A" for weld
classes) or others as defined by either EMD Weld Manufacturing Engineering or Welding
Engineering i.e. joints such as a pivot pin or collision posts etc.
Qualification of procedures may follow AWS, ASME, CWB, ISO/EN or Military Specifications.
Acceptable minimum standards for welding procedure qualifications include AWS B2.1 Specification
for Welding Procedures and Performance Qualification, latest edition, or ASME Section IX Welding
and Brazing Qualification, latest edition. Suppliers outside North America may use ISO 15614
Specification and Qualification of Procedures for Metallic Material, latest edition.
The use of AWS or other codes’ pre-qualified joints and/or WPS’s still requires that the supplier
furnish this information in their company's approved WPS format with actual parameters used.
References to AWS or other code specifications only, is NOT acceptable.
A WPQR and WPS must be tested and submitted to either EMD Weld Manufacturing Engineering
or Welding Engineering when a change to a process essential variable occurs (e.g., shielding gas,
filler wire, base material composition, welding process, etc.) Copies of all qualified procedures that
will be used on EMD products must be submitted to either EMD Weld Manufacturing Engineering or
Welding Engineering for review and approval. If there are questions or concerns, EMD Welding
Engineering may request actual weld samples for further evaluation. Class C1 joint samples must
be reviewed by either EMD Weld Manufacturing Engineering or Welding Engineering.

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1.A.3. Welding Processes

EMD Weld Manufacturing Engineering (in-house) and the supplier (for purchased components) are
responsible for determining the welding process to be used in the fabrication of EMD products when
not specifically defined on the Engineering drawing, provided they have been properly qualified and
approved by either EMD Weld Manufacturing Engineering or Welding Engineering. Follow the
requirement in "Section 1.C" for each welding process. Wherever possible, welding should be done
in the flat or horizontal position.
1.A.3.A. Class C1 or C2 welds are not to be produced using the GMAW short circuit
mode of metal transfer unless accepted by either EMD Weld Manufacturing
Engineering or Welding Engineering and covered by an approved WPQR.
1.A.3.B. Shielding gas mixtures used in the production of EMD products must be of
welding grade quality to minimize porosity. Conformance with the guidelines
specified in AWS A5.32, Specifications for Welding Shielding Gases or ISO
14175, Gases and gas mixtures for fusion welding and allied processes, is
acceptable.
1.A.4. Welding Consumables

All consumables and electrodes, regardless of the welding process, must have an AWS
classification, unless an alternative is accepted by Welding Engineering. In addition to the AWS
classification, an ISO classification may also be required on certain products, if required the
Engineering drawing and/or an A.I. will indicate this.
Consumable long-term storage area, all welding consumables must be stored in a dry location and
handled in a manner that avoids damage to consumables and packaging. The storage area must
protect consumable from the weather (rain or snow), water, shop cutting oils or lubricants, excessive
grinding dust and paint overspray.
If welding plain carbon steel, AWS class E60XX or E70XX welding electrodes or equivalent shall be
employed. If welding high strength low alloy steels, AWS class E70XX welding electrodes or
equivalent shall be employed. In applications where plain carbon steel is welded to high strength
low alloy steel, AWS class E70XX welding electrodes or equivalent shall be used. For materials see
"Section 4.E". These rules are general and will govern most shop applications. Any special
electrode application will be indicated on the EMD Engineering drawings or in an A.I.

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1.B. Welding Qualification & Certification

1.B.1 Welder Qualification - All welders (including welding operators & tack welders) who are to
work on EMD products must be qualified in accordance with A.I 2208, AWS, ASME, CWB, ISO/EN,
Military Standards, or an in-house procedures if approved by either EMD Weld Manufacturing
Engineering or Welding Engineering. A copy of the welder performance qualification procedures
that are used must be submitted to either EMD Weld Manufacturing Engineering or Welding
Engineering for approval. The procedures should include a statement as to how qualification of
welders is reviewed, maintained and updated. See A.I. 2208 & Section 1.B.2, below.
Acceptable minimum standards for welder qualifications include A.I 2208 Qualification of Welders,
AWS D15.1 welder qualification section, AWS B2.1 Specification for Welding Procedures and
Performance Qualification, latest edition, or ASME Section IX, Welding and Brazing Qualification,
latest edition. Suppliers outside North America may use ISO 9606 Qualification testing of welders –
Fusion Welding, latest edition.
1.B.2 Facility Requirements – All facilities (suppliers and Rail Division facilities) fabricating EMD
product must satisfy all additional requirements below.
All suppliers must submit the following information to either EMD Weld Manufacturing Engineering
or Welding Engineering with copies sent to the Purchasing Department and Supplier Quality prior to
the start of production for approval as part of the original SPAP, re-approval of a SPAP process:
1.B.2.1. All facilities fabricating EMD products must demonstrate a welder certification,
qualification testing and training program, by:
A. Demonstrating a functioning weld training and testing program.
B. Providing a new welder qualification test acceptance criteria.
C. Providing welder qualification procedures.
D. Establishing a period of weld audits, along with re-certification period and the
training of welders.
1. Welders are to be audited at a six month interval on the production
line. “Auditing” may consist of visual examination of a production
weld, but it must be documented.
2. Welders are to be retested every two years for each process that they
are qualified for. “Re-testing” means fillet break or groove side bend
testing, or radiography. Only one test per process is required every
two years.
3. If a welder has not used a process for over six months, re-testing is
required. Again, “re-testing” means fillet break or groove side bend
testing, or radiography.
4. Indicate how weld training is accomplished, internal or by a third party
weld lab.

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1.B.2.2. Name a responsible Welding Coordinator:

A Welding Coordinator is the individual or group responsible for the welding
operations in the facility producing EMD welded components as they apply to
welder training and testing, weld procedure process development and testing.
A. The responsible welding coordinator shall have a thorough knowledge of
welding and fabrication operations, welding processes, and welding procedure
specifications.
B. The responsible welding coordinator must have the ability to read engineering
drawings, interpret welding symbols, and have knowledge of weld fault causes
and cures, welding quality control and inspection methods.
C. The responsible welding coordinator shall have practical knowledge of the
proper operation and basic maintenance of the welding equipment used in the
companies welding operations.
1.B.2.3. Welding Coordinator responsibilities:

A. Qualify welding procedures to be used on EMD products by the usage of
WPQR's. The use of AWS or other codes pre-qualified joints and/or WPS’s
still requires that the supplier furnish this information in their company's
approved WPS format with actual parameters used. References to AWS or
other code specifications only is NOT acceptable.
B. Establish WPQR’s and WPS’s for use in the production of EMD products. All
WPS’s must be furnished to either EMD Weld Manufacturing Engineering or
Welding Engineering for approval prior to production runs. Include electrode
type and size along with shielding gas type if applicable.
C. Establish inspection procedures used on EMD products.
D. Administer welder qualification tests and audits.
E. Establish a list of certified welders and indicated each applicable process and
procedure each welder is certified to. Test and audit dates must be included
in the list.
1.B.2.4. Minimum internal weld testing and training area equipment:
Suppliers with an internal weld testing and training capability should have at least
one dedicated weld test and training area or weld booth with a table. Peripheral
equipment such as tacking fixtures and vises are optional but recommended. Also
recommended is the necessary non-destructive and destructive test equipment
needed to perform the required testing of welder qualification samples. This
equipment must be properly maintained and calibrated according to the applicable
standard. The objective is to have welder training and testing done in an area
separate from production, to avoid distraction and interruption.

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1.C. Welding Requirements
1.C.1 Before starting to weld any assembly, the welder must clearly understand the Engineering
requirements for welding such as size and length of welds. The welder must follow all
specified procedures including all weld parameters settings, directions of welds, their starting
and stopping points and sequence of passes in accordance with the WPS, processing
drawings, routings or visual routings.
1.C.2. Work piece lead connector- When welding, the work piece lead connector (formerly referred
to as the ground) clamp must be securely attached as close as possible to the welding area.
For example, the work piece lead connector should not be attached to the remote leg of a
positioner; instead, it should be attached directly to the work piece or to the approved work
lead contact rings on the positioner. The work piece lead connector must never be clamped
to the rail on which the locomotive is standing or attached to a building structure's ground
directly. Prior to welding on an operational or out of service locomotive, the appropriate
disarming procedures must be followed.
1.C.3. Vertical welds - When welding is applied in the vertical position, the weld must be done in the
vertical up direction in all cases except for repair filling of undercut. Vertical down welding
may be permissible on a thickness of 0.19” (4.8 mm) or less material, or when 0.19"
(4.8mm) or less material is welded to a thicker material only if approved by EMD Welding
Engineering. Then a WPQR and a WPS must be established for the joint. The welder must
be tested on the joint with the WPS in the position and weld progression to be used in
production before they can perform the weld in production.
1.C.4. Slag/Silica - Slag or silica must be removed from all welds and all previous weld passes
before applying the next weld pass. The exception to this rule is multi-pass welding
procedures that are specifically qualified (WPQR) without interpass cleaning, as in heavy-
section automatic robotic welding. When the weld is finished, slag and silica and foreign
material must be removed adequately to successfully visually inspect the weld pass.
1.C.5. Distortion – Byproduct of heat input from the welding process that may or may not be
controllable. When heat input will or has caused a distortion problem, various welding
techniques may be employed to alleviate this condition. For example, the staggering of weld
passes, as shown on Figure 1.1 View A, is one acceptable method. The back-step
sequence of welding, as shown on Figure 1.1 View B, is another method. Restraining
weldments or allowing for movement should be designed into weld fixtures. Larger single
pass weld sizes or larger individual bead sizes in multi –pass welds can also be helpful in
minimizing distortion.

