Filler Materials Testing
Filler Materials Testing
Filler Materials Testing
application note: The German text of this Procedural Instructions VA 918 490 will be binding.
Content Page
1 General information, Scope 3
2 Requirements to be met by filler materials 3
2.1 Filler metals rail for vehicle construction work in accordance with the 3
DIN EN 15085 series of standards, DIN 27201-6 and DB Guidelines
951.0010 and 951.0020
2.2 Filler metals for rail joint welding and rail resurfacing by welding in 4
accordance with DB Guideline 824
2.3 Filler metals for railway bridge construction work and other engineer- 4
ing structures in accordance with DB Guidelines 804
3 Certification procedure 5
3.1 Initial product certification 5
3.2 Transfer of product certification 5
3.3 Product modification / -extension 5
3.4 Approval certificate 6
3.5 List of code numbers 7
3.6 Validity 7
3.7 Expiry and extension 7
3.8 Costs 7
3.9 Online register of certified filler metals 7
4 Quality assurance 8
5 Product marking/labelling and declaration of conformity 8
6 Liability for defects 8
7 Jointly applicable standards, regulations and guidelines 9
Annexes:
Annex 1 Application for certification of filler metals
Annex 2 Approval certificate for filler metals and welding consumables
Annex 3 Information on the scope of approval certificates issued for certified
materials
Annex 4 Requirements to be met by filler metals used for joint welding and
build-up welding on rail vehicles, railway bridges and other engineering
structures
Annex 5 Requirements to be met by filler metals used for rail joint welding and
rail resurfacing by welding
Annex 6 Requirements governing the marking/labelling of filler metals
2.1 Filler metals for rail vehicle construction work in accordance with the DIN EN 15085
series of standards, DIN 27201-6 and DB Guidelines 951.0010 and 951.0020
2.1.1 According to DIN EN 15085-4, Fig. 5.3.2, filler metals used for rail construction work
shall meet the following requirements:
Classification of welding accessories: according to the relevant DIN EN standards relating
to the classification of filler metals, based on the “A” classification system
Type qualification testing:
a valid approval certificate with the planned welding process, the materials, the welding posi-
tions and the current type shall be available for each welding additive. The basis for the ap-
proval certificate is a suitability test according to
DIN EN 14532-1 Welding consumables - Test methods and quality requirements Part
1: Primary methods and conformity assessment of consumables for steel, nickel and
nickel alloys
DIN EN 14532-3 Welding consumables - Test methods and quality requirements Part
3: Conformity assessment of wire electrodes, wires and rods for welding of aluminium
alloys
Factory production control (FPC):
according to the DIN EN 13479:2004 Welding consumables - General product standard for
filler metals and fluxes for fusion welding of metallic materials
2.1.2 In accordance with the provisions of DB Guidelines 951.0010 (for rail vehicle
construction) and 951.0020 (for rail vehicle maintenance), filler metals shall meet the follow-
ing requirements:
Product certification by DB Systemtechnik as verified by a DB approval
certificate. The requirements to be met for product certification are:
Initial inspection by the manufacturer, supplier or trader and its FPC system in
accordance with DIN EN 13479:2004, Annex ZA, System 2+ with verification provided via an
initial inspection certificate issued by one of the FPC certification bodies listed in section
2.1.2.1 below. The FPC system shall to continuous monitoring conducted (at least once a
year) by one of the FPC certification bodies listed in section 2.1.2.1.
Type qualification testing as set out in DIN EN 14532-1 to DIN EN 14532-3 (initial type
testing as per DIN EN 13479:2004) to be carried out by one of the product testing centres
listed in Sec. 2.1.2.1 below. Type qualification testing shall also meet the requirements set
out in Annex 4 to these PIs.
2.2 Filler metals for rail joint welding and rail resurfacing by welding in accordance with
DB Guideline 824
Detailed specifications regarding the use of filler metals for resurfacing welding work on rails and
other parts of the permanent way and for the welding of rail joints are provided in DB
Guideline 824.
The requirements set out in Sec. 2.1.2.1 are supplemented by those in Annex 5 to these PIs.
Certification is carried out by DB Systemtechnik (see Sec. 2.1.2.1). The scope of type
qualification testing shall be agreed between the certification body for product certification
and the product testing centre. The certification body for product certification shall specify the
product testing centre to be used following consultation with the applicant. Before filler metals
are used for work for DB AG, operational testing shall be carried out by DB Netz AG in
addition to type qualification testing.
