AWS D15 1 D15 1M-2012 Railroad Welding Specification for Cars and Locomotives (Fifth Edition Second Printing Incorporates Amendment October 2013).pdf

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1、Railroad WeldingSpecificationfor Cars andLocomotivesAWS D15.1/D15.1M:2012An American National StandardAWS D15.1/D15.1M:2012An American National StandardApproved by theAmerican National Standards InstituteApril 18, 2012Railroad Welding Specificationfor Cars and Locomotives5th EditionSupersedes AWS D1

2、5.1/D15.1M:2007Prepared by theAmerican Welding Society (AWS) D15 Committee on Railroad WeldingUnder the Direction of theAWS Technical Activities CommitteeApproved for Publication by theAWS Board of DirectorsAbstractThis specification establishes minimum standards for the manufacture and maintenance

3、of railroad equipment. Clauses 4through 17 cover the general requirements for welding in the railroad industry. Clauses 18 through 24 cover specificrequirements for the welding of base metals thinner than 1/8 in 3 mm.iiAWS D15.1/D15.1M:2012International Standard Book Number: 978-0-87171-813-6America

4、n Welding Society8669 Doral Blvd., Doral, FL 33166 2012 by American Welding SocietyAll rights reservedPrinted in the United States of AmericaPhotocopy Rights. No portion of this standard may be reproduced, stored in a retrieval system, or transmitted in anyform, including mechanical, photocopying, r

5、ecording, or otherwise, without the prior written permission of the copyrightowner.Authorization to photocopy items for internal, personal, or educational classroom use only or the internal, personal, oreducational classroom use only of specific clients is granted by the American Welding Society pro

6、vided that the appropriatefee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, tel: (978) 750-8400; Internet:.iiiAWS D15.1/D15.1M:2012Statement on the Use of American Welding Society StandardsAll standards (codes, specifications, recommended practices, methods, class

7、ifications, and guides) of the AmericanWelding Society (AWS) are voluntary consensus standards that have been developed in accordance with the rules of theAmerican National Standards Institute (ANSI). When AWS American National Standards are either incorporated in, ormade part of, documents that are

8、 included in federal or state laws and regulations, or the regulations of other govern-mental bodies, their provisions carry the full legal authority of the statute. In such cases, any changes in those AWSstandards must be approved by the governmental body having statutory jurisdiction before they c

9、an become a part ofthose laws and regulations. In all cases, these standards carry the full legal authority of the contract or other documentthat invokes the AWS standards. Where this contractual relationship exists, changes in or deviations from requirementsof an AWS standard must be by agreement b

10、etween the contracting parties.AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While the AWS administers theprocess and establishes rules to promote fairn

11、ess in the development of consensus, it does not independently test, evalu-ate, or verify the accuracy of any information or the soundness of any judgments contained in its standards.AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whethers

12、pecial, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or relianceon this standard. AWS also makes no guarantee or warranty as to the accuracy or completeness of any informationpublished herein.In issuing and making this standard available, A

13、WS is neither undertaking to render professional or other services for oron behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek

14、 theadvice of a competent professional in determining the exercise of reasonable care in any given circumstances. It isassumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.This standard may be superseded by the issuance of new editi

15、ons. This standard may also be corrected through publicationof amendments or errata. It may also be supplemented by publication of addenda. Information on the latest editions ofAWS standards including amendments, errata, and addenda are posted on the AWS web page (www.aws.org). Users shouldensure th

16、at they have the latest edition, amendments, errata, and addenda.Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard acceptany and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringe

17、ment ofany patent or product trade name resulting from the use of this standard.The AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.On occasion, text, tables, or figures are printed incorrectly, constituting errata. Such errata, when discov

18、ered, are postedon the AWS web page (www.aws.org).Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society,Attention:

19、Managing Director, Technical Services Division, 8669 Doral Blvd., Doral, FL 33166 (see Annex G). Withregard to technical inquiries made concerning AWS standards, oral opinions on AWS standards may be rendered. Theseopinions are offered solely as a convenience to users of this standard, and they do n

20、ot constitute professional advice.Such opinions represent only the personal opinions of the particular individuals giving them. These individuals do notspeak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpretations of AWS.In addition, oral opinions a

21、re informal and should not be used as a substitute for an official interpretation.This standard is subject to revision at any time by the AWS D15 Committee on Railroad Welding. It must be reviewedevery five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendatio

22、ns, additions,or deletions) and any pertinent data that may be of use in improving this standard are required and should be addressedto AWS Headquarters. Such comments will receive careful consideration by the AWS D15 Committee on RailroadWelding and the author of the comments will be informed of th

23、e Committees response to the comments. Guests are in-vited to attend all meetings of the AWS D15 Committee on Railroad Welding to express their comments verbally. Proce-dures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of theTechnical Activit