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Technique of Staggering Weld Passes View A
18
3 4 9 10 15 16
17
6
1 2 7 8 13 14 5
11
12
View B
Back Step Sequence of Weld Passes
3 2 1
Figure 1.1
1.C.6. Maximum single pass fillet weld size - The maximum fillet weld size for GMAW & FCAW
process are given in Table 1.1. Deviation from Table 1.1 is permissible, but must be
qualified by an approved WPQR.
Table 1.1
Max Single Pass Fillet Size
0.375" (10 mm) Flat
0.31" (8 mm) Horizontal
0.25" (6 mm) Vertical
0.31" (8 mm) Overhead
1.C.7. Maximum groove root pass size - The root pass effective throat for groove welds must not
exceed 0.25" (6 mm). Deviation must be qualified by an approved WPQR.

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1.C.8. Multi pass welding - Whenever multi pass welds are required, the cascade (stepped weld
passes occurring in succession) weld pass system shall be employed. This also requires
that starts and stops be staggered so as not to create an abrupt sectional change that may
result in craters and un-fused cold starts. Examples of cascaded welds are shown in Figure
1.2.
Figure 1.2
Where staggering of starts and stops cannot be carried out, all starts and stops shall be
carefully checked for presence of imperfections such as porosity, crater cracks, etc. Such
imperfections must be removed and repaired prior to application of succeeding weld passes or
release of assembly for subsequent operations.
Where possible, extension bars or run-off plates (tabs) should be used to terminate the ends of
a multiple pass weld and removed upon completion. After removing the extension bars or run-
off tabs, the edges of the welds must be ground or machined smooth and flush with the edges
of the adjacent parts. Run-off tabs may also be cut or burned integral with the piece parts. All
tab removal requirements still apply.
1.C.9. Tack welds - Tack welds are just as important as final welds; they must be of the
same quality as all other welds. A defective tack (i.e. a cracked tack) must never be
welded over, it must be completely removed. Many assemblies are tacked in a fixture and
moved to a positioner, so quality tacks are required for the safety of production personnel.
Sometimes specific tack welding sequences are called out on Engineering drawings,
Process Specifications, Process drawings or Visual routings to help minimize distortion and
provide sufficient strength for safety purposes. Place tack welds in the straight sections of
weld joints, do not place tack welds in corners. Tack welds not completely consumed by the
final welds must be completely removed. The same preheat as required for the remainder of
the weld must be used for tack welding.

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1.C.10. Backing - Materials that are used to aid in the welding of parts that have a designed root
opening (gap) between them. Both metallic and ceramic removable backing material can be
employed. Water-cooled copper backings may also be used. Consumable backing
material must be equivalent to the base material. All consumable backing material used
must be approved by Welding Engineering prior to their application.
1.C.11.CJP - When making complete joint penetration (CJP) groove welds without backing.
1.C.11.1. The root of the weld must be back-ground or back-gouged to sound metal
before welding is started from the second side. Inspect for discontinuities
using NDT.
1.C.11.2. Melt through must be present for single side CJP welds when weld access
is limited from the backside.
1.C.12. Weld wraparounds - The following examples of symbol placement and notes on the
Engineering drawings indicate that a wrap around (outside corner) or tie-in (inside corner)
weld is required. Also see Section "2.C.18 Tie-in".
• The all around symbol is placed on the weld symbol.
• When adjoining edges of a part require welds of the same type.
• A seal weld note is indicated.
• An air/oil tight note is indicated.
• A wrap or tie-in weld note is specified for certain items.
One method of weld wraparound is that the weld should progress around a corner as shown
in Figure 1.3., with no stops unless otherwise specified on the Engineering drawings.
Achieving a wraparound at a square outside corner without rejectable undercut can be aided
by the application of a “rosebud” or “triggered” round weld deposit at the corner. The weld
must wraparound the corners such that the weld has a minimum (L) of 2 X the thickness (T)
of the material, but not less than 0.5” (13 mm) unless specified otherwise on the Engineering
drawing. Do not apply welds to edges that are not indicated by a weld symbol on the
Engineering drawing.
L
T
Figure 1.3

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1.C.13. Depth to width ratio - The depth to width ratio should be as close to 1:1 as possible for a
single pass weld or for each pass of a multi pass weld, see Figure 1.4. Deep narrow and wide
shallow welds are prone to cracking. Deviation from the above ratio must have a proven WPQR
established that demonstrates a weld free of cracks and all other discontinuities. If the above ratio
cannot be met for a single pass weld then a multi pass weld may be required.
DEPTH
DEPTH
WELD
WIDTH WELD WIDTH
GROOVE WELD FILLET WELD
Figure 1.4
1.C.14 Weave and Stringer Beads – Either weave or stringer beads may be used in the deposition
of weld metal as appropriate, unless otherwise specified per print.
1.C.15. Wind and draft - Any welding process using a shielding gas must have the weld area
protected from any draft and/or wind. Maximum wind or draft 5 MPH (8 KM/H).
1.C.16. Temporary welds - Temporary welds use for applying manufacturing process bars (aids)
must be of the same quality as all other final welds. When the process bars (aids) are
removed, all weld residue must be ground smooth and any craters or tears must be
repaired. The surface of the base material must be flush with the original surface.

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2. Class, Inspection and Acceptance
2.A. Weld Classes

2.A.1. Weld joints at EMD are divided into weld performance classes, based on EN 15085 and
AWS D15.1. Three classes, C1, C2 and C3, have been developed to classify all welds on
EMD products. Class C1 is the highest performance level, and class C3 is the lowest
performance level. These classes will have differences in acceptance criteria. See "Section
2.C.".
2.A.2 Welding Engineering has the direct responsibility of determining the weld class. Weld
classes are determined by the relationship between weld strength and load applied to the
weld joint with a factor of safety included.
2.A.3 Unless otherwise noted, all weld joints on EMD engineering drawings are considered C2. No
designation is required in the weld symbol tail for C2 welds. Weld joints of different classes
other than C2 are to be called out in the weld symbol tail on the Engineering drawing.
2.A.4. The structurally important weld designation “S” in the tail of the weld symbol on Engineering
drawings has been abolished. All legacy engineering drawings with the "S" in the weld
symbol tail shall be designated and treated as a class C2 weld.
2.A.5. EMD Weld Manufacturing Engineering along with Welding Engineering will develop
processes for weld joints that have an unusual condition and/or inspection audit procedure
including all class C1 welds. These can and are usually covered by a separate A.I. that will
be indicated on the Engineering drawing.
2.A.6. When required, Welding Engineering and Engineering will determine the type of and
sequence of NDT (Non-Destructive Testing) to be employed on a weld joint, unless a
customer or contract requires otherwise. When the type of NDT is not specified, suppliers
shall choose the inspection methods appropriate to insure that weld joints meets the
designed requirements. At a minimum, all weld joints must be visually inspected as
indicated in "Section 2.B." using the acceptance criteria found in “Section 2.C.”

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2.B. Inspection
Inspection of all welds and welded products should conform to NDT practices in AWS B1.10 Guide
for the Nondestructive Examination of Welds, latest revision. Either EMD Weld Manufacturing
Engineering or Welding Engineering may authorize deviations from forementioned practices, e.g., if
a newer innovative test method achieves similar results.
All welds will be subjected to a 100% visual inspection by someone other than the person
performing the weld. Self-inspection alone is not acceptable. Either EMD Weld Manufacturing
Engineering or Welding Engineering will be responsible for final determination of weld acceptance
or rejection in the event of a dispute.
All visual inspection must be performed by a CWI (AWS Certified Welding Inspector) or weld
inspectors working under the technical supervision of an internal or external CWI.
AWS D15.1:2012 clause 6.7.1 forbids inspection after any painting, coating, or caulking. However,
it has long been recognized by EMD that a primer coat can actually enhance the visibility of defects
and provide a more sensitive inspection (note that this is not true when caulk and intermediate or
final coats of paint are present).
Therefore, EMD visual weld examination shall be performed with the welds cleaned, unpainted, and
uncaulked, or after application of a single primer coat. Visual weld inspection shall not be
performed after application of any caulk, or intermediate or top coats of paint.
The following is a list of items that must be followed to attain a quality product:
2.B.1. All parts to be welded must be subjected to inspection before welding for correct joint
preparation, correctness and quality of material, heat-treated conditions, and conformance to
dimensions as specified on the Engineering drawing.
2.B.2. All welding jigs or fixtures must be inspected before production is started to insure that
finished parts will be dimensionally correct when the proper welding procedure is followed.
2.B.3. In process inspection must be conducted during the welding process to insure proper
dimensions, alignment, and conformance to the respective WPS.
2.B.4. Engineering drawings are designed on the basis of line-to-line fit-up unless otherwise
specified. It is recognized that tolerances exist on steel mill products and that these
tolerances are necessary with regard to metal working practices. These tolerances can
cause gaps that reduce the effective throat of the specified weld on the Engineering drawing.
The weld throat for a fillet weld is derived by multiplying 0.707 by the leg size.