2.3 Filler metals for railway bridge construction work other engineering structures in
accordance with DB Guidelines 804
Filler metals used in areas subject to technical approval by the building inspectorate shall meet
the requirements of European Directive 89/106/EEC as implemented by Regulation (EU)
No. 305/2011. In accordance with Annex ZA to DIN EN 13479, filler metals to be used in these
areas shall be labelled with the CE mark based on System 2+.
For railway bridge construction work and other engineering structures for DB AG, DB
Guidelines 804 and DB railway standard DBS 918 005 shall also apply. The DB railway stand-
ard DBS 918 005 stipulates the following requirements:
Product certification by DB Systemtechnik as verified by a DB approval certificate. The
requirements to be met for product certification are:
o Initial inspection of manufacturer, supplier or trader and its FPC system in accordance with
DIN EN 13479:2004, Annex ZA, System 2+ with verification provided via an initial
inspection certificate issued by one of the FPC certification bodies listed in section 2.1.2.1
below. The FPC system shall to continuous monitoring conducted (at least once a year) by
one of the FPC certification bodies listed in section 2.1.2.1.
o Type qualification testing as set out in DIN EN 14532-1 to DIN EN 14532-3 (initial type
testing as per DIN EN 13479:2004) by one of the product testing centres listed in
Sec. 2.1.2.1 below.
3. Certification procedure
3.1 Initial product certification
Applications for product certification shall be submitted to DB Systemtechnik by the applicant
(manufacturer, supplier or trader) using the application form shown in Annex 1 of these PIs.
Application documents shall be sent by e-mail to the e-mail address listed in Sec. 2.1.2.1
Applications shall be accompanied by:
A description of the product and a current TÜV identification sheet
If product is manufactured under licence: a manufacturer's certificate and a declaration of
consent using the pre-printed form in Annex 1
If a filler metal is manufactured in several production facilities:
o A list of all production facilities using the pre-printed form in Annex 1.
o Evidence that all production facilities manufacture the product according to the same
specifications.
Type qualification report and the results for the filler metal.
Evidence of initial inspection of the FPC system according to DIN EN 13479: 2004 (certifi-
cate, report) or, if already provided, evidence of monitoring of FPC system (monitoring re-
port).
Note: all submitted documents shall be submitted in German language version.
3.6 Validity
Certification shall be deemed valid if the period of validity has not expired and the requirements
of these PIs are met. If no extension is requested after the expiry of the certificate is invalid and
the DB-approval certificates are deleted rail vehicles maintained by SLV Halle.
Certification applies only to the manufacturer, supplier or trader stated in the certificate and its
FPC-certified / monitored production facilities (corresponding to the list of code numbers).
The brand name appearing in the approval certificate can only be used in association with the
specified manufacturer, supplier or trader and the DB approval number / code number.
A DB approval number or brand name shall not be used for any production facility that has not
been inspected as part of the DB approval procedure.
3.8 Costs
The costs for certification, expansion, transfer and extension shall be borne by the applicant.
These fees include management of and free access to the online register of rail vehicles
maintained by SLV Halle.
The costs of carrying out operational testing (see Sec. 2.2) shall be borne by DB AG.
The approval certificates can be accessed free of charge from the websites “www.en15085.net”
or “www.en1090.net” from where they can be downloaded as pdf files.
4 Quality assurance
To verify quality consistency, the FPC system according to DIN EN 13479: 2004 operated by
the manufacturer, supplier or trader shall be monitored at least once a year by t one of the FPC
certification bodies listed in section 2.1.2.1 below and the results documented in a monitoring
report for DB Systemtechnik.
If FPC monitoring is refused even after a reminder notice has been issued, the product
certification body reserves the right to revoke the approval certificates.
Annex 1
DB Systemtechnik
Zertifizierungsstelle für Schweißzusätze
14774 Brandenburg-Kirchmöser
Germany
Applicant: Telephone:
Street: Fax:
Postcode, town E-mail:
Initial certification 1)
Transfer of a DB certification 1) (Part 1)
Extension of an existing DB certification 1) (Part 2)
Product modification / -extension of an existing DB certification1) (Part 3)
Change of company name of existing DB certifications1) (Part 4)
This application to initial certification for the following filler metal:
Type of filler metal:
Brand designationc):
Designation of standard3):
Area of application applied for:
Welding procedures:
Welding positions:
Diameter range:
Remarks /
Welding conditions:
1)
Tick appropriate box.
