In English language mandatory <DOCUMENT DESCRIPTION>

MAIN WELDING TERMS

TABLE OF CONTENTS

1. FOREWORD ................................................................................ 7

2. INTRODUCTION .......................................................................... 7

3. FIELD OF APPLICATION ............................................................. 7

4. MAIN REFERENCES (INFORMATIVE LIST) ....................................... 7

4.1. QUALITY ASSURANCE ............................................................................................................... 7

4.2. DESIGN AND MANUFACTURE ...................................................................................................... 8

4.3. PERSONNEL QUALIFICATION ...................................................................................................... 8

4.4. WPS / WPQR ......................................................................................................................... 8

4.5. MATERIALS / GAS ..................................................................................................................... 8

4.6. NON-DESTRUCTIVE INSPECTIONS .............................................................................................. 8

4.7. DESTRUCTIVE TESTING ............................................................................................................. 9

4.8. DEFECTS ............................................................................................................................. .... 9

4.9. ALSTOM STANDARDS ................................................................................................................ 9

5. TERMS AND DEFINITIONS ........................................................ 10

6. MANUFACTURER CERTIFICATION .......................................... 10

7.CONTRACT REVIEW AND TECHNICAL REVIEW ..................... 10

7.1. GENERAL ............................................................................................................................... 10

7.2. CALL-FOR-TENDERS ............................................................................................................... 11

7.3. CONTRACT REVIEW ................................................................................................................ 11

7.4. DESIGN CALCULATION AND VALIDATION REQUIREMENTS OF THE WELDED JOINTS ........................ 11

7.5. DESIGN REVIEW ..................................................................................................................... 11

8. PURCHASE / SUBCONTRACTING AND ACTIVITY TRANSFER12

8.1. PURCHASE – SUBCONTRACTING .............................................................................................. 12

8.2. INTER-SITE PRODUCTION TRANSFER ........................................................................................ 12

9. WELDING PERSONNEL ............................................................ 13

9.1. WELDING COORDINATION ........................................................................................................ 13

9.2. QUALIFICATIONS OF THE WELDERS AND THE OPERATORS ......................................................... 13 9.2.1. FOR CARBON AND STAINLESS STEELS .................................................................................. 13 9.2.2. FOR ALUMINIUM ALLOYS ..................................................................................................... 13 9.2.3. MECHANISED, AUTOMATIC AND ROBOTISED ......................................................................... 13 9.2.4. COMMUN RULES ................................................................................................................. 13 9.2.5. SPECIAL CASES .................................................................................................................. 14

10. NON DESTRUCTIVE TESTING PERSONNEL .......................................... 14

10.1. CPB AND CPC1 JOINTS ......................................................................................................... 15

10.2. CPC2, CPC3 AND CPD JOINTS .............................................................................................. 15

11. EQUIPMENT .............................................................................. 15

11.1. PRODUCTION AND TEST EQUIPMENT ........................................................................................ 15

11.2. DESCRIPTION OF THE EQUIPMENT............................................................................................ 15

11.3. EQUIPMENT APTITUDE ............................................................................................................ 15

11.4. MAINTENANCE, FOLLOW-UP, MARKING, CONTROL AND CALIBRATION OF EQUIPMENT ................... 15

11.5. JIGS ............................................................................................................................. ......... 15

11.6. IMPLANTATIONS ...................................................................................................................... 16

12. WELDING ACTIVITIES ............................................................... 16

12.1. PRODUCTION SCHEDULE ......................................................................................................... 16

12.2. WPS ..................................................................................................................................... 16

12.3. WPQR .................................................................................................................................. 16 12.3.1. GENERAL RULE .............................................................................................................. 16

12.3.2.MANUAL AND PARTLY MECHANIZED ARC WELDING ............................................................ 16 12.3.3. LASER BEAM WELDING ................................................................................................... 17 12.3.4. LASER HYBRID WELDING ................................................................................................ 17

12.3.5.STUD-WELDING (FORBIDDEN FOR CPB, C1 ET C2 WELDING) ........................................... 17 12.3.6.RESISTANCE WELDING (FORBIDDEN FOR CPB WELDING) ................................................. 17