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2.B.4.1Fit-up gap of 0.06" (1.6mm) or less is acceptable for fillet welds and no corrective
action is necessary. To satisfy the design performance requirement of a component,
a separate A.I. or the Engineering drawing may indicate a stricter gap or fit-up
requirements for that component. If an A.I. is created, it must be indicated on the
Engineering drawing.
2.B.4.2 The following conditional situation must be followed to increase the fillet weld size
based on the gap to maintain the effective throat of the original designed leg size, or
reworking of the piece part. See Figure 2.1.
A. When a fit-up gap of 0.06" (1.6 mm) to 0.19" (4.8 mm) exists, the fillet weld
size must be increased by the size of the gap. Fit-up gaps of 0.06" (1.6 mm)
to 0.19" (4.8 mm) must not be for the entire length of a joint or in the case of a
sub-assembly, must not involve all joint surfaces or planes. See Figure 2.1.
B. If a fit-up gap greater than 0.19" (4.8 mm) exists, the parts are to be
reworked. This may be accomplished by building up an edge or end of the
part with weld metal to satisfy requirements in 2.B.4.1 or 2.B.4.2.A.
C. Where fit-up gaps chronically exist, corrective action must be taken on the
job. Manufacturing, Weld Manufacturing Engineering, Welding Engineering,
Quality Control, Engineering and other support groups must remedy the
condition.
L
L
G
L
• Where “G” (gap) equals 0.06” (1.6 mm) or less, weld size “L” equals size specified by
Engineering print.
• Where “G” is greater than 0.06” (1.6 mm) but does not exceed 0.19” (4.8 mm ), “L” equals
weld size specified by Engineering print plus “G”.
• Where “G” exceeds 0.19” (4.8 mm), pieces must be reworked such that “G” does not exceed
0.19” (4.8 mm) and weld size is governed by above statements.
Figure 2.1

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2.B.5. Complete major/minor assemblies must be checked for correctness of dimensions and
completeness of weld.
2.B.6. Validate the use of qualified welders for the welding process to be completed.
2.B.7. All weld joints on pipe sub-assemblies and pipe assemblies used for liquid or gas must not
leak. Unless otherwise specified on the Engineering drawing, pressure test to a minimum of
90 PSI (620 KPa) for minimum 2 minutes. This is a critical requirement for piping used for
liquid or gas. Pressure testing is not required where pipe or tubing is used in a structural
application. If it is not clear from the print what the application is, request clarification from
Weld Engineering or the responsible Purchasing Agent.

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2.C. Acceptance Standards
2.C.1. Fillet Weld Size - The weld size in leg length as specified on the Engineering Drawing
reflects the minimum requirement. The throat size of the weld is derived from the designed
leg size X 0.707, as shown in Figure 2.2. The minimum throat size must be maintained over
the entire length of weld, regardless of weld profile. Weld profile called out on welding
symbols such as a concave weld profile may require the leg size to be increased in order to
maintain the throat size. Oversize welds are generally acceptable unless a maximum size is
specified on the Engineering Drawing, however, caution must be used because excessive
welding is costly and may interfere with parts or assemblies applied at a later time.
Oversized welds may be detrimental to the structural integrity of the assemblies because as
the weld size is increases, heat input increases, leading to distortion and increased rigidity.
The additional heat can increase the heat affected zone size, altering the mechanical
properties of the weld.
2.C.2. Fillet Weld Concave Profile - The profile or surface contour of a finished weld has a direct
effect on the performance of the weld under load. The ideal fillet weld contour incorporates a
flat face that will result in a throat dimension equal to 0.707 X the specified leg length.
Examples of flat, convex, and concave fillet welds are shown in Figure 2.2 that shows their
relationship to leg length and throat dimensions. A concave fillet weld may meet the
minimum requirements for leg length; however, the throat dimension is less than the required
0.707 X leg length resulting in a weld that does not meet the design criteria. The calculated
throat of the original leg length specified must be met.
2.C.3. Fillet Weld Convex Profile - The convex fillet weld includes a right isosceles triangle plus a
convex reinforcement. The most important factor of convexity is the angular relationship
between the base metal and the surface of the weld at the toes of the weld, see Table 2.1
below. This angle will result in points of stress concentration when the weld is subjected to a
load. See Figure 2.2.
Table 2.1
Fillet Weld Weld Class
Convex Profile C1 C2 C3
Angle Greater than or = to 110° Greater than or = to 105° Greater than or = to 90°
Angle Pictorial 110º MIN. 105º MIN. 90º MIN.

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L = SPECIFIED LEG LENGTH

T = REQUIRED THROAT (T = .707 x L)
L L L
T T T
L L L
FLAT CONVEX CONCAVE
ACCEPTABLE FILLET WELD PROFILES
INSUFFICIENT EXCESSIVE OVERLAP UNDERCUT INSUFFICIENT LEG INCOMPLETE

THROAT CONVEXITY FUSION
UNACCEPTABLE FILLET WELD PROFILES
R
NOTE: Groove welds shall be made with a slight reinforcement, unless
otherwise specified. The convexity (reinforcement) shall not exceed
T the following:
(1) Up to 0.50” (13 mm) thick inclusive, R= 0.09” (2.0 mm).
(2) Over 0.50” (13 mm) in to 1” (25 mm) thick inclusive, R= 0.125” (3.0 mm).
R (3) Over 1” (25 mm) thick, R= 0.156” (4 mm).
ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINTS
EXCESSIVE INSUFFICIENT EXCESSIVE OVERLAP

CONVEXITY THROAT UNDERCUT
UNACCEPTABLE GROOVE WELDS PROFILES IN BUTT JOINTS
Figure 2.2

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2.C.4. Butt Weld Convex Profile - The convexity of a butt weld directly relates to the load capacity
of the weld. The angle will result in points of stress concentration when subjected to a load.
See Figure 2.2 and Table 2.2.
Table 2.2
Butt weld Weld Class
Convex Profile C1 C2 C3
Angle ≥ 150° ≥ 110° ≥ 90°
2.C.5. Flush Groove Weld Profile - Groove welds that require a ground flush profile shall not have
the thickness of the materials joined excessively compromised by the grinding operation. The
reduction in thickness of the flush-ground surface has a tolerance of +/-0.03” (0.8 mm) or
15% of the thinner member being joined; whichever is the lower value will be regarded as the
requirement.
Groove welds that require an as-welded flush profile shall have a tolerance of +0.06” (1.5mm)
-0.03” (0.8mm) or + 30% - 15% of the thinner member being joined; whichever is the lower
value will be regarded as the requirement.
2.C.6. Multi Pass Welds - In multiple pass welds (groove or fillet), excessive convexity of weld
passes that cause notches are unacceptable, see Figure 2.3. The minimum angle of
convexity profile between weld passes (weld bead to weld bead) is 120°. Notches between
weld passes to be covered are points of possible slag entrapment and lack of fusion. The
between pass notches in conjunction with the finishing passes are also points of stress
concentration under load, see Figure 2.3. The notches must be gouged, ground and re-
welded and/or blended out completely. Excessive convexity in multi-pass weld passes must
be reworked. The notches between weld passes may actually reduce the effective throat
dimension. The repair must maintain the minimum throat dimension length.
A concave fillet may meet the minimum requirement for leg length; however, the throat
dimension is less than the required 0.707 X leg length resulting in a weld that does not meet
specifications. Therefore, concave multiple pass fillet welds must be checked for their throat
dimensions. The calculated throat of the original leg length specified must be met.
POINTS OF STRESS
NOTCHES ARE
CONCENTRATION
POINTS OF
REMAIN
STRESS
MULTI-PASS FILLET WELD MULTI-PASS FILLET WELD WITH

EXCESSIVE CONVEXITY INCOMPLETE GROUND SURFACE
Figure 2.3

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2.C.7. Overlap or Rollover - Overlap in fillet welds is defined as an extension of convexity (rollover)
to the degree that the weld fusion line is not visible indicating lack of fusion. See Figure 2.2
This condition is never acceptable anywhere on the weld due to resultant high stress
concentrations and a reduction in effective fillet size.
2.C.8. Undercut - Is a reduction in the parent metal at the toe(s) of a fillet weld or at the edges of a
butt weld. Undercut on welds must not exceed values per joint weld class in Table 2.3.
Visible undercut in excess of the depths in Table 2.3 can be points of stress concentrations
under load. Undercut in excess of specifications must be reworked by the application of a
covering weld pass, toe dressing, or other appropriate method. When the Engineering
drawing indicates a grind blend smooth note for a weld, no undercut is allowed for that weld
regardless of weld class.
Table 2.3
Allowable Weld Class
Thickness T
Undercut C1 C2 C3
T less than or equal to 10% of T 12.5% of T 20% of T
Max #11 GA 0.1196" (3 mm)
Depth T greater than Less than 0.02" 0.03" Max 0.06" Max
#11 GA 0.1196" (3 mm) (0.5 mm) (0.8 mm) (1.5 mm)
Max Length All Thickness Accumulated 10% 100% 100%
of weld length of weld length of weld length
2.C.9. Surface Porosity - Surface porosity is an indication that something is wrong with the welding
process, such as welding over a surface contaminated with loose scale, rust, grease or oil,
etc. Moisture in the electrode coating is another source of porosity. Surface porosity in
excess of values in Table 2.4 must be excavated and reworked.
Table 2.4
Weld Class
Surface Porosity
C1 C2 C3
Single Maximum Dia. 0.06" (1.6 mm) dia. 0.06" (1.6 mm) dia.
Not
Maximum Sum of Acceptable Sum of 0.125" (3.2 mm) Sum of 0.25" (6 mm)
Multiple Pores. In 6" (152 mm) In 6" (152mm)
The surface porosity acceptance criteria is not applicable to welds on electrical laminations
in alternators and traction motors. All visible surface porosity is acceptable when welding on
electrical laminations.

