231121_Eargle_ISO5817 VT-3 Training Material.pptx

Click to insert Picture Highlights of WN 10570  Mr. Sidney Eargle  Weld Inspector  KION NA - Summerville, SC WN 10570 • KION/Linde Works Standard providing fabrication and quality requirements for arc welding of steel components • Three (3) parts 1. Visual inspection requirements (acceptance...

Click to insert Picture Highlights of WN 10570  Mr. Sidney Eargle  Weld Inspector  KION NA - Summerville, SC WN 10570 • KION/Linde Works Standard providing fabrication and quality requirements for arc welding of steel components • Three (3) parts 1. Visual inspection requirements (acceptance criteria per EN ISO 5817) 2. Symbols and dimensioning (per guidelines of EN 22553) 3. Shielding gases, weld metal and welding positions • Also describes requirements for welded components groups to assure that they are only manufactured by authorized companies (ISO 3834). 2 Highlights of WN 10570 Part 1: Fusion weld joints to steel • Assessment groups: Based upon the design and service requirements for a component, welds are assigned an assessment group --- this basically an assignment of the appropriate acceptance criteria level • Based on design and safety requirements, Annex A specifies the recommended assessment groups for lift truck components ANNEX A (information) 3 Highlights of WN 10570 Assessment group WN 10570-E • Certain configuration, design and accessibility conditions could prevent the achievement of the assigned assessment group requirements, even though welds are workmanlike • Because of these production conditions, and the fact that they do not require volumetric inspection, certain irregularities are expected and allowed when the weld is designated as WN 10570-E. Examples include: • Edge meltdown • Unequal leg length • Excess weld filling 4 Highlights of WN 10570 Examples of WN 10570-E conditions • OHG roof panel • X = do not wrap the weld • X = stop at a 10mm form the edge = do not wrap weld. Assessment group applicable for a distance “x” of 10mm 5 Highlights of WN 10570 1. Welding company requirements • Manufacturers must hold EN ISO 3834 certification • Manufacturers of EN ISO 5817 assessment groups "B" or "C" components important to structure and safety shall be manufactured by companies meeting the requirements of EN ISO 3834-2 or -3 • Any deviations from this rule must be recorded in writing in each case and approved by the responsible welding supervisor in the relevant KION business unit 6 Highlights of WN 10570 3.3 Welder reference markers • Welded components in compliance with EN ISO 5817 assessment groups "B" or "C" shall be traceable back to the welder • How will this be accomplished at KION NA? 7 Highlights of WN 10570 3.4 Welding process qualification requirements • Welds classified as EN ISO 5817 assessment groups "B" or "C" shall be qualified using a preproduction welding test in accordance with EN ISO 15613 • How will this be accomplished at KION NA? 8 Highlights of WN 10570 4 Tolerances required for production • 4.1 Related to robotic welding, so not applicable at this time • 4.2 Related to robotic welding, so not applicable at this time • 4.3 Length tolerance for weld seams per Table 1 9 Highlights of WN 10570 5 Other standards • If other standards are used, it must be shown that the requirements are equivalent to this standard 10 Highlights of WN 10570 6 Examination • Compliance with this standard is verified using visual inspection of the surface condition, or, if called for, by measuring some representative sections 11 Highlights of WN 10570 Part 2: Symbols and dimensioning 1. Scope and Purpose This WN is an extract from EN 22553 (~ ISO 2553). It contains the most frequently encountered symbols and practical rules. In addition, the standard includes rules of application for drawing up weld seam tables for complex weld assemblies. 12 Highlights of WN 10570 Basic symbols 13 Highlights of WN 10570 Composite symbols 14 Highlights of WN 10570 Supplementary symbols 15 Highlights of WN 10570 3 Position of symbols on drawings 16 Highlights of WN 10570 3.3 Depicting side of joint where weld is to be placed 17 Highlights of WN 10570 Depicting side of fillet weld placement 18 Highlights of WN 10570 Dimensioning of welds • Groove [butt] weld size D = depth of bevel S = size of grove weld (butt) 19 Highlights of WN 10570 Fillet weld size From EN 22553 Convex = length dimension = z Concave = throat dimension = a = load dimension Leg Length = a (x 1.4) 20 Highlights of WN 10570 Fillet weld size - AWS • The largest right isosceles triangle (based on leg dimension) that can be contained within the fillet weld cross-section 21 Highlights of WN 10570 Fillet weld size – EN ISO • In EN ISO system, fillet weld size is based on same inscribed isosceles [right] triangle • Major difference is that the size of that triangle can be specified using either the throat thickness "a" or the leg length "z" • On KION drawings, fillet weld sizes are specified using the throat thickness "a" 22 Highlights of WN 10570 Measuring fillet welds with EN ISO dimensioning • AWS system specifies the leg dimension of the inscribed right isosceles triangle as fillet weld size • In the EN ISO system, detailer has the option of specifying either the leg or throat dimension of that right isosceles triangle 23 Highlights of WN 10570 Measuring fillet welds - AWS • With AWS system, the size of the inscribed right isosceles triangle is determined by measuring different features of that triangle using differently shaped gages, depending on the profile of the fillet weld 24 Highlights of WN 10570 Measuring fillet welds - EN ISO • With EN ISO system, depending on which of the triangle dimensions is specified, only one fillet weld profile shape can be directly measured, unless the fillet weld face is flat If “a” dimension specified – only concave profiles can be measured 25 Highlights of WN 10570 If “a” dimension specified – only convex profiles can be measured How do we overcome this limitation? • A mathematic [trigonometric] relationship exists between the "a" and "z" dimensions for a right isosceles triangle z = a√2 = a(1.414) = a(1.4) For a = 5mm, z = 5(1.4) = 7mm a = z/√2 = z/1.414 = z/1.4 For z = 7mm, a= 7/1.4 = 5mm 26 Highlights of WN 10570 Solutions • Symbolize using "z" dimension − Fillet weld gages with standard dimensions can be used for both concave and convex weld profiles • Create custom gages for measuring convex fillet welds adjusted to measure "z" dimension equivalent to specified "a" dimension • Calculate equivalent leg length dimensions and use resulting convex fillet weld gages − Conversion table on next page 27 Highlights of WN 10570 Fillet weld size conversion table X1.4 28 Highlights of WN 10570 Details of weld length Figure 7: V weld over the whole length of the workpiece 29 Highlights of WN 10570 Intermittent fillet welds EN ISO AWS 30 Highlights of WN 10570 [Chain] intermittent fillet welds EN ISO AWS 31 Highlights of WN 10570 [Staggered] intermittent fillet welds EN ISO AWS 32 Highlights of WN 10570 Weld dimensioning 33 Highlights of WN 10570 Part 2 Shielding gases, weld metal and welding positions 1. RANGE OF APPLICATION • Extract from various DIN, EN and EN ISO standards • Regulates the application of welding filler metals using shielding gases • Should be applied when welding components made from materials listed in Annex B • Supplemental to specifications contained in WN 10570-1 2. PURPOSE • Specify requirements for welding processes and the shielding gases and filler materials used in their application 34 Highlights of WN 10570 Annex B base metals 35 Highlights of WN 10570 WELDING METHODS - TERMINOLOGY 3.1 Metal-inert-gas-shielded arc welding in accordance with 1S0857-1 • Metal-arc welding with wire electrode, where the arc and weld pool are protected from the atmosphere by a shielding gas, supplied from an external source 3.2 Classification in terms of electrode type and shielding gas 3.2.1 • Metal inert gas welding (MIG) - #131 per EN ISO 4063 Metal electrode with inert shielding gas (Argon or Helium) 3.2.2 Metal active gas welding (MAG) - #135 per EN ISO 4063 • Metal (solid) electrode with chemically active shielding gas (100% CO 2, or additions of CO2 or 02 to inert gas [typically argon]) 3.2.3 Metal active gas welding (MAG) - #138 per EN ISO 4063 • Metal (metal core) electrode with chemically active shielding gas (100% C0 2 or additions of CO2 or 02, to Inert [typically argon] 36 Highlights of WN 10570 SHIELDING GASES • Shielding gas classifications from EN 439 37 Highlights of WN 10570 5.2 Shielding gas combinations 38 Highlights of WN 10570 Shielding gases 5.3 Composition accuracy • For minor constituents up to 5% (by volume)  ± 0.5% • For minor constituents from 5 to 50% (by volume)  ± 10% 5.4 Identification number for gases in Group M containing He - N/A 5.5 Designation - per Table 2 • Gas being used - 90% Ar -10% CO2 - Designation - M21 Co2 : 10% 39 Highlights of WN 10570 Co2 range: 9-10% Ar: 90% 6 ACCESSORIES • 6.1 Fillers 40 Highlights of WN 10570 AND WELD METAL 7 Welding positions – EN ISO 6947 41 Highlights of WN 10570