12.3.7. EXCHANGE OF WPQR ................................................................................................... 17

12.4. WELDING CONDITIONS ............................................................................................................ 17

12.5. WELDING SEQUENCES ............................................................................................................ 18

12.6. MANUFACTURING START-UP - REPAIRS ................................................................................... 18

12.7. IMPLEMENTATION OF TEST ASSEMBLIES : BEFORE, DURING AND AFTER PRODUCTION. ................. 18

12.8. WELD RETURN ....................................................................................................................... 19

12.9. WELD FINISHING - GRINDING .................................................................................................. 19

13. WELDING CONSUMABLES ...................................................... 19

13.1. DESIGNATION OF CONSUMABLES FOR PROCESSES 131/135/141 –STANDARD ALSTOM- ........... 19

13.2. QUALIFICATION OF FILLER METAL ............................................................................................. 19

13.3. SUPPLIES, STORAGE, DISTRIBUTION ....................................................................................... 20

14. BASE MATERIAL ....................................................................... 20

14.1. DEFINITION ............................................................................................................................ 20

14.2. SUPPLYING, STORAGE AND MANIPULATION ............................................................................... 20

14.3. PRIMARY PARTS ..................................................................................................................... 20

15. CLEANING AND PASSIVATION OF STAINLESS STEEL ........... 20

15.1. DEGREASING ......................................................................................................................... 20

15.2. RINSING ................................................................................................................................. 21

15.3. MECHANICAL OR CHEMICAL PICKLING ...................................................................................... 21

15.4. RINSING ................................................................................................................................. 21

15.5. PASSIVATION ......................................................................................................................... 21

15.6. RINSING ................................................................................................................................. 21

15.7. DRYING.................................................................................................................................. 21

16. POST-WELD HEAT TREATMENT .............................................. 21

16.1.FOR CARBON STEEL................................................................................................................ 21

16.1.1. LOADING IN THE OVEN .................................................................................................... 21 16.1.2. CONTROL OF TEMPERATURE .......................................................................................... 21 16.1.3. INCREASE OF TEMPERATURE .......................................................................................... 21 16.1.4. TREATMENT .................................................................................................................. 21 16.1.5. COOLING ....................................................................................................................... 22 16.1.6. INSPECTION ................................................................................................................... 22

16.2. FOR ALUMINIUM ALLOYS AND STAINLESS STEELS ...................................................................... 22

17. INSPECTIONS AND TESTS ....................................................... 22

17.1. GENERAL ............................................................................................................................... 22

17.2. GOOD PRACTICES .................................................................................................................. 22

17.3. INSPECTION PLAN ................................................................................................................... 22 17.3.1.DIMENSIONAL AND GEOMETRIC INSPECTIONS .................................................................. 23 17.3.2. DESTRUCTIVE INSPECTIONS ........................................................................................... 23 17.3.3. NON-DESTRUCTIVE INSPECTIONS ................................................................................... 23 17.3.4. LEAK TESTING ............................................................................................................... 24 17.3.5.QUALITY LEVEL OF IMPERFECTIONS ................................................................................ 24

18. NON-COMPLIANCE AND CORRECTIVE ACTIONS .................. 24

19. CALIBRATION AND VALIDATION OF MEASURING, INSPECTION AND

TEST EQUIPMENT .............................................................................. 24

20. IDENTIFICATION AND TRACEABILITY .................................... 24

20.1. MATERIAL .............................................................................................................................. 24

20.2. PERSONNEL ........................................................................................................................... 25

20.3. SUB-ASSEMBLIES, COMPONENTS AND ASSEMBLIES ................................................................ 25

20.4. MODIFICATIONS ..................................................................................................................... 25

21. QUALITY RECORDS .................................................................. 25

ANNEXE A (INFORMATIVE) ...................................................................... 26

1. FOREWORD

This document – DTRF 150221 - is an application document (or working document) which takes up parts of the standards in order to clarify how ATSA apply and implement them

This document is drawn up within the framework of Alstom Transport APSYS process, thus enabling a common welding document to be handed out to our customers, for example within the scope of a tender. It is compliant to the requirements of the IND-PRO-002 “control of special processes”

The French version is the reference.