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2.C.10.Wormhole Porosity - Surface porosity that is not spherical in shape and larger than the
values in Table 2.4 may indicate gross sub-surface porosity that will directly affect the
strength of the weld. When porosity is observed in this condition, the weld must be
excavated to determine the extent of the porosity, and reworked.
2.C.11. Internal Porosity - A sub-surface cavity type discontinuity formed in the weld metal by gases
evolving from the solidifying weld metal. When detected by UT or RT, acceptance criteria
shall be provided by Welding Engineering. When detected by probing using arc or plasma
gouging, or grinding, apply the acceptance criteria of Table 2.4. Any weld with porosity
exceeding this standard must be reworked.
2.C.12. Visible Slag Inclusions - Slag inclusions are surface oxides and non-metallic solids that are
entrapped in the weld metal or between the weld metal and base metal during solidification.
They may be caused by improper inter-pass cleaning of multiple pass welds or improper
welding technique. Any visible surface slag inclusion is not acceptable and must be
repaired.
2.C.13. Radiographic Standards - If radiographic testing (RT) is specified on an Engineering

Drawing, ETI, AI, or ESFR, then ASME Boiler and Pressure Vessel Code, Section VIII-
Division I, UW-51 may be used as a guide. In general, RT is performed on a best-effort
basis for information, and acceptance criteria will be provided by Welding Engineering.
Rejected joints must be repaired and re-inspected using RT.
2.C.14. Ultrasonic Test Standards - If ultrasonic testing (UT) is specified on an Engineering Drawing,
ETI, AI, or ESFR, then ASME Boiler and Pressure Vessel Code, Section VIII- Division I, UW-
53 may be used as a guide. In general, UT is performed on a best effort basis for
information, and acceptance criteria will be provided by Welding Engineering. Rejected
joints must be repaired and re-inspected using UT.
2.C.15. Incomplete Fusion - Welds must have thorough fusion between the base metal joint faces
and filler metal throughout the entire weld length. Incomplete fusion must be removed and
repaired by gouging, grinding, and then re-welding.
2.C.16. Cracks - Cracks are not acceptable in welds or in the parent metal on EMD products,
including crater cracks. All cracks must be completely removed by gouging, grinding, and
re-welding.

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2.C.17. Spatter - The cosmetic appearance of a weld is very important from the standpoint of
customer acceptance. Welds should be smooth and spatter-free, including the area around
the weld. All loose spatter must be removed from surfaces. Spatter that cannot be removed
with a hand held putty knife or paint scraper is considered tightly adhered and does not
require removal except in a Level 1 area indicated in Table 2.5. Below in Table 2.5 is a list
of allowable levels of fused spatter based upon location and application on the locomotive.
The presence of excessive spatter is indicative of the welding process being out of control,
and can be caused by incorrect welding parameters or improper welding technique.
Note: Table 2.5 provides numerical guidelines for spatter, however, it is recognized that it
will be time consuming to follow the guides to the letter. Therefore, it is our intention not to
have the operator or quality control person measure and count spatter, but rather use the
numbers as a rough guide since spatter is not a damaging defect. In the event of a
disagreement, a measurement could be used as the final method of judgment.
If it is unclear of what category spatter level applies to a component, then default to a level 1
category for that component.
Table 2.5
LEVEL 1 LEVEL 2 LEVEL 3 LEVEL 4 LEVEL 5
- Absolutely no - No globules of - One globule of - Four globules of Exempt from
spatter allowed. spatter allowed. spatter with a max. spatter with a max. any/ all cleaning
- Fine spatter with a diameter of 0.06" (1.5 diameter of 0.09" (2.3 snags unless
diameter of less than mm) in any 6" (152 mm) in any 6" (152 otherwise
0.015" (0.39 mm) no mm) x 6" (152 mm) mm) x 6" (152 mm) specified on
more than 10 area. area. engineering
individual pieces in - Fine spatter with a - Fine spatter with a drawing.
any 6" (152 mm) x 6" diameter of less than diameter of less than
(152 mm) area. 0.015" (0.39 mm) no 0.015" (0.39 mm) no
more than 20 more than 40
individual pieces in individual pieces in
any 6" (152 mm) x 6" any 6" (152 mm) x 6"
(152 mm) area. (152 mm) area.
Applications Applications Applications Applications Applications
- Inside liquid carrying - Carbody and cab - Carbody interior - Underframe under -Concealed
vessels, such as fuel exterior - Underframe exterior hoods, equipment enclosed non-
tanks and oil pans - Engine exterior - Air duct plenum and areas. plenums of u/f and
- Surfaces of - Generator exterior chambers - Bogie frame bogie frames.
machined - Underframe crew - Tight corners of -Sand box interior
components. access areas. carbody interior -Areas hidden by
- Internal engine - Fuel tank exterior permanently
components install equipment.
- Mating surfaces of
parts to be applied or
connected together.
- Cab Interior
- Crew safety related
areas
-Electrical tie rods,
contact area for wires
and bundles.
-Cable raceways

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2.C.18. Tie-in - Intersecting welds at inside corners must be complete, and must fully penetrate into
intersection weld, unless specified differently on the Engineering drawing (see Figure 2.4). If
possible a tie in weld should terminate into a previous welds start point, see Figure 1.1 P. 8.
Tie-ins at inside corners can also be made using a “rosebud” or circular weld deposit. In
EMD’s experience, this is beneficial to fatigue resistance (see Figure 2.5). Also reference
Section "1.C.12. Weld wraparounds".
Acceptable
Tie-in
Figure 2.4
“Rosebud” Weld tie-in
Figure 2.5

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2.C.19. Arc strikes - Are not acceptable. Cracks or blemishes that may have been caused by an arc
strike must be ground to a smooth contour and checked to ensure soundness.
2.C.20. Fused Weld Wire - Welding wire that is not consumed by the molten weld pool must be
removed. Any protruding un-fused weld wire is not acceptable.
2.C.21. Spot Weld Surface Dimples - Dimples left by the welding process shall not exceed 10% of
the thinner sheet metal thickness or as agreed upon with the customer.
2.C.22. Crater - No crater pits or cracks are allowed (see Figures 2.6 and 2.7). Weld starts and
stops, whether at the beginning or end of a weld or at an intermediate stop and start, should
be completely filled, but may be concave as long as the minimum specified leg size and
minimum throat size are achieved (see Figure 2.8).
Crater Porosity
Crater Pit
Figure 2.6 Crater Pit (Unacceptable)

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Figure 2.7 Crater Crack (Unacceptable)
Figure 2.8 Weld Stop and Start Properly Filled In (Acceptable)
2.C.23 Intermittent and Continuous Welds – Unless otherwise specified on the print, when stitch or
intermittent welds are called for, continuous welds may be substituted (as long as other
dimensional requirements of the print are met).

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2.D. Preparation of Base Metal
2.D.1. The cleanliness of a surface to be welded is a very important consideration and directly
affects the quality of the applied weld. Water, snow, grease, oil, and all foreign material
must be removed from surfaces to be welded.
2.D.1.1. Paint must not be present on the surface to be welded. Never weld over
paint. Remove all paint on and around the weld joint before welding.
2.D.1.2. Water based or oil based anti-spatter compounds including nozzle dips or jells
are not to be used on or near the weld equipment or base materials used in
the construction of the joint. Robotic applications with a nozzle cleaning
station must be qualified through a WPQR and approved by either EMD Weld
Manufacturing Engineering or Welding Engineering.
2.D.1.3. Base metal preparation for GMAW and MCAW

For the gas-shielded solid wire GMAW and metal core MCAW processes, all
surfaces to be welded and surfaces adjacent to the weld must be completely
free from scale, slag (dross), rust, moisture, paint, grease and other foreign
material. Surfaces on which weld metal is to be deposited must be smooth,
uniform and free from fins, tears, cracks and other discontinuities which would
adversely affect the quality and strength of the weld. Wire brushing, needle
peening, grinding, sanding and shot blasting may be used to remove
discontinuities and prepare the base metal for welding. See Figure 2.9 for
acceptable degree of rust and mill scale. A color photograph of Figure 2.9 is
available upon request from EMD's Document Control and Information
Release group.
2.D.1.4. Base metal preparation for FCAW, SMAW & SAW

For the flux-shielded FCAW, SMAW, and SAW processes, light mill scale that
is tight to the surface on sheet and light plate will not adversely affect weld
quality. Thicker mill scale on heavier plate that exhibits a tendency to lift off or
flake must be removed. It is not necessary to remove scale that is tight to the
base metal and will withstand wire brushing; however, all loose scale in the
path of a weld must be removed prior to welding. If the welding process
chosen requires the removal of the mill scale per the consumable
manufacturer's specification in order to produce a sound weld, then the mill
scale must be removed completely in the weld area.
Loose rust must be removed prior to welding when it is present to the degree
that it feels granular to the touch and is removable by wire brushing. It is not
necessary to remove a light flash of rust prior to welding.

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2.D.2. Edges or surfaces of the base metal may be sheared, machined, ground, chiseled (nibbled),
saw cut, or flame cut, but must be free from tears, cracks, rough edges, and any other
discontinuities that would adversely affect the quality or strength of the weld.
• When chiseled (nibbled) the edge will require grinding to remove any burrs or rollover.
2.D.3. Minimum base metal temperature unless otherwise specified on Engineering drawing for
welding is 50° F (10° C). When the base metal temperature is below the minimum, then pre-
heat the metal above 50° F (10° C) or to the requirements indicated on the Engineering
drawing before welding.
2.D.4. Occasionally laminations are found in base metal materials. Follow the guidelines in AI 2296
for acceptance and repair.