24、ies Committee. A copy of these Rules can be obtained from the American Welding Society, 8669 DoralBlvd., Doral, FL 33166.This page is intentionally blank.ivAWS D15.1/D15.1M:2012vAWS D15.1/D15.1M:2012PersonnelAWS D15 Committee on Railroad WeldingM. R. Untermeyer, Chair Union Tank Car CompanyR. A. Wol

25、bert, 1st Vice Chair Progress Rail Services CorporationJ. B. Pearson Jr., 2nd Vice Chair LTK Engineering ServicesS. N. Borrero, Secretary American Welding SocietyD. M. Allbritten General ElectricRailR. C. Bly TTX CompanySRDC. Boulden Trinity Industries, IncorporatedL. B. Broadway American Railcar In

26、dustriesN. S. Brown Canadian Pacific RailwayR. A. Conrad Hobart BrothersS. A. Coughlin ConsultantM. R. Desjardins National Steel Car LimitedJ. Haacke Trinity Rail GroupD. S. Lassen Greenbrier Rail ServicesT. M. Nelson LTK Engineering ServicesB. W. Siebold BNSF Railway CompanyT. D. Spry Electro Motiv

27、e Diesel, IncorporatedL. H. Strouse U.S. Department of TransportationA. Willaredt American Railcar IndustriesAdvisors to the AWS D15 Committee on Railroad WeldingB. C. Blackwell Standard Car Truck CompanyW. Blamire Norfolk Southern CorporationJ. L. Cooley J. C. AWS D1.2/D1.2M, Structural Weld-ing Co

28、deAluminum; AWS D1.3/D1.3M, Structural Welding CodeSheet Steel; and AWS D1.6/D1.6M, StructuralWelding CodeStainless Steel.AWS D15.1-86 was titled simply Railroad Welding Specification. For the 1993 revision, the suffix Cars and Locomo-tives was added because the locomotive section had been introduce

29、d. A later revision was published in 2001, AWSD15.1:2001. The welding of rail is addressed in AWS D15.2, Recommended Practice for the Welding of Rails andRelated Rail Components for Use by Rail Vehicles.Several significant modifications have been made in AWS D15.1/D15.1M:2012. A vertical line in the

30、 margin indicates arevision from the 2007 edition. Limitations of essential variables for welding procedure qualification and welder perfor-mance qualification have been set up in table format (Tables 10.1 and 11.1, respectively). Friction stir welding has beenincluded in the list of approved weldin

31、g processes. Additional prequalified joint details for FCAW and GMAW havebeen added (see Figures 7.1G and 7.2A). Table 17.1 (Weld Crater Limitations) has been added. Clause 18 (Welding ofSheet Metal) has been revised.Comments and suggestions for the improvement of this standard are welcomed. They sh

32、ould be sent to the Secretary,AWS D15 Committee on Railroad Welding, American Welding Society, 8669 Doral Blvd., Doral, FL 33166.This page is intentionally blank.viiiAWS D15.1/D15.1M:2012ixAWS D15.1/D15.1M:2012Table of ContentsPage No.Personnel vForeword.viiList of Tables. xiiiList of Figuresxiv1. G

33、eneral Requirements 11.1 Scope.11.2 Units of Measurement.11.3 Safety 12. Normative References .13. Terms and Definitions .44. General Information .55. Requirements for All Welding65.1 Processes .65.2 Welding Procedure Qualification 65.3 Qualification of Welders and Welding Operators65.4 Design of We

34、lded Joints75.5 Consumables .106. Technique and Workmanship 226.1 General 226.2 Preparation of Base Metal.226.3 Steel and Aluminum Assembly Criteria246.4 Weld Profiles .256.5 RepairsAfter Welding256.6 Arc Strikes.266.7 Cleaning and Protective Coatings .266.8 Weld Termination 276.9 Groove Weld Backin

35、g .276.10 Heat Input Control for Quenched and Tempered Steel .276.11 Stress Relief Heat Treatment.276.12 Peening276.13 Workmanship for Stud Arc Welding (SW) .286.14 Workpiece Leads .286.15 Welding Air Brake Pipe 287. Prequalified Welding Procedure SpecificationsJoint Design Details327.1 Groove Weld

36、Size (Effective Weld Size) 327.2 Joint Designs .327.3 Fillet Welds327.4 Details of Plug and Slot Welds327.5 Complete Joint Penetration Groove Welds337.6 Partial Joint Penetration Groove Welds.338. Technique for Prequalified Welding Procedure Specifications .648.1 Base Metal, Filler Metal, and Relate