2. INTRODUCTION

This document DTRF 150221 shall be applied to all Alstom Transport sites where welding operations are carried out.

All European sites mentioned below depend on the same Engineering Department of Alstom Transport.

Barcelone BCN

Valenciennes Le Creusot FBO

VPF

Salzgitter SLZ Belfort FLO

Alstom Transport welding activities

Savigliano SAV Ornans FMO

Katovice KTW Reichshoffen

REI

La Rochelle LRH

3. FIELD OF APPLICATION

This document shall apply to all contracts dealt with by Alstom Transport and is mandatory for any welding operation. There is no retroactive effect. Depending of the case, it can be add a document which precise the complementary requirements This document is based on standard ISO3834-2 (annexe A) and completed by EN 15085 requirements

4. MAIN REFERENCES (INFORMATIVE LIST)

4.1. Quality assurance

ISO 9000

IRIS International Railway Industry Standard ISO 3834 parts 1 to 5 Quality requirements for welding – comprehensive quality requirements. EN 15085 parts 1 to 5 – Welding in the railway field - parts 1 to 5 included

4.2. Design and manufacture

ISO 6947 Welds – Working position - Definitions of angles of slope and rotation. ISO 9692 parts 1 to 3 : metal-arc welding with coated electrodes, gas-shielded metal-arc welding and gas welding - Preparation of steel joint. ISO 4063 Welding, brasing, soldering welding and braze welding of metals – Process and number list for symbolic representation on drawings. ISO 2553 Welded and brazed joints – Symbolic representation on drawings. ISO 13920 Welding – General tolerance regarding welded constructions. Dimensions for lengths and angles. Shape and position.

4.3. Personnel qualification

ISO 14731 Welding coordination – Tasks and responsibilities. EN 473 / ISO 9712 Qualification and certification of NDT personnel – General principles. EN 287-1 Fusion welding – Welder qualification test - steel. ISO 9606-2 Fusion welding - Welder qualification test - Aluminium and its alloys. EN 1418 Welding personnel qualification test for welding operators for fusion welding and resistance weld setters for fully mechanised and automatic welding of metallic materials.

4.4. WPS / WPQR

ISO 15607 Specification and approval of welding procedures for metallic materials. General rules for fusion welding. ISO 15609 Specification and approval of welding procedures for metallic materials. ISO 15611 Specification and approval of welding procedures for metallic materials – Approval related to previous experience- ISO 15613 Specification and approval of welding procedures for metallic materials - approval by a pre-production welding test. ISO 15614-1 Specification and approval of welding procedures for metallic materials - welding procedure tests for the arc welding of steels. ISO 15614-2 Specification and approval of welding procedures for metallic materials - welding procedure tests for the arc welding of aluminium and its alloys. EN ISO 14555 Welding – arc stud welding of metallic materials

4.5. Materials / Gas

ISO14175 Welding consumables. Shield gases for arc welding. ISO14341 Welding consumables. Wire electrodes and deposits for gas shield metal arc welding of non alloy and fine grain steels - Classification EN 1011 parts 1 to 4 Recommendations for welding of metallic materials. EN 10204 Metallic products – types of inspection document – ISO 14343 Welding consumables – Electrode wire, filler rods for arc welding and cutting of stainless steels resisting to high temperature. EN ISO 18273 Welding consumables – Electrode wire, rods for welding aluminium and alloys CR ISO/TR 15608 Welding - Guidelines for metallic materials – Grouping system. EN ISO 17663 welding - quality requirements for heat treatment in connection with welding and allied proesses

4.6. Non-destructive inspections

EN 462 parts 1 to 5 Non-destructive testing – Image quality of radiographs EN 571-1 Non-destructive testing – Penetrant testing – General principles. EN 970 Non-destructive examination of fusion welds. Visual examination

EN 1435 Non-destructive examination of welds. Radiographic examination of welded joints. ISO/FDIS 11666 : Non-destructive examination of welds. Ultrasonic examination of welding joints. Acceptance levels. EN ISO 23279 Non-destructive inspection of welded assemblies - Inspection by ultrasound – Characterization of indications in the welded assemblies

EN 1714 Non-destructive examination of welds. Ultrasonic inspection of welded joints.