2)
The brand designation is linked to the manufacturer and the DB-approval number.
3)
Use the mandatory designation of the standard as per the “A” system (yield strength and notch impact
energy parameters – as far as specified in the standards – as well as chemical composition).
4)
For Al - alloys is to be given to materials after DIN EN 573.
Evidence of origin: 5)
DB approval number: Brand designation Manufacturer (name, address)
Declaration of consent:
.............................................................. ...............................................................................
Place and date Signature (supplier/manufacturer) and stamp
The applicant
- undertakes to comply with accepted engineering standards (EN 15085-4 as well as the valid
DIN EN standards for filler metals),
- agrees that the certified filler metals be included in the SLV Halle Rail Vehicle online register,
viewed in the free access area and downloaded,
- assumes the costs of the certification procedure.
Enclosures:
Product description
TÜV identification sheet
Manufacturer's certificate / Declaration of consent for manufacture under licence
Test report concerning suitability testing of the filler metal
Test report concerning initial inspection of the FPC
Evidence of monitoring the FPC
__________________________________ _______________________________________
Place, date Stamp and signature (the applicant)
5)
Required if the applicant is not also the production facility
We hereby apply for transfer of the DB certification for filler metals from
Company:
.......................................................................................................................................
to our brand designation for the following products:
We undertake to inform you of any change to the evidence of origin without delay.
.............................................................. ...............................................................................
Place and date Signature (supplier/manufacturer) and stamp
Declaration of consent:
__________________________________ _______________________________________
Place, date Stamp and signature (the applicant)
.............................................................. ...............................................................................
Place and date Signature (supplier/manufacturer) and stamp
Declaration of consent:7)
We confirm that we continue to supply the above-mentioned product(s) to company:
.....................................................................................................................................................
and accept extension of the transfer. We undertake to inform you of any changes without delay.
__________________________________ _______________________________________
Place, date Stamp and signature (the applicant)
6)
Mandatory designation of standard as per the “A” system
7)
Required if the applicant is not also the production facility
We hereby apply for modification / extension of an existing DB certification for filler metals for
the following products:
We undertake to inform you of any change to the evidence of origin without delay.
.............................................................. ...........................................................
Place and date Signature and stamp
Enclosures:
Product description
TÜV identification sheet
Test report concerning suitability testing of the filler metal
Test report concerning initial inspection of the FPC
Evidence of monitoring the FPC
.............................................................. ...............................................................................
Place and date Signature (supplier/manufacturer) and stamp
Enclosures:
Test report concerning suitability testing of the filler metal
Test report concerning initial inspection of the FPC
Evidence of monitoring the FPC
Annex 2
DB Systemtechnik
Zertifizierungsstelle für Schweißzusätze
14774 Brandenburg-Kirchmöser
Germany
Zulassungszertifikat
für
Schweißzusätze und Schweißhilfsstoffe
Bemerkungen / ./.
Schweißbedingungen:
1)
For details of other materials covered by the approval certificate: see VA 918 490, Annex 3.
The second block is a three-digit number that identifies the owner of the certification (manu-
facturer, supplier or trader).
Examples:
1. Approval number in the approval certificate:
42.999.01
type of filler metal sequential number
company no.