37、d Metal Requirements .64xPage No.AWS D15.1/D15.1M:20128.2 Preheat, Interpass, and Postweld Heat Treatment (PWHT) Requirements.648.3 Shielded Metal Arc Welding (SMAW) .648.4 Submerged Arc Welding (SAW) .658.5 Gas Metal Arc and Flux Cored Arc Welding (GMAW and FCAW).678.6 Plug and Slot Welds 688.7 Wel

38、ding Wear Plates and Wear Liners 699. General Requirements for Qualification.809.1 Prequalified Procedures.809.2 Qualified Procedures .809.3 Welders, Welding Operators, and Tack Welders .809.4 Qualification Responsibility8010. Procedure Qualification8110.1 Limitation of Essential Variables 8110.2 Ty

39、pes of Tests and Purposes8110.3 Base Metal and Its Preparation8110.4 Position of Test Welds.8110.5 Joint Welding Procedure Specification .8310.6 Test Specimens: Number, Type, and Preparation8310.7 Special Test Conditions.8510.8 Method of Testing Specimens .8510.9 Test Results Required8610.10 Records

40、8710.11 Retests .8711. Welder Qualification .11411.1 General 11411.2 Limitation of Variables11411.3 Qualification Tests Required .11411.4 Groove Weld Plate Qualification Test for Plate 11411.5 Groove Weld Qualification Test for Pipe or Square or Rectangular Tubing.11411.6 Fillet Weld Qualification T

41、est for Fillet Welds Only 11411.7 Position of Test Welds.11511.8 Base Metal.11511.9 Joint Welding Procedure Specification .11511.10 Test Specimens11511.11 Method of Testing Specimens .11511.12 Test Results Required11611.13 Retests .11711.14 Period of Effectiveness11711.15 Records11712. Welding Opera

42、tor Qualification 13212.1 General 13212.2 Limitation of Variables13212.3 Qualification Tests Required for Welding Operators 13212.4 Base Metal.13212.5 Joint Welding Procedure Specification .13212.6 Test Specimens: Number, Type, and Preparation13212.7 Method of Testing Specimens .13212.8 Test Results

43、 Required13212.9 Retests .13212.10 Period of Effectiveness13312.11 Records133xiPage No.AWS D15.1/D15.1M:201213. Tack Welder Qualification13513.1 General 13513.2 Limitation of Variables13513.3 Qualification Tests Required .13513.4 Base Metal.13513.5 Test Specimens: Number, Type, and Preparation13513.

44、6 Method of Testing Specimens .13513.7 Test Results Required13513.8 Retests .13513.9 Period of Effectiveness13513.10 Records13514. InspectionGeneral Requirements 13714.1 Manufacturers Responsibility 13714.2 Designated Inspector (Fabrication Inspector) .13714.3 Inspection of Welding .13714.4 Weld Siz

45、e and Location.13714.5 Visual Inspection of Completed Welds .13714.6 Documentation 13714.7 Verification Inspection 13714.8 Personnel Qualifications13815. NDE General Requirements.13815.1 Nondestructive Testing13816. NDE Methods.13916.1 Radiographic Testing of Groove Welds 13916.2 Ultrasonic Testing

46、of Groove Welds .13916.3 Liquid Penetrant Testing of Welds 14116.4 Magnetic Particle Testing of Welds.14117. Acceptance Criteria.15117.1 Temporary Welds 15117.2 Visual Inspection Acceptance Criteria 15117.3 Radiographic Inspection Acceptance Criteria.15117.4 Ultrasonic Inspection Acceptance Criteria

47、15117.5 Liquid Penetrant Acceptance Criteria .15117.6 Magnetic Particle Acceptance Criteria15118. Requirements for Welding Sheet Metal 15418.1 Design of Welded Joints15418.2 Joint and Procedure Qualification for Welding Sheet Metal.15419. Welder, Welding Operator, and Tack Welder QualificationCarbon

48、, Low Alloy, andStainless Steel Sheet Metals16519.1 General 16519.2 Limitation of Variables16519.3 Retests .16519.4 Period of Effectiveness16520. Technique and Workmanship for Welding Sheet Metal16821. Inspection of Welding Procedure Qualification and Equipment for Welding Sheet Metal16822. Weld Det

49、ailsSheet Metal.16822.1 Groove Welds (Butt Joints) .16822.2 Fillet Welds168xiiPage No.AWS D15.1/D15.1M:201223. Sheet Metal Weld QualityVisual Inspection Acceptance Criteria168Annex A (Normative)Alternate Base Material Specifications (Steel)169Annex B (Informative)Filler Metal Classifications171Annex C (Informative)Effective Weld SizeSpecial Cases175Annex D (Informative)Sample Report Forms 179Annex E (Informative)Gage Thickness of Sheet Metal and Aluminum Filler Alloy Selection Guide205Annex F (Informative)Macroetch Procedures209Annex G (Informative)Guidelines for the Pr