ISO 9934-1 Non-destructive testing - Magnetic particle examination – General principles. EN ISO 17635 Non-destructive inspection for welded assemblies – General rules for metallic materials EN ISO 23277 Non-destructive examination of welds - Penetrant testing of welds - Acceptance levels. EN ISO 17638 Non-destructive inspection of welded assemblies – Inspection by magnetic particle inspection of the welded assemblies- EN ISO 23278 Non-destructive examination of welds - Magnetic particle testing of welds - Acceptance levels.

4.7. Destructive testing

EN 875 Destructive tests for welds on metallic materials. Impact tests. Tests specimen location, notch orientation and examination. EN 876 Destructive tests for welds on metallic materials. Longitudinal tensile test on weld metal in fusion welded joints. EN 895 Destructive tests for welds on metallic materials. Transversal tensile test. EN 910 Destructive tests for welds on metallic materials. Bend tests EN 1320 Destructive tests for welds on metallic materials. Fracture test. EN 1321 Destructive tests for welds on metallic materials. Macroscopic and microscopic examination of welds EN 10002-1 Metallic materials. Tensile testing. Part 1: method of test (at ambient temperature). EN 1043-1 Destructive tests on welds on metallic materials. Hardness test – Hardness test of arc-welded joints. EN 10045-1 Destructive tests for welds on metallic materials. Charpy impact test - test method. (V and U grooves). EN 10109-1 Destructive tests for welds on metallic materials. Hardness test - Rockwell tests and superficial Rockwell test.

4.8. Defects

ISO 5817 Arc-welded joints in steel. Guidance on quality levels for imperfections. ISO 10042 Arc-welded joints in aluminium and its weldable alloys. Guidance on quality levels for defects. EN 12517 Non-destructive test of welds. Radiographic examination of welded joints. Acceptance levels ISO 6520 Classification of imperfection in metallic fusion welds, with explanations ISO 9013 Thermal cutting –classification of thermals cuts – Geometrical product specification and quality tolerances ISO 13920 Welding – General tolerances for welded constructions – dimensions for lengths and angles – Shape and position

4.9. Alstom Standards

DTRF 150201 - thin, medium and strong carbon steel sheet DTRF 150202 – profiles in structural aluminium alloy DTRF 150203 - casted parts aluminium DTRF 150204 – steel castings DTRF 150207 - forged parts aluminium DTRF 150208 – steel forgings DTRF 150211 – Design (the supplier carries out the design) DTRF 150215 – General welding conditions for our suppliers and subcontractors DTRF 150016 - Sheet in structural aluminium alloy SSC RS WMS 001 : colored penetrant testing SSC RS WMS 002 : qualification of personnel for visual inspection SSC RS WMS 003 : ultrasonic testing

SSC RS WMS 005 : magnetic particules testing SSC RS WMS 006 : wire electrode for welding of aluminium alloys – receipt SSC RS WMS 007 : quality of surfaces before welding SSC RS WMS 008 : WPQR, WPS definition, management SSC RS WMS 009 : visual testing SSC RS WMS 010 : visual testing –training support- SSC RS WMS 011 : technical specification of MIG/MAG welding equipment

5. TERMS AND DEFINITIONS

Procedure : Specified way to proceed for an activity or process (dye penetrant or ultrasonic inspection procedures) Site procedure: generic term for procedure, instruction, specification defined by the site Transferability : capacity to receive WPQR files of a different sites and to use it without additional test, except tests as production weld test to check spot welding conditions, stud welding…etc according EN15085-4 Traceability : Capability to retrieve the history, the implementation or the location of what is to be examined Tooling : generic term including templates, jigs, assembly jigs, etc. WPQR : Welding Process Qualification Record WPS : Welding Process Specification Coordinator : the person responsible and competent to perform welding coordination of manufacturing operations for all welding and welding-related activities. Instruction: comprehensive description of the stages to be followed for a certain operation (instructions for mounting of sub-assemblies, machining, etc.) Manufacturing sheet: list of successive operations required for the production of a sub-assembly or assembly or vehicle Welding Specialist : person qualified according to EN287-1, ISO9606-2 to set up primary parts in order to proceed to the weld. Automatic welding : generic term for automated, mechanised, robotized welding Standard : a process is called “standard” when it respect the wire + gas + techno defined by this DTRF. The standard as defined shall be apply for all contracts manufactured by Alstom before end 2010 Common : a process is called ‘common” if it’s used by the majority of sites (more than 50%). Otherwise it’s a “non common” process Transferable : a process is technically transferable if :