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Shot Blasted (Acceptable) Light Rust (Acceptable)
Cut Surface with no Cutting

Oxides (Acceptable)
Excessive Rust (Unacceptable)
Figure 2.9

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3. Arc Welding Processes and Electrodes
All facilities must have valid WPQR’s and WPS's when using any welding process in the production
of EMD products.
Welding electrodes and fluxes must be stored in sealed containers and in dry, secured storage
areas when not in use to avoid damage and moisture contamination.
Electrodes used on material other than plain carbon steel or high strength low alloy steel will be
called out on the engineering drawing.
3.A. Gas Metal Arc Welding (GMAW)

3.A.1. The following electrodes (wires) are commonly used for the welding of plain carbon steel and
high strength low alloy steel with an ultimate tensile strength of 70 Kpsi (482 MPa) or less.
AWS A5.18 ER70S-2,-3, or -6.
3.A.2. Metal-Cored Arc Welding (MCAW)
Metal cored arc welding, commonly known as metal core, is grouped in the GMAW family.
The following electrode used for welding plain carbon steel and high strength low alloy steel
with an ultimate tensile strength of 70Kpsi (482 MPa) or less.
AWS A5.18 E70C-6M H8
3.B. Shielded Metal Arc Welding (SMAW)
3.B.1. The type and size of welding electrode to be used shall be selected so that with the correct
welding technique, the resultant weld will meet the specified requirements of the design with
acceptable quality. To obtain root fusion in single bevel and "V" groove weld joints without a
root gap, a WPQR must be established and approved by either EMD Weld Manufacturing
Engineering or Welding Engineering.
3.B.2. When welding plain carbon steel, high strength low alloy steel, or plain carbon steel to high
strength low alloy steel, AWS class E60XX or E70XX welding electrodes shall be used. Any
special applications will be covered by a WPQR, Engineering drawings or special welding
procedures and must be approved by Welding Engineering.
3.B.3. There are many types of electrodes within a given class. Each individual type has some
characteristic which makes it more suitable for a given application. The manufacturers
recommended parameter ranges should be followed and approved through a WPQR.
3.B.4. Welding electrodes are consumables and must be stored per requirements indicated in
"Section 1.A.4" welding consumable.

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3.B.5 Very few EMD weldments have the combination of strength, hardenability, and thickness to
actually need low hydrogen electrodes or processes. In the vast majority of cases, low
hydrogen covered electrodes are used for other reasons, such as their welder appeal, good
appearance, and high deposition rates. High strength steel applications that are truly
susceptible to hydrogen embrittlement and require special covered electrode pre-baking
procedures will be noted on the Engineering print.
3.C. Gas Tungsten Arc Welding (GTAW)

Gas mixture, filler metal, and techniques to be used on EMD products must be qualified through the
(WPQR) process and approved by Welding Engineering before starting production.
3.D. Flux-Cored Arc Welding (FCAW)
All FCAW process used on EMD products must be qualified through the (WPQR) process and
approved be Welding Engineering before starting production.
3.E. Submerged Arc Welding (SAW)

EMD does not recommend the use of hand-held SAW methods.
Electrodes and flux combinations to be used for SAW should be usages recommended by the
consumable manufacture. SAW fluxes containing reprocessed, crushed slag shall not be used in
EMD applications. Recovery of unfused flux is acceptable.
When fluxes are in hoppers ready for welding, it is recommended that the hoppers be covered to
avoid foreign material contamination. It is also recommended, but not required, that hoppers be
equipped with heaters to help prevent moisture contamination of the flux.
Each application of the SAW process at EMD must be covered by an approved WPS which details
the wire, flux, and welding parameters that are required and each application must be approved by
Welding Engineering.
3.F. Resistance Welding (RW)
Resistance welding is not an individual welding process, it is actually a group of welding processes.
3.F.1. Resistance Spot Welding (RSW)

Resistance spot welds can substituted with a intermittent 0.5" (13 mm) long fillet weld with a pitch of
2 X the original spot weld pitch, when approval by Welding Engineering.

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3.F.2. Projection Welding (PW)

Projection welds can be replaced by fillet welds in accordance with AI 2630.
3.G. Arc Stud Welding (SW)
Alternative process may be used to fasten studs, provided Welding Engineering has approved a
WPQR and that process does not affect the assembly of parts later in the assembly process. For
testing the stud weld process, see A.I.1970, Qualification of Weld Studs.
• All Stud Welding must be done using an arc shield (ferrule) unless Welding Engineering has
approved a WPQR.
• The arc shields are to be removed after welding by chipping or use of an appropriate tool.
The work lead clamp must be located on the part being welded as close as possible without
interfering in the welding operation.
3.H. Electroslag Welding (ESW)
Welding Engineering must approve a WPQR for each application of ESW used on EMD products.

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4. Fabrication
4.A. Technical Review (Manufacturing Control)

4.A.1. Production line supervisors and welders must understand what is required of them in regards
to the process specification, routing, visual routing and WPS's. Instructions of weld
sequence, base metal preparation, welding and post weld cleaning etc. Welders must have
access to the WPS’s.
Communication and surveillance is required. It is important that if a deviation in material, joint
design, or weld consumable is observed, it must be brought to the attention of the appropriate
Engineering Group for immediate action.
4.A.2 Preventive maintenance must be performed on all welding related equipment. Welding
equipment must be properly maintained and calibrated according to the applicable standard.
4.B. Reworking Welded Assemblies
4.B.1. Welds that exceed the acceptance criteria of Section 2.C are considered to be faulty or
defective and must be reworked. An investigation of the discontinuities must be conducted
to determine the extent of the discontinuity and to determine the root cause(s). Then an
appropriate corrective action plan must be implemented. The plan may cause adjustments to
welder training, welding procedures, material, or design. Re-inspect with the original method
that was used to find the defect.
4.B.2. Never cover up a faulty weld by a second pass without first removing the defective
area of the weld. Remove the defective area by grinding, flame cut gouging, or carbon arc
gouging. All surfaces that have been flame cut or carbon arc gouged must be ground clean,
removing all slag and carbon deposited before the repair welding begins.
4.C. Heat Treatment After Welding

Heat treatment of a weldment shall be specified on the drawings where required. In stress relieving,
the structure or parts of the structure shall be properly supported to minimize distortion. The WPS
must be qualified with post weld stress relief. Post weld stress relief shall be indicated in the body
of WPS document.
Note: Absolutely no straightening is allowed after stress relieving without written approval of
Welding Engineering.

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4.D. Peening of Welds
4.D.1. Peening has a two-fold purpose. Peening is utilized where distortion caused by welding
must be held to a minimum. It also induces a favorable compressive residual stress system
in the surface layers of the weld metal. Peening is essential and very effective in providing a
successful welding rework procedure for parts that have already been furnace stress-
relieved and machined. Refer to A.I. 2525 Needle Peening for further instruction in regards
to peening.
4.D.2. To minimize distortion due to welding and to induce beneficial compressive stresses,
peening should be done after each weld pass. The first (root) pass of groove welds must
never be peened because of the danger of cracking a weld with minimal thickness (this
restriction does not apply to fillet welds). In order to induce compressive residual stresses,
peening should be done at a temperature of 300° F (150° C) or lower.
4.D.3. If the weld repair surface was peened and then grinding was utilized to achieve the original
contour or to remove sharp corners, etc., this area must be re-peened. This is because
grinding removes all the beneficial compressive residual stress and introduces harmful
tensile residual stresses. Therefore, peening must always be the final operation.
4.D.4. Parent metal for a distance of 0.50" (13 mm) around the weld shall be peened.
4.D.5. The tools required for peening may be of three types (needle, hammer or ultrasonic peened).
The preferred method of peening is with a pneumatic needle peening gun in accordance with
AI 2525. The needles may vary in diameter. The great advantage to needle peening is that
the needles will conform to the contour of the area to be peened, especially in tight corners,
resulting in superior coverage.
4.D.6. An example of the effect of peening to control distortion is shown on View A in Figure
4.1. The deformation of a weld due to peening is shown on View B in Figure 4.1. The
composite photographs, Figure 4.2 exhibits a face view of welds in the welded
condition, properly peened and improperly peened condition for both SMAW and
GMAW. A color photograph of Figure 4.2 is availed upon request from EMD's
Document Control and Information Release group.

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Effects of Peening on Shrinkage
View A
Effects of Peening on Weld Profile
A B C
A –Weld profile as welded

View B
B – Properly peened Weld profile
C – Excessively peened weld profile
Figure 4.1

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AS WELDED AS WELDED
INSUFFICIENTLY NEEDLE INSUFFICIENTLY NEEDLE

PEENED PEENED
PROPERLY NEEDLE PROPERLY NEEDLE

PEENED PEENED
SMAW GMAW
Figure 4.2

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4.E. Materials
4.E.1. General
If a specified material requires special preheating, post weld heat treatment or thermal stress
relieve, or welding electrode, this will be specified on the Engineering drawing
The Carbon equivalent of a steel relates the chemical composition to hardenability, which
directly relates to the microstructure of the heat affected zone of a weld determining the
weldability of the steel. The equation that is used is the following:
CE = % C + % Mn + % Si + % Cr + % Mo + % V + % Ni + % Cu
6 5 15
If CE is greater than 0.4%, then a special welding procedure will be specified by Welding
Engineering. This may include the use of preheat, post weld heat treatment, and low
hydrogen electrodes.
4.E.2. Plain Carbon Steel

Plain carbon steels to be welded in this group shall not have a carbon content exceeding
0.25%, a manganese content exceeding 0.70%, a Silicon content exceeding 0.50%, a
Phosphorous content exceeding 0.05%, nor a Sulfur content exceeding 0.05%. Some of the
more common material specification numbers for plain carbon steel group used at EMD are
listed in Table 4.1.
4.E.3. High Strength, Low Alloy Steel

High strength, low alloy steels to be welded in this group shall not have a carbon content
exceeding 0.25%. The above limit of 0.25% carbon indicated for easily weldable low alloy
steels cannot be applied to all compositions. It will vary from this value in both directions
dependent upon the amount of additive alloying elements present, particularly those which
are quite effective in conferring hardenability, such as manganese, molybdenum and
chromium. Some of the more popular material specification numbers in the high strength,
low alloy group used at EMD are listed in Table 4.1.
4.E.4. High Alloy Steels

There are a number of steels other than those listed above that are used on EMD products.
High carbon steels, manganese steels, and Stainless Steels all have some special
applications that require welding. Generally, these steels will require some particular
welding procedure. If so, such procedures will be clarified on Engineering drawings or by
written specifications. Some of the common material specification numbers of high alloy
steels used at EMD are listed in Table 4.1.