Materials group 1 as defined in CEN ISO/TR 15608 (unalloyed steels with ReH ≤ 460 MPa)
1.1 S235JR to S275J2+N DIN EN 10025-2 1.1
S275N DIN EN 10025-3
S275M DIN EN 10025-4
1.2 S235JR to S355K2 DIN EN 10025-2 1.1, 1.2
S275N to S355N or NL2) DIN EN 10025-3
S275M to S355M or ML2) DIN EN 10025-4
GE200, GE240 DIN EN 10293
B500A, B500B DIN 488-1
1.3 S235JR to S355K2 DIN EN 10025-2 1.1, 1.2, 1.3, 2.1
S275N to S460N or NL2) DIN EN 10025-3
S275M to S460M or ML2) DIN EN 10025-4
GE200, GE240 DIN EN 10293
B500A, B500B DIN 488-14)
1.4 S235JR to S355K2 DIN EN 10025-2 1.1, 1.2, 1.4
S275N to S355N or NL2) DIN EN 10025-3
S275M to S355M or ML2)_ DIN EN 10025-4
S275J0W - S355J2W DIN EN 10025-5
GE200, GE240 DIN EN 10293
Materials group 2 as defined in CEN ISO/TR 15608
(Thermomechanically treated fine-grained steels with ReH > 360 MPa)
2.1 S420M to S460M or ML2) DIN EN 10025-4 1.1, 1.2, 1.3, 2.1
S355MC to S460MC DIN EN 10149-2
2.2 S500MC to S700MC DIN EN 10149-2 1.2, 1.3, 2.1, 2.2 3)
Materials group 3 as defined in CEN ISO/TR 15608 (quenched and tempered fine-grained steels with
ReH > 360 MPa)
3.1 S460Q to S690Q, QL or QL 12) DIN EN 10025-6 1.2, 1.3, 2.1, 2.2, 3.1 3)
3.2 S890Q to S960Q, QL or QL 12) DIN EN 10025-6 2.2, 3.1, 3.2 3)
Materials group 11 as defined in CEN ISO/TR 15608 (unalloyed steels with carbon content > 0.25%)
11 E295 to E360 DIN EN 10025-2 11
C35 to C60 DIN EN 10083-2
GE300 DIN EN 10293
1)
In addition to the steels listed, all unalloyed steels in the same strength class but designated in
accordance with another steels standard are also considered to be covered by the approval certificate.
This also applies to steels supplied in different delivery conditions (e.g. S690Q DIN EN 10025-6 also
includes S700MC DIN EN 10149-2).
2)
The approval certificate applies to steels with the delivery condition codes NL, ML or QL only if the
required Charpy V-notch impact energy is included as part of the relevant standardised material desig-
nation.
3)
The approval certificate only applies to materials that lie within the range for the upper yield strength
(ReH) specified in the section “Scope of approval certificate”.
4)
The approval certificate also applies to the welding of load-bearing butt welded joints in reinforcing steel
(as specified in DIN EN ISO 17660-1, 7.2) if in the relevant standardised material designation the code
number indicating yield strength is at least “50”.
Materials group 7 as defined in CEN ISO/TR 15608 (ferritic, martensitic stainless steels)
7.1 X2CrNi12 (1.4003) DIN EN 10088 7.1
X2CrTi12 (1.4512) DIN EN 10088
X5CrNiMoTi 15-2 (1.4589) DIN 5512-3
Materials group 8 as defined in CEN ISO/TR 15608 (austenitic stainless steels)
8.1 without Mo X5CrNi18-10 (1.4301) DIN EN 10088 8.1 without Mo
X6CrNiTi18-10 (1.4541) DIN EN 10088
8.1 X5CrNi18-10 (1.4301) DIN EN 10088 8.1
X6CrNiTi18-10 (1.4541) DIN EN 10088
X5CrNiMo17-12-2 (1.4401) DIN EN 10088
X6CrNiMoTi17-12-2 (1.4571) DIN EN 10088
3)
In addition to the steels listed, all steels in the same materials group are also considered to be covered
by the approval certificate.