- the welding equipment is available on all sites - or able to be rent or buy (into a delivery time enough to training involved people and to receive

the equipment) - or easy to implant and a minimum of training is needed for the involved workers In opposite case, the process is considerated not transferable

Additional Welding Specification : addition document which complete this DTRF in order to fulfil the customers’ requirements

6. MANUFACTURER CERTIFICATION

Alstom Transport is certified according to ISO3834-2. The report of audit can be consulted. Each Alstom

Transport site quoted before is certified CL1 in accordance with standard EN 15085 and have available the organisation, the quality system and documentation according to ISO3834-2. The site coordinator shall guarantee the validity of certification (modifications, change to the field of application, the range of certification, renewal, etc.) for current welding works. He is also responsible that the certification will be changed (if new welding work has to be done) in accordance with certification body

7. CONTRACT REVIEW AND TECHNICAL REVIEW

7.1. General

The requirement review is made by Alstom Transport in order to verify that the content of the work falls within its implementation capacity, that the sufficient resources are available and that the documentation is clearly written and without ambiguity.

Alstom Transport carries out:

The review of contractual requirements, as well as the non contractual ones. The review of all the technical information provided by the purchaser or the in-house data upon

the design itself.

Alstom Transport makes sure: That all the information is complete and available before beginning of the work in the production.

That the scheduling of all the quality-related activities is adequate through the « Design

For Quality » system. Via the « clause by clause » review, that any discrepancies between the contract and

any former estimation be identified and that the purchaser is informed of any

modification in the programme, cost or technical data that could result from the review.

Alstom Transport explains : - How the quality system is applied for the contract - How the legal, regulation and contractual requirements are satisfied - How the organization and the management of the activities reaches the quality target - How the conformity to the requirements is evaluated

7.2. Call-for-tenders

This document may be forwarded with the files to explain the welding conditions which will be applied, during the call-for tenders stage.

7.3. Contract review

If necessary upon the contract review, the main coordinator of the concerned site should draft up a additional document entitled : « Additional Welding Specification for the project X » which completes the DTRF150221 in accordance with the contract.

These documents are considered as a review of the contract terms according to the requirements of the EN ISO 3834-2.

7.4. Design calculation and validation requirements of the welded joints

Directly based on DTRF 150211

This document obliges the presence of proper and complete welding indications on the list of welded joint and /or drawings to be checked: · The definition of different quality classes of the weld depending on its stress and safety levels(CP). · The definition of the different imperfection acceptance level. · The definition of the different inspection class (CT). · The definition of the certification level of the manufacturer (CL).

· Correlation between quality classes, imperfection acceptance level and the inspection class. · The constructive recommendations in the railway field. · Joint preparations. · Explanations regarding the certification requirements for welded parts. When using old drawings, defined before the publication of EN15085 and/or according to other standards and when a pre-established document (as DVS 1623) doesn’t exist, Alstom submits to the customer the transposition rules which it propose to apply through the “additional welding specification”.

7.5. Design review

As indicated in the EN 15085-5, during the design phase, the welding coordinator (or his deputy) shall carry out the welding design review according the following points :

· No CPA joint · Specificity of CPB and CPC1 welding (preparation, control, production weld tests …) · Weldability and mechanical characteristics of the materials …) - accessibility for NDT during the manufacturing and during the maintenance operation according with

the RAMS manager. · Location and accessibility of the welds. · Edge preparation and dimensioning of the welds. ·

Presence and necessity of fully penetrated welds.

· Presence and necessity of permanent or mobile backing. · Necessity of run-on/run-off plates · Qualitative requirements and acceptance level of imperfections ·

Specific requirements: heat treatment, pre-heating, etc… . weld toe improvement

; list of welded joints

. return of experience At this step, the coordinator should make production weld tests assemblies for validation or modification of the design according the results obtained.