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4.E.5. Pipe, Pipe Products, Pipe Fittings

Pipe and pipe products can have up to 0.30% maximum carbon content. Forged pipe fittings
can have up to 0.35% maximum carbon. The material specification numbers are listed in
Table 4.1.
Note: See AI-2009, Welding of Steel Pipe.

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Table 4.1
High Strength, Low Alloy
Plain Carbon Steel High Alloy Steel Tube / Pipe / Fittings
Steel
Trade Trade Trade Trade
Material Spec. Name Material Spec. Name Material Spec. Name Material Spec. Name
IND 0008, MS 4361 IND 0075 EMS 050 IND 0119, EMS 091 IND 0009, EMS 069
IND 0032, EMS 015 IND 0107 EMS 154 Corten IND 0075, EMS 050
IND 0041, EMS 160 Cobble IND 0110, EMS 064 INS 0076, EMS 051
IND 0100, EMS 055 IND 0111, MS 4398 IND 0077, EMS 052
IND 0101, EMS 056 IND 0116, EMS 066 Corten IND 0078, EMS 053
EMD Material Specification Number
IND 0102, EMS 057 IND 0018, EMS 084 IND 0079, EMS 054
IND 0103, EMS 058 IND 0120, EMS 092 T1 IND 0081, EMS 097
IND 0104, EMS 059 IND 0121, EMS 093 Ex-Ten IND 0082, EMS 096
IND 0106, EMS 061 IND 0133, EMS 182 Domex IND 0085, EMS 152
IND 0108, EMS 062 IND 0135, CMS 10 Corten IND 0086, EMS 170
IND 0109, EMS 063
IND 0112, MS 4430
IND 0117, EMS 067
IND 0130, EMS 095 A 36
IND 0131, EMS 156 44 W
IND 0136, EMS 181
IND 0180, EMS 180 Q-235
IND 0325, MS 4624
IND 0002, SAE 1018 IND 0051, SAE 8620 IND 0006, SAE 1045
SAE No.
IND 0003, SAE 1020 SAE 4615 IND 0007, SAE 1060
IND 0004, SAE 1022 SAE 8615 IND 0012, SAE 1095
SAE 1010 SAE 1070
SAE 1015 SAE 1075
AISI 304
AISI No.
AISI 347
AISI 409
AISI 410

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5. Brazing of Ferrous and Non-Ferrous Metals
5.A. The success of a brazed joint is dependent on eight important design and processing functions.
The omission or improper application of any one of the operations is detrimental, and will result in
an inferior joint, affecting the function of the product.
The eight important steps are as follows:
1. Joint design
2. Selection of materials and appropriate brazing alloys and fluxes
3. Cleanliness of materials at the braze joint
4. Assembling and fixturing
5. Heating the braze joint
6. Brazing technique
7. Post braze cleaning
8. Inspection
5.A.1. Joint Design

The shear value of silver brazing alloy is 25,000 PSI (172 MPa) and all joints are designed with this
as a minimum requirement.
Depending on the alloy selected, the calculated room temperature clearance between members to
be joined can be between 0.0015" (0.038 mm) and 0.005" (0.13 mm) to obtain the best possible
condition for capillary attraction in wetting the full area of the joint, when the joint reaches the
brazing temperature.
The desired strength of tubular joint may be calculated using the following formula:
X= W (D-W) YT
LD
Where
X = Depth of lap or shear area
W = Wall thickness or thinnest member
D = Diameter of shear area
*Y = Factor of safety
T = Tensile strength of weakest member
L = 25,000 psi (172 MPa)
* Factor of safety normally 3 to 4
The desired strength of a lap joint on flat materials may be computed from the following formula:
X= YTW
L

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5.A.2. Appropriate Brazing Alloys and Fluxes

The preferred alloy for brazing carbon and stainless steels, copper alloys, and nickel alloys is
cadmium free IND0517/EMS 913. IND 0510/EMS 870 white flux or AWS A5.31 FB3-C black flux
should be used with IN 0517/EMS 913. The selection of base metals and compatible brazing filler
metals are shown in Table 5.1. Cadmium braze alloy IND 0504/EMS 864 will no longer be placed
on new designs. IND 0517/EMS 913 is used in it place. EMD manufacturing and Suppliers can
substitute IND 0517/EMS 913 for IND 0540/EMS 864 on legacy drawings.
• IND 0502/EMS 862, IND 0503/EMS 863 and IND 0504/EMS 864, brazing alloys are not
suitable for use in connection with food processing or for storing of liquids intended for
human consumption. The cadmium content of the alloy is sufficient to cause
contamination.
• The use of IND 0501/EMS 861 brazing alloy should be limited to parts functioning at the
maximum temperature of 350° F (177° C).
• The use of IND 0502/EMS 862, IND 0503/EMS 863, IND 0504/EMS 864 & IND 0508/EMS
868 should be limited to parts functioning at the maximum temperature of 500° F (260° C).
• IND 0501/EMS 861 is high in phosphorous and is suitable for brazing copper to copper
without the use of flux, if properly cleaned and the cleanliness maintained through the
brazing process. However, to insure an optimum joint where pressure and strength are
required, the use of flux is recommended.
• IND 0517/EMS 913 and IND 0518/EMS 914 are cadmium free, a cadmium free substitute
recommended for IND 0504/EMS 864.
• The use of gas flux as a sole fluxing agent on socket or lap type silver brazing joints is
prohibited although it may be used in conjunction with the paste flux. The gas flux alone
will not penetrate the joint to protect the brazing surface unless the surface is exposed.
5.A.3. Cleanliness of Materials at the Braze Joint

This is the most important operation for successful brazing. Each mating part should be thoroughly
cleaned. The removal of grease, oxides, oil, scale, paint, grinding debris, shop dust, crayon marks
or any foreign material is essential.
Cleaning is commonly divided into two major categories: chemical and mechanical.
Chemical cleaning is most commonly used on high quantity production operations and is the most
effective because of the ability to remove grease and oils commonly picked up in preliminary
machining operations.
Mechanical cleaning is usually employed on low quantity production and in mating of sub-
assemblies to the final product. Mechanical cleaning may be achieved by machining (dry), sand
papering, steel wool, sand or grit blasting.
Whether mechanical or chemical cleaning is used, care should be taken to avoid contaminating the
cleaned surface with finger marks, dirty gloves or excessive storage between cleaning and brazing.

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5.A.4. Assembling and Fixturing

The method of assembling joints should be pre-determined before being released to a production
department. The best approach is to select the simplest method wherein the design of the joint is
self-jigged, and capable of securely holding joint members in correct alignment during the heating
and cooling cycle of the brazing operation.
Where it is necessary to employ holding fixtures, the design must incorporate the ability to expand
with the part being brazed. The fixture material must withstand the elevated temperatures of the
brazing operation without distorting, or alloying with the filler metals.
1. Fixtures for torch and furnace brazing must be such that it permits access of the braze
joint without interfering with the even heating of the parts by removing heat through
conduction from the brazing area.
2. Fixtures for induction brazing should be such that all metal except that part which is
being brazed is kept out of the induction coil field.
3. In general, position parts while brazing so that the braze alloy can climb the joint by
capillary action. Positioning joints while brazing that allows the braze to pull out by the
use of gravity and not capillary action can result in a poor braze joints. Joints brazed
using gravity for pull through, must have a proven process specification or WPS for that
joint.
5.A.5. Heating the Braze Joint

EMD is mainly concerned with four methods of applying heat to the braze joint. The four methods
are: torch (TB), furnace (FB), induction (IB), and resistance (RB) heating. The method to be used
may be called out in the weld symbol tail on the Engineering drawing.
5.A.6. Brazing Technique

The procedures for manual or automatic torch brazing are identical except for the manipulation of
the torch. For optimum results, the joint must be clean, properly fluxed and heated. The operator
must be skilled in obtaining the proper flame at the torch tip and the application of the flame to the
braze joint. A rosebud torch tip is recommended for faster, more even heating of the joint.
5.A.7. Post Brazing Cleaning

After the brazing operation, it is always necessary to clean the braze joint if a flux has been used.
Parts that have been brazed in a controlled atmosphere should emerge bright and clean if the
proper procedure was used, and no cleaning will be necessary.
On parts where flux was used, it is imperative that any residue is completely removed from inside
and outside surfaces in order to prevent corrosion and deterioration of the joint. Normal removal of
flux can be accomplished by washing in hot water. However, if the flux has formed into a glasslike
substance, more aggressive measures are necessary for proper cleaning. These may be in the
form of a chemical dip, wire brushing, sand blasting, grit blasting, or chipping.