Table 3: Aluminium and aluminium alloys (material designation as per DIN EN 573)
Filler metal as per Certified materials Other materials covered by the Applicable material
DIN EN ISO 18273 approval cert. groups according to
CEN ISO / TR 15608
S Al 5556A (AlMg5Mn) DIN EN AW-5083 DIN EN AW-5049 [Al Mg2Mn0,8] 22.2, 22.3, 22.4
or DIN EN AW-7020 DIN EN AW-5052 [Al Mg2,5] 23.1, 23.2
S Al 5356 (AlMg5Cr(A)) DIN EN AW-5754 [Al Mg3]
or DIN EN AW-5083 [Al
S Al 5087 Mg4,5Mn0,7]
(AlMg4,5MnZr) DIN EN AW-5019 [Al Mg5]
or DIN EN AW-6060 [Al MgSi]
S Al 5183 DIN EN AW-6063 [Al Mg0,7Si]
(AlMg4,5Mn0,7(A)) DIN EN AW-6005A [Al SiMg]
DIN EN AW-6082 [Al Si1MgMn]
DIN EN AW-7020 [Al Zn4,5Mg1]
S Al 5754 (AlMg 3) DIN EN AW-5754 DIN EN AW-5052 [Al Mg2,5] 22.3
DIN EN AW-5754 [Al Mg3]
S Al 4043 (AlSi5) DIN EN AW-6005A DIN EN AW-6005A [Al SiMg] 23.1
or DIN EN AW-6060 [Al MgSi] ]
S Al 4043A (AlSi5(A)) DIN EN AW-6063 [Al Mg0,7Si]
DIN EN AW-6082 [Al Si1MgMn]
AlSi casting alloys AlSi and AlSiMg casting alloys 24.1, 24.2
up to 7% Si
Al-Gusslegierungen in Kombina- 22.1-22.4 / 24.1-24.2
tion mit Al-Knetlegierungen 23.1-23.2 / 24.1-24.2
S Al1450 DIN EN AW-1050A DIN EN AW-1098 [Al 99,98] 21
(Al 99,5Ti) DIN EN AW-1080A [Al 99,8]
DIN EN AW-1050A [Al 99,5]
DIN EN AW-1200 [Al 99,0]
Materials group 71 as defined in CEN ISO/TR 15608 (lamellar graphite cast iron / grey cast iron)
71 EN-GJL-100 bis DIN EN-GJL-350 DIN EN 1561 71
Materials group 72 as defined in CEN ISO/TR 15608 (spheroidal graphite cast iron)
72 EN-GJS-350 bis DIN EN-GJS-900 DIN EN 1563 72
Materials group 73 as defined in CEN ISO/TR 15608 (malleable cast iron)
73 EN-GJMW-350 bis DIN EN-GJMW-800 73
DIN EN 1562
2. Scope of approval certificate in the case of cold-wire feeder systems and hybrid weld-
ing processes:
If a certified GMAW wire electrode is fed as “cold wire” (e.g. 52 with cold wire feeding) or if a
hybrid welding process is used (e.g. 52 / 135), the scope of the approval certificate with respect
to materials is the same as that for the certified GMAW process.
3. Build-up welding:
Approval applies only to the tested material listed under “Scope of approval certificate” or for the
specified hardness.
4. Rail steels:
4.1 Rail joint welding:
In addition to the tested rail steel listed under “Scope of approval certificate” and designated in
accordance with the DIN EN 13674-1 standard, all rail steels of lower strength are also
considered to be covered by the approval certificate, including rail steels designated in
accordance with other relevant standards.
Note:
The final 10 mm below the top of the rail shall be welded with a filler metal that has been
approved for build-up welding (rail resurfacing) work on the rail steel.
4.2 Rail resurfacing by welding:
Approval applies only to the tested rail steel listed under “Scope of approval certificate” and
designated in accordance with the DIN EN 13674-1, including rail steels of the same hardness
designated in accordance with other relevant standards.
Annex 4: Requirements to be met by filler metals used for joint welding and build-
up welding on rail vehicles, railway bridges and other engineering structures
1. General requirements
All of the filler metals covered by the standards listed in Table 1 may be certified. The
restrictions and/or supplementary requirements listed in Table 2 also apply.
If different grades of steel are to be joined by welding, the minimum requirement to be met by
the all-weld metal shall be that for the steel grade with the lower yield strength.