The design as defined shall respect the use of common and transferable welding process. Process (ISO4063) Common Non common Transférable Non Transferable

111 X X

141 (thin sheet, finishing, X X

piping, repairing, access

difficulties)

131 (manual) X X

131 (automatic) X X

135 (manual) X X

135 (automatic) X X

781 X X

2 (except aluminium X For manual application : (welding

alloys) machine type ARO XZA 21A /

1000Hz)

Current > 20kA

Tightening torque > 500 daN.m

CMT (mark FRONIUS) X X

521 X X

522 X X

8. PURCHASE / SUBCONTRACTING AND ACTIVITY TRANSFER

8.1. Purchase – subcontracting

The procedure DTRF150215, which define management, production, testing, quality requirements, shall be respected by the supplier. The suppliers are qualified and belong to ATSA supplier’s list. The suppliers of welded sub-assemblies shall respect the EN15085-2. The external testing and calibration laboratories shall be in compliance with ISO/CEI 17025. According to the contract requirements, the specificity of the bought parts (traceability for safety parts for example), the welding coordinator can complete the DTRF 150215 with specific requirements

8.2. Inter-site production transfer

In the case of activity transfer, depending of the production progress, the welding documentation related to the sub-assembly is transferred to the « receiving site »:

Additionnal Welding Specification of the project X drawings or /and Model. Manufacturing processes (primary parts, assembly, machining…) Instructions, sketchs, jigs list… Welded joints list WPQR WPS Inspection plan and Inspection procedures

In order to secure the transfer, welding coordinators of both sites have to set up a Personnel Welding Process Training for the product either.

Before making the transfer and held on the « Dispatching » siteor

At the time of the transfer and held on the « Receiving » site

If the WPQR performed are in compliance with Alstom standards (see §12.3 and 13.1), no « requalification » need be organized. The “receiving” site” simply implements the instructions transmitted. If the WPQR performed are not in compliance with Alstom standards, the « receiving » site « re-qualifies » the transmitted WPS of the WPQR once these are in accordance with Alstom standards.

9. WELDING PERSONNEL

9.1. Welding coordination

Each Alstom Transport manufacturing site tends to have coordination personnel whose experience is validated at the time of the certification audit. The organisation put in place depends upon the welding activity of the site :

Minimum number of coordinators

Number of welders Level A Level B Level C

< 30 2 0 2

> 30 2 1 3

This organization shall be defined by an site organization chart. Coordinators’ tasks and fields of competencies are clearly defined through a job description sheet. Annex B from EN15085-2 may be used.

9.2. Qualifications of the welders and the operators

On each site, a written procedure for the process of qualification of test and delivery of qualification will include : - the kind of required documents (standards, WPS, evaluation report ) - the identification and storage of coupon-plate - the traçability of information taken during the welding - the performance of visual examination, destructive testing and non-destructive testing - the determination of field of validity of the qualification, - the numbering of certificates. - the form for the welder qualification record. The release of coupon-plates will be made after a visit of surveillance of the certification body The welders and operators received a theoretical training course

9.2.1. For carbon and stainless steels

The qualifications of the welders are made in accordance with standard EN 287-1

9.2.2. For aluminium alloys

The qualifications of the welders are made in accordance with standard EN ISO 9606-2.

9.2.3. Mechanised, automatic and robotised

Welding operators have to be qualified in accordance with standard EN 1418. An operator qualified in accordance with standard EN 287-1 or EN ISO 9606-2, is able to operate a mechanised, automatic or robotised machine through training required for such installation validated by the coordinator. In no case, shall a welding operator qualified according to standard EN 1418 be able to replace a manual welder.