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In the event that the cleaning is done immediately after brazing, care should be taken to prevent a
rapid chill of the braze joint. The part must be allowed to cool below 600° F (315° C) before
immersing in hot water at a temperature of 120°F (50° C) minimum. Sudden cooling can cause
thermal shock which impairs the strength of the brazed joint.
5.A.8. Inspection
Inspection of the final product actually begins at the start of the process. The parts should be
checked before assembling for proper clearances, correct dimensions, cleanliness, proper fluxing,
operator's technique, heat cycles, and the final cleaning.
The final brazed joint is readily inspected visually. Joints that have been manually fed from one side
only, and are visually accessible from the opposite side, may be considered successfully brazed if a
complete line of braze alloy is visible on the side from which alloy is fed, and there is evidence of
filler metal flow through the joint. There should be no cracks, voids or pits on the side from which
alloy is fed.
Joints that have been fed with a pre-placed ring, plug, or foil of braze allow must show evidence of
filler metal flow through the joint. A complete line of braze alloy in not required.
Joints that are accessible from one side only, must be calculated to determine the amount of alloy
necessary to completely wet the joint. The operator must be trained to determine if the joint was
adequately filled.
Fillets are not required unless specified on the Engineering drawing.
Pressure testing is the most common of inspection processes. The joint should be subjected to a
hydrostatic pressure of at least 1.5 x the operating pressure. Specific testing requirements will be
described on the Engineering print.

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5.B. Cast Iron

Ductile and malleable iron may be structurally damaged if heated to 1400° F (760° C) for
prolonged periods of time, so it is imperative that the brazing be done in the lower
temperature ranges, below 1400° F (760° C). The most compatible brazing alloy, which
brazes below this temperature and is suitable for brazing cast iron to carbon steel,
stainless steel, and copper and nickel alloys, is IND 0517/EMS 913.
Cast iron parts must be thoroughly cleaned after machining, to remove surface deposits
of graphite and sand before they can be consistently and successfully brazed. One
option is an electro-chemical process referred to as Kolene. Blast cleaning can be an
effective alternative to Kolene. The specific cleaning technique must be qualified as an
integral part of the brazing procedure qualification and SPAP process.

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TABLE 5.1
Selection of Base Materials and Compatible Silver Brazing Alloys
Low Carbon and Stainless Copper and Nickel and Carbides and
Low Alloy Steels Steels Copper Alloys Nickel Alloys Tool Steels
IND 0502, EMS 0862 IND 0502, EMS 0862 IND 0502, EMS 0862 IND 0502, EMS 0862 Low Carbon
IND 0504, EMS 0864 IND 0504, EMS 0864 IND 0504, EMS 0864 IND 0504, EMS 0864
IND 0508, EMS 0868 IND 0508, EMS 0868 IND 0508, EMS 0868 IND 0508, EMS 0868
IND 0503, EMS 0863 and Low
*IND 0517, EMS 0913 *IND 0517, EMS 0913 *IND 0517, EMS 0913 *IND 0517, EMS 0913 Alloy Steels
IND 0503, EMS 0863
Stainless
IND 0508, EMS 0868 IND 0508, EMS 0868 IND 0508, EMS 0868 Steels
*IND 0517, EMS 0913 *IND 0517, EMS 0913 *IND 0517, EMS 0913
IND 0501, EMS 0861 IND 0502, EMS 0862 Copper and
IND 0504, EMS 0864 IND 0504, EMS 0864
IND 0508, EMS 0868 IND 0508, EMS 0868
IND 0503, EMS 0863 Copper
*IND 0517, EMS 0913 *IND 0517, EMS 0913 Alloys
IND 0503, EMS 0863

Nickel and
Nickel Alloys
Carbides and
IND 0503, EMS 0863
Tool Steels
Use IND 0510 EMS 870 flux with all of the above applications
* Preferred alloy
NOTE: IND 0508 EMS 868 or IND 0517 EMS 913 cadmium free alloys must be used
when brazing is performed on containers or piping through which liquids for
human consumption may be passed or stored.

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6. Soldering of Ferrous and Non-Ferrous Materials
6.A. General
Soldering is a method of joining materials to themselves or to other materials with a non-ferrous
filler metal having a melting temperature below those of the base metal and not exceeding 800° F
(427° C).
Materials that can be joined by soldering are listed in Table 6.1 P. 44 are in alphabetical order, with
flux requirements.
In successful soldering, the solder is distributed between the two mating parts by capillary attraction
and involves the following:
1) The mating surfaces must be shaped to fit properly.
2) The mating surfaces must be thoroughly cleaned.
3) The mating surfaces must be fully fluxed.
4) The application of proper heat and solder alloy.
5) The removal of excess solder.
6) The removal of the flux residue. (Removal of corrosive flux is mandatory.)
The fit-up solder joints should not exceed 0.005” (0.13 mm) in most cases and can be as low as
0.001” (0.03 mm) on pre-coated materials. The soldering surfaces must be cleaned either
mechanically or chemically. Mechanical cleaning includes: machining, shot or grit blasting,
sanding, grinding, filing, wire brushing, or scuffing with steel wool.
Chemical cleaning consists of pickling or acid dips to remove rust, scale, oxides or sulphides, to
promote a chemically clean surface for soldering. The inorganic acids, hydrochloric, sulphuric,
orthophosphoric, nitric and hydrofluoric, singly or mixed, all fulfill this function, although hydrochloric
and sulphuric acid are most commonly used.
6.B. Joint Design

The joint design should be such that the strength is not entirely dependent upon the solder.
Wherever possible, the joint should be shaped to interlock or engage in a manner to be self-
supporting, with the solder acting as a means of sealing only. Butt joints on equal cross-sections of
material should be confined to sealing only, while lap joints can be made of sufficient width
increased to compensate for the lower strength of the solder material.
In designing joints for soldering, the operating temperature must be taken into consideration, since
the loss of strength is accelerated proportionately with the temperature increase.
Joints designed for electrical conductivity should be such that the current is transferred through the
contact of parent conductors and not through the solder alone.

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Table 6.1
Base Metal, Alloy Special Soldering
or Non- Flux and- Not
Existing Finish Corrosive Flux Corrosive Flux or Solder Recommended
Aluminum X X
Aluminum Bronze X
Beryllium X
Beryllium Copper X
Brass X X
Cadmium X X
Cast Iron X
Chromium X
Copper X X
Copper Chromium X
Copper-Nickel X
Copper-Silicon X
Gold X
Inconel X
Lead X X
Magnesium X
Mang. Bronze Hi-Ten X
Monel X
Nickel X
Nichrome X
Palladium X
Platinum X
Rhodium X
Silver X X
Stainless Steel X
Steel X
Tin X X
Tin Bronze X X
Tin Lead X X
Tin Nickel X X
Tin Zinc X X
Titanium X
Zinc X
Zinc Die Casting X

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6.C. Heating the Solder Joint

The heat for soldering can be obtained from several sources in several different ways: solder iron,
open flame, induction method, hot dip, resistance heating, spray gun, oven heating, and the ultra-
sonic method.
6.D. Fluxing the Solder Joint

Fluxing of the solder joint is a critical item and it is imperative that the proper flux be chosen for a
given material or combinations thereof.
A soldering flux is a liquid, solid, or gaseous material which when heated, is capable of promoting
and accelerating the wetting of the metal with the solder. The flux should be readily displaced from
the metal by the action of the molten solder.
Soldering fluxes are divided into two categories: Corrosive and non-corrosive. The corrosive fluxes
are a formulation of acids and chlorides, which the non-corrosive fluxes are a formulation of basic
water white rosin, and/or alcohol, turpentine, petroleum spirits or bromides.
The choice between corrosive and non-corrosive flux is not always possible on all materials, as can
be gathered by referring to Table 6.1 P. 44. However, it is imperative that non-corrosive fluxes be
used in conjunction with food containers, electrical appliances, and on assemblies where a corrosive
residue cannot be removed. On occasions, problems will present themselves wherein a material or
part not solderable with non-corrosive flux, and which does not lend itself to proper cleaning as an
assembly, must be pre-coated with a solder using a corrosive flux and subsequently joined into the
assembly with a non-corrosive flux.
At EMD, the corrosive fluxes are IND 0990, EMS-894 and IND 0991, EMS-895; the non-corrosive
fluxes are IND 0992, EMS-896 and IND 0993, EMS-897.
6.E. Selection of Solder Alloy

Solder alloys are selected for their properties to flow, sealing ability, electrical conductivity, and for
general body work to provide a smooth surface for finishing.
Solders currently in use at EMD are shown in Table 6.2.

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Table 6.2
Solder Alloys Soldering Fluxes
Material Spec. Trade Name Material Spec. Trade Name
IND 0950, EMS 0850 IND 0990, EMS 0894
EMD Material Specification Number

IND 0951, EMS 0851 IND 0991, EMS 0895
IND 0952, EMS 0852 IND 0992, EMS 0896
IND 0953, EMS 0853 IND 0993, EMS 0897
IND 0954, EMS 0854 IND 0994, EMS 0950
IND 0955, EMS 0855
IND 0956, EMS 0856
IND 0957, EMS 0857
IND 0958, EMS 0858
IND 0959, EMS 0859
IND 0960, EMS 0930
IND 0961, EMS 0931
IND 0962, EMS 0932
6.F. Cleaning to Remove Flux Residue

The removal of corrosive flux residue is mandatory to prevent corrosion within the solder joint or the
immediate area. The removal of this corrosive flux can be accomplished by washing in hot water
containing 2% of concentrated hydrochloric acid per gallon of water, followed by a hot water rinse.
A further neutralizing rinse can be instituted by using hot water and washing soda (sodium
carbonate) and a subsequent rinse.
The residue from non-corrosive rosin fluxes need not be removed unless for appearance sake or
prior to painting. These, if necessary, can be removed with common organic solvents; alcohol,
turpentine, petroleum spirits, etc.
6.G. Inspection and Testing

The need for testing and inspection of soldered joints are normally specified in detail on assembly
drawings. Visual inspection and pressure testing is most common.