Table 1: List of welding filler metal product groups for use in rail vehicle
construction
Construction product / Product group Applicable standard
Welding consumables – Rods, wires and deposits for tungsten inert gas DIN EN ISO 636:
welding of non-alloy and fine-grain steels 2016-05
Welding consumables – Covered electrodes for manual metal arc welding of DIN EN ISO 18275:
high-strength steels 2012-07
Welding consumables - Covered electrodes, wires, rods and tubular cored DIN EN ISO 1071:
electrodes for fusion welding of cast iron 2016-05
Welding consumables – Covered electrodes for manual metal arc welding of DIN EN ISO 3581:
stainless and heat-resisting steels 2016-12
Welding consumables – Covered electrodes for manual metal arc welding of DIN EN ISO 2560:
non-alloy and fine grain steels 2010-03
Welding consumables – Covered electrodes for manual metal arc welding of DIN EN ISO 3580:
creep-resisting steels 2011-05
Welding consumables -— Rods for gas welding of non alloy and creep- DIN EN 12536: 2000-08
resisting steels
Welding consumables – Solid wire electrodes, tubular cored electrodes and DIN EN ISO 14171:
electrode/flux combinations for submerged arc welding of non alloy and fine 2016-12
grain steels
Welding consumables – Covered electrodes for manual metal arc welding of DIN EN ISO 14172:
nickel and nickel alloys 2016-02
Welding consumables – Fluxes for submerged arc welding and electroslag DIN EN ISO 14174:
welding 2012-05
Welding consumables – Wire electrodes and weld deposits for gas shielded DIN EN ISO 14341:
metal arc welding of non alloy and fine grain steels 2011-04
Welding consumables – Wire electrodes, strip electrodes, wires and rods for DIN EN ISO 14343:
arc welding of stainless and heat resisting steels 2010-04
Welding consumables – Welding consumables for hard-facing DIN EN 14700: 2014-07
Welding consumables –Wire electrodes, wires, rods and deposits for gas DIN EN ISO 16834:
shielded arc welding of high strength steels 2012-08
Welding consumables – Tubular cored electrodes for gas shielded and non- DIN EN ISO 17632:
gas shielded metal arc welding of non-alloy and fine grain steels 2008-08
Welding consumables – Tubular cored electrodes and rods for gas shielded DIN EN ISO 17633:
and non-gas shielded metal arc welding of stainless and heat-resisting 2011-03
steels
Welding consumables – Tubular cored electrodes for gas shielded metal arc DIN EN ISO 17634:
welding of creep-resisting steels 2015-12
Welding consumables - Wire electrodes, wires and rods for welding of alu- DIN EN ISO 18273:
minium and aluminium alloys 2014-06
Welding consumables – Solid wire electrodes, solid strip electrodes, solid DIN EN ISO 18274:
wires and solid rods for fusion welding of nickel and nickel alloys 2011-04
Welding consumables – Tubular cored electrodes for gas-shielded and non- DIN EN ISO 18276:
gas-shielded metal arc welding of high strength steels 2006-09
Welding consumables – Wire electrodes, wires, rods and deposits for gas- DIN EN ISO 21952
shielded arc welding of creep-resisting steels 2012-08
Welding consumables – Solid wire electrodes, tubular cored electrodes and DIN EN ISO 26304:
electrode-flux combinations for submerged arc welding of high strength 2009-11
steels
Welding consumables – Solid wires and rods for fusion welding of copper DIN EN ISO 24373:
and copper alloys 2009-08
Welding consumables – Solid wire electrodes, tubular cored electrodes and DIN EN ISO 24598:
electrode-flux combinations for submerged arc welding of creep-resisting 2012-08
steels
Coating type “RR” with an electrode efficiency Approval applies only to:
125 % and RC, thick covering(D/d 1.6) S235 (St 37) with t 16 mm and a 10 mm
and a designator for the Charpy V-notch impact S275 (St 44) with t 12 mm and a 8 mm
energy A or 0 as detailed in DIN EN ISO 2560. 1) S355 (St 52) with t 8 mm and a 6 mm.
[previously: RR5, RR(C)5, RR6, RR(C)6 as per
DIN 1913]
Coating type “RR” with an electrode efficiency Approval applies only to fillet welds with a 10 mm
> 125 % and RA with an electrode efficiency and for the materials S235 to S355.
> 160 % as per DIN EN ISO 2560.
[previously: RR11 with an efficiency > 150 %,
AR11 with an efficiency 160 % as per DIN 1913]
1)
D = diameter of electrode covering; d = diameter of core wire
Table 2 (continued)
Filler metals Restrictions / Additional requirements
Welding rods, wire electrodes and flux-cored wire electrodes for gas metal arc welding in ac-
cordance with
DIN EN ISO 636, DIN EN ISO 1071, DIN EN ISO 14341, DIN EN ISO 14343, DIN EN ISO 16834, DIN
EN ISO 17632, DIN EN ISO 17633, DIN EN ISO 17634, DIN EN ISO 18273,
DIN EN ISO 18274, DIN EN ISO 18276, DIN EN ISO 21952
For unalloyed steels and fine- Approval for welding rods, wires and flux-cored wires covers the
grained construction steels with scope specified in the approval certificate in combination with the
ReH 500 MPa tested shield gas(es) as set out in DIN EN 14532-1, Table 42).
The shielding gas main group(s) listed in the approval certificate
is/are designated in accordance with DIN EN ISO 14175.
The wall thickness limits in DIN EN ISO 14532-1 do not apply.
For stainless steels, quenched and Approval for welding rods, wires and flux-cored wires covers the
tempered fine-grained construction scope specified in the approval certificate in combination with the
steels with tested shield gas(es) as set out in DIN EN 14532-1, Table 42).
ReH 500 MPa Shielding gas subgroup(s) listed in the approval certificate is/are
designated in accordance with DIN EN ISO 14175..
The wall thickness limits in DIN EN ISO 14532-1 do not apply.
For aluminium and aluminium al- Approval for welding rods, wires and flux-cored wires covers the
loys scope specified in the approval certificate in combination with the
tested shield gases as set out in DIN EN 14532-3.
The shielding gas main group listed in the type-approval certificate is
designated in accordance with DIN EN ISO 14175.
For cold-wire laser welding and Approval for GMAW wire electrodes also covers:
hybrid laser welding welding process 52 with cold-wire feeding
The combined welding processes 52 / 135 or 52 / 131.
Granulated flux and wire electrodes for submerged arc welding in accordance with
DIN EN ISO 14171, DIN EN ISO 14174, DIN EN ISO 16834, DIN EN ISO 26304, DIN EN ISO 24598
Granulated welding flux Approval for granulated flux applies to the wire electrodes for
submerged arc welding (SAW) listed in the scope of the approval
certificate and designated in accordance with the relevant standard
for SAW wire electrodes.
The wall thickness limits in DIN EN ISO 14532-1 do not apply.
Wire electrodes for submerged arc Approval for a SAW wire electrode applies to all approved granular
welding fluxes whose scope of approval contains the relevant SAW wire
electrode.
2)
If type qualification testing is carried out with shielding gases from two different main groups or
subgroups, the testing shall also cover the intermediate gas main groups or subgroups.
Parameter / quantity under test Type of test Relevant standard Measuring instruments / Notes
equipment 1)
Dimensions ./.
- Diameter Dimensional measurement DIN EN ISO 544 Vernier callipers
- Coating thickness Dimensional measurement - Vernier callipers
- Length Dimensional measurement DIN EN ISO 544 Measuring rod
- Grain size Dimensional measurement DIN EN ISO 14174 Test sieve
Physical condition
- Adhesion of electrode coating Visual inspection - Visual inspection
- Clamping surface, ignition sur- Visual inspection, dimen- DIN EN ISO 544 Visual inspection, measur-
face sional measurement DIN EN 22401 ing rod
- Electrode efficiency Dimensional measurement Scales, vernier callipers,
- measuring rod
- Adhesion of copper coat (or Coiling test, visual inspec- Visual inspection, magnify-
similar) tion DIN EN ISO 544 ing glass
- Spools, cast, helix
Dimensional measurement DIN EN 14532-3 Visual inspection, plane nur für Aluminium
- Surface roughness table, measuring rod
Visual inspection magnifying glass, micro-
scope
Marking/Labelling Visual inspection DIN EN ISO 544 Visual inspection ./.
Chemical composition Handbuch f. d. Eisenhüttenla- ./.
- Analysis of rod and wire materi- Chemical analysis boratorium [Lab Manual for Chemical laboratory
als Chemical analysis Ferrous Metallurgy] (wet chemical analysis,
- Analysis of weld metal also: DIN EN ISO 6847 spectral analysis)
Weldability Electrode acceptance test ./. Visual inspection [previously: E DIN 1913-101]
Weld metal DIN EN ISO 15792-1 Tensile testing machine, ./.
- Mechanical properties Tensile strength test 2) DIN EN DIN EN ISO 5178 pendulum impact tester,
Notched-bar impact test DIN EN ISO 6892-1 cooling equipment, ther-
DIN EN ISO 148-1 mometer
DIN EN ISO 9016
Delta ferrite content Dimensional measurement DIN EN ISO 8249 Annex E (EN14532) Only for Cr-Ni alloys
Metallographic lab
Parameter / quantity under test Type of test Relevant standard Measuring instruments / Notes
equipment 1)
Welded joint Visual inspection DIN EN ISO 17637 Visual inspection ./.