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7. Weldment design
The following section deals with guidelines for the design of weldments. Welding Engineering may
deviate from these guidelines to satisfy overall design criteria.
7.A. Edges for Fillet Welds

7.A.1. Gusset and Stiffener Ends -The gussets or stiffeners should be designed to allow a 0.25” (6
mm) between the edge and the toe of the weld. This can be seen in Figure 7.1.
H = Weld Size + 0.25" (6 mm)
Figure 7.1
7.A.2. Fillet Weld Size for Edge of Lap Joint - For thickness (T) of 0.25” (6 mm) and less, the fillet
size can be equal to T. For thickness greater than 0.25 (6 mm), the fillet size shall be T-0.06"
(1.6 mm). See figure 7.2.
0.06 in. [1.6mm]
BASE METAL LESS THAN BASE METAL 0.25” (6mm])

0.25”. (6mm])THICK OR MORE IN THICKNESS
Figure 7.2

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7.A.3. Fillet Weld Edge to Distance - When designing weldments with fillet welds near the edge of
the base metal, the edge distance must be taken into consideration. Figure 7.3 shows the
recommended design requirements for fillet welds near edges.
E
L – Represents the leg length
L T – Represents the base material thickness
E – Represents the edge distance
E >= T + L (leg, weld size)
Figure 7.3
7.A.4. Termination of Weld - Terminate welds a minimum of 0.25" (6 mm) from the edge of high
cyclically loads joints or joints were the load is close to 100% of permissible allowable stress,
see Figure 7.4.
"T" denotes the distance from the

edge the welds terminated.
Figure 7.4
7.B. Weld Size Indications
7.B.1. Minimum Single Weld length - The minimum weld length must be 4 x the nominal weld size
(e.g. a 1/4” (6.35mm) weld must be at least 1” (25.4mm) in length). Wraps are excluded from this
minimum length.
7.B.2. Minimum Intermittent Weld Length - The minimum intermittent weld length for material
thickness including 0.19" (5 mm) and greater is 1.5" (38 mm).
7.B.3. Minimum Weld Size- Minimum weld size are based on the minimum material thickness to
achieve full joint strength.

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7.C. Plug and Slot design

7.C.1. Plug Size - The plug diameter minimum is "T" plus 0.31" (8 mm). The maximum diameter is
2.25 X T, once the minimum diameter conditions are met. The "T" is the thickness of the
material in which the plug will be placed in. The plug spacing is 4 X the plug diameter.
7.C.2. Slot Size - The minimum slot width is "T" plus 0.31" (8 mm). The "T" is the thickness of the
material in which the slot will be placed in. The maximum width is 2.25 X T, once the
minimum width conditions are met. Maximum length is 10 X T.
7.D. Welded & Bolt/Riveted Connection - Welded and bolted/riveted connections cannot share the
joint load. The welds must be designed to withstand the entire connection load alone.
7.E. Spot Weld Design - When joining dissimilar thickness the permissible ratio cannot exceed 3:1. No
work piece may be more than three times the thickness of the other work piece.
When joining sheet metal to a structural member the sheet metal or the combined thickness of
sheets joined cannot exceed 0.15” (3.7 mm).
The shear, minimum spot size, spacing and edge distance overlap for a range of materials are listed
in Table 7.1. for Inch and Table 7.2 for Metric.
Table 7.1
Spot Weld Chart for Inch Material
Thickness of Thinner
Sheet Shear
Decimal Strength Minimum Spot Minimum Spot Minimum
Gauge # (inches) Pounds Dia. Spacing Overlap
22 0.0299 550 0.125 0.50 0.44
20 0.0359 700 0.125 0.50 0.44
19 0.0418 820 0.125 0.75 0.50
18 0.0478 1400 0.19 0.88 0.56
16 0.0598 1750 0.19 1.00 0.63
14 0.0747 2900 0.25 1.25 0.69
13 0.0897 3500 0.25 1.38 0.75
12 0.1046 4100 0.25 1.50 1.00
11 0.1196 5000 0.25 1.75 1.00
10 0.1345 6600 0.31 1.75 1.25
8 0.1644 8000 0.31 2.00 1.50
7 0.1793 10000 0.38 2.00 1.75

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Table 7.2
Spot Weld Chart for Metric Material
Thickness Shear
of Thinner Strength Minimum Minimum Spot Minimum
Sheet (mm) Newton Spot Dia. Spacing Overlap
0.7 2000 4.8 12 10
0.8 2500 6.4 12 10
0.9 3000 6.4 12 10
1.0 3500 6.4 20 12
1.1 4000 6.4 20 12
1.2 4500 6.4 22 14
1.4 6000 6.4 22 14
1.6 7500 7.9 25 16
1.8 9000 7.9 28 16
2.0 10500 7.9 32 18
2.2 12500 9.5 35 18
2.5 15000 9.5 38 20
2.8 17500 14.3 40 20
3.0 20000 14.3 42 22
3.2 21500 14.3 45 22

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8. Terms Definitions & Acronyms
8.A Terms and Definitions
Auto Weld: Auto or automatic welding is a welding process with equipment that controls the
movement of the welding torch or the part, and performs the welding operation
without in-process adjustment of the controls by a welding operator.
Component Engineer: The engineer responsible for certain parts or section of the
Locomotive.
Welding Engineering: The EMD Welding Engineering group that defines the welding
standards, interprets the weld standards, develops the engineering
weld requirements, approves EMD engineering drawings and
approves welding procedures. Also known as the Fabricator’s
Engineer as referenced in AWS D15.1.
Welding Coordinator: The individual responsible for the welding operations in the facility
producing EMD welded components, including welder training and
testing, and weld procedure process development and testing.
Weld Manufacturing Engineering: The EMD Weld Manufacturing group that develops the
welding manufacturing procedures, develops PQR’s and WPS’s,
monitors welding manufacturing processes, and trains and tests
welders.

EMD 01/12/2015 REV. A
Page 53 of 54
AI 1651
8.B Acronyms
AI - Apparatus Instructions
AC - Alternating Current
AISI - American iron Steel Institute
ANSI - American National Standards Institute
AWS - American Welding Society
ASME - American Society of Mechanical Engineers
ASTM - Original know as American Society for Testing Materials
CSA - Canadian Standards Association
CWB - Canadian Welding Bureau
CWI - Certified Welding Inspector
DC - Direct Current
DCEN (DCRP) - Direct Current Electrode Positive (Direct Current Reverse Polarity)
DCEP (DCSP) - Direct Current Electrode Negative (Direct Current Straight Polarity)
EC - European Community
EMD - Electro-Motive Diesel
EMS - Engineering Material Specifications
EN - European Norm Standards
ESFR - Engineering Specification for Factory Rebuilt
ETI - Engineering Test Instructions
ISO - International Organization for Standardization
MIL - Military Standards Specifications
NDT - Non-destructive Testing
SAE - Original know as Society of Automotive Engineers, a standards developing
organization
SPAP - Supplier Product Approval Process
WPQR or PQR - Welding procedures Qualification Record
WPS - Welding Process Specification

EMD 01/12/2015 REV. A
Page 54 of 54

Engineering Apparatus Instructions: N. F. Bratkovich 1651

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Engineering Apparatus Instructions: N. F. Bratkovich 1651

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________________________________________________________________________________________________________________________

ENGINEERING FIRST ISSUED

SUBJECT EMD WELDING, BRAZING AND SOLDERING SPECIFICATION

REF DRAWINGS See Applicable References

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A.I. 1651 check list

1.A. Procedure Qualification

2. Class, Inspection and Acceptance

2.A. Weld Classes

3. Arc Welding Processes and Electrodes

3.A. Gas Metal Arc Welding

4.A. Technical Review (Manufacturing Control)

5. Brazing of Ferrous and Non-Ferrous Metals

6. Soldering of Ferrous and Non-Ferrous Metals

8. Terms Definitions & Acronyms

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A.I. 1651 Check List

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1.A. Procedure Qualification

1.A.2. Welding Procedure Qualification

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1.A.3. Welding Processes

1.A.4. Welding Consumables

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1.B. Welding Qualification & Certification

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1.B.2.2. Name a responsible Welding Coordinator:

1.B.2.3. Welding Coordinator responsibilities:

1.B.2.4. Minimum internal weld testing and training area equipment:

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1.C. Welding Requirements

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Technique of Staggering Weld Passes View A

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GROOVE WELD FILLET WELD

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2. Class, Inspection and Acceptance

2.A. Weld Classes

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2.C. Acceptance Standards

Angle Pictorial 110º MIN. 105º MIN. 90º MIN.

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L = SPECIFIED LEG LENGTH

FLAT CONVEX CONCAVE

ACCEPTABLE FILLET WELD PROFILES

INSUFFICIENT EXCESSIVE OVERLAP UNDERCUT INSUFFICIENT LEG INCOMPLETE

UNACCEPTABLE FILLET WELD PROFILES

ACCEPTABLE GROOVE WELD PROFILE IN BUTT JOINTS

EXCESSIVE INSUFFICIENT EXCESSIVE OVERLAP

UNACCEPTABLE GROOVE WELDS PROFILES IN BUTT JOINTS

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MULTI-PASS FILLET WELD MULTI-PASS FILLET WELD WITH

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2.C.13. Radiographic Standards - If radiographic testing (RT) is specified on an Engineering

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“Rosebud” Weld tie-in