- Mechanical properties Tensile strength test DIN EN ISO 15792-2 (steel) Tensile testing machine,
Bending test 2) DIN EN ISO 4136 Bending machine,
Notched-bar impact test DIN EN ISO 5173 Pendulum impact tester,
DIN EN ISO 148-1 Cooling equipment, thermome-
DIN EN ISO 9016 ter
- Hardness profile Hardness testing DIN EN ISO 9015-1 hardness tester after Brinell or ./.
DIN EN ISO 6507-1 Vickers
DIN EN ISO 6506-1
- Weld structure / bead sequence Macrosection DIN EN ISO 17639 Metallographic lab ./.
Microsection
Susceptibility to hot cracking 3) Double fillet weld test DIN EN ISO 17641-2 Magnifying glass, Surface in- ./.
specimen spection tools
Internal defects Fillet weld test specimen DIN EN ISO 15792-3 Destructive and non- ./.
(FW) DIN EN 12517 destructive testing equipment
Butt weld (BW)
Hydrogen content Measurement of hydrogen DIN EN ISO 3690 Lab equipment to determine ./.
content in weld metal hydrogen content
IGC resistance Cross-over joint test DIN EN ISO 3651-2 Lab equipment for corrosion ./.
testing
1) In addition to the test instruments and equipment listed, welding equipment may also be needed to make the requisite test pieces / specimens from the par-
ticular filler metal under test.
2) Testing in untreated state within 72 hours of the start of the manufacturing process. This test shall be carried out for all ferritic covered electrodes, flux-cored
wire electrodes and granulated welding flux with the exception of hydrogen-controlled electrodes of type H5 or H10.
3) Only required for “Cr-Ni alloys with FN < 3”.
4)
Table 5: Extent of a weld metal test specimen X120Mn12 (1.3401) with the material group 72 or 1.2 according to CEN ISO / TR
15608
For the weld specimen X120Mn12 / GJS 400 and X120Mn12 / S355J2 is than an overlap weld sample (X120Mn12, t = 4 - 8 mm) to be welded, each
with a single-layer and multi-layer fillet weld. The scope of testing is given in the following table.
Parameter / quantity under test Type of test Relevant standard Measuring instruments / equipment1)
- surface inspection dye penetrant testing (PT) DIN EN ISO 3452-1 penetrant system
DIN EN ISO 9015-1
Hardness testing from the
- Hardness profile DIN EN ISO 6507-1 hardness tester after Brinell or Vickers
middle macrosection
DIN EN ISO 6506-1
three macrosection
- Weld structure / bead se-
(beginning, middle, end of DIN EN ISO 17639 Metallographic lab
quence
weld metal test specimen)
1. Supplementary requirements to be met by filler metals used for rail joint weld-
ing
Rail profile Steel grade as per DIN Maximum ap- Minimum ap- No. of load
EN 13674-1 plied force (Po) plied force cycles
(Pu)
UIC R260, R350HT - 340 kN + 10 kN 2 x 106
S 54 R260, R350HT - 250 kN + 10 kN 2 x 106
S 49 R260 - 225 kN + 10 kN 2 x 106
Po
______________
440 mm 120 mm
_______________________________ __ _
Pu 1000 mm Pu
Fig. 1: Sample label in accordance with DIN EN 13479: 03.2005 (without reference to a
declaration of performance)
Mustermarke 100
MAG wire electrode for welding unalloyed and low-alloy steels
DIN EN ISO 14341-A - G 46 4 M 3Si1
Shielding gas as per DIN EN ISO 14175 - M 21
Approvals: TÜV (00000); GL, DB approval no.: 42.999.01/01
0035
05
0035-CPD-12345
DIN EN 13479 + MusterWeld Schweißtechnik KG, 1000 Berlin, Lichtbogenstr. 1
DIN EN ISO 14341
Weight Serial no. ø
15 kg 47111 1.2 mm
Mustermarke 100
MAG wire electrode for welding unalloyed and low-alloy steels
DIN EN ISO 14341-A - G 46 4 M21 3Si1
Shielding gas as per DIN EN ISO 14175 - M 21
Approvals: TÜV (00000); GL, DB approval no.: 42.999.01/01
0035 05
Ref. MM100-2013-06
DIN EN 13479: 2004
MusterWeld Schweißtechnik KG, 1000 Berlin, Lichtbogenstr. 1
For use in metallic www.musterweld.de
structures or in com-
posite metal and con- Weight Serial no. ø
crete structures 15 kg 47111 1.2 mm