9.2.4. Common rules

The qualification based on the following sample

BW FW T-Joint

+

cover the following production assemblies (according with the range of validity fixed by reference standards) :

9.2.4.1. BW

9.2.4.2. FW

9.2.4.3. T-Joint partial penetration (single side welded or both side welded)

9.2.4.4. T-Joint full penetration (both side welded)

9.2.5. Special cases

Welded joints CPB and CPC1 full penetrated but without possibility of volumetric testing (UT or RT) : qualification based on representative production test (according note b table 1 from EN15085-5). This qualification test is only valid for the specific relevant joint. T-Joint full penetration single side welded : qualification based on representative assembly. This type of test qualify automatically for T-Joint partial penetration. In case of specific assemblies (see EN15085-4 §4.2.4), the coordinator shall qualify the welders and operators according a qualification test connected with these assemblies.

10. NON DESTRUCTIVE TESTING PERSONNEL

The supervision of non-destructive testing operations is under the responsibility of the welding coordinator. He can delegate Quality Department and/or Production Department to this activity according to site organization.The NDT can be perform by an external inspection body. NDT personnel carrying out Penetrant Inspection, Magnetic particle Inspection, Ultrasonic Inspection, Radiographic inspection must be certified according to EN473 / ISO9712. Visual inspection carried out on welds of class CPB, CPC1 is performed by NDT personnel qualified according to the instruction SSC RS WMS 002

11. EQUIPMENT

11.1. Production and test equipment

The Alstom sites have available production means commonly and usually used for the manufacturing of railway vehicles. The specific needs will be evaluated case by case and will be solved by :

- Investment - Rental - Sub-contracting

11.2. Description of the equipment

Alstom Transport, on each of its production sites keeps a list of equipment essential for production up to date. This list consists in identifying the important elements of heavy equipment that are essential for the evaluation of the technical capacities of a workshop, for example:

The maximum capacity of the lifting vehicle(s). The dimensions of the components that can be handled in the workshop. The capacity in mechanized and automatic welding equipment. The dimensions and the maximum temperature of the thermal treatment ovens after welding. The equipment capacities in rolling, bending and cutting.

11.3. Equipment Aptitude

The aptitude of equipment is checked according to site procedures:

At the tender stage if there are requirements for base metals or welding processes At the time of investment when changing any obsolete equipment When manufacturing processes are defined and set up in the context of a new project For the performance of test assemblies after maintenance operation etc…

11.4. Maintenance, follow-up, marking, control and calibration of equipment

Site procedures are written (according to IND WMS 002 “Maintenance of equipments and tools”) in the target to :

forbid the use of any faulty equipment define the tests to be carried out and results to be obtained in order to validate new or

repaired equipment

define the maintenance conditions, preventive maintenance, curative maintenance define the verification / calibration and results to be obtained define equipment management

11.5. Jigs

For the manufacturing of each welded sub-assembly or assembly, Alstom use jigs.

These equipments are used for:

proper implementation of assembly workpieces limit tack weld, even suppress avoid tacking operation. obtain an optimal welding position ensure the reproducibility of the obtained results

The tooling equipment must seek to limit the deformations during the welding through judicious fastening and a constant preservation of workpieces. These positioning jigs or equipments must be rigid enough to ensure the proper geometry of workpieces after welding. For the welding of austenitic stainless steel and aluminium and its alloys and if the jigs are manufactured with carbone steel, the surfaces in contact with workpieces do not create of pollution (by using for example : nylon, aluminium alloy stainless steel interfaces) These tooling equipments are identified, followed and marked. They are checked according the relevant drawings after the implantation. The adjustment can be change during the fabrication of the first parts or if there are modifications (design, manufacturing process, etc…)

The manufacturing of conform parts validates the conformity of the tooling equipment.

11.6. Implantations

Working areas for carbon steel, stainless steel and aluminium alloys shall be separate by a : - distance greater than 5 m - or curtain (height +2m than the working position) - or partition

12. WELDING ACTIVITIES

12.1. Production schedule

Alstom Transport proceeds to the scheduling of the different steps from the design to end of warranty of each contract according site procedures.

12.2. WPS

In all cases, whatever welding process is employed, each weld must have a WPS according to standard ISO 14555 for stud welding or the appropriate part of standard EN ISO 15609 for other processes. Please note that a WPS can be applied to different welds. It must be attached to the WPQR when this is required The arc-welding WPS form is common to all Alstom sites according the instruction SSC RS WMS 008 The WPS are recorded under a common database (when available). These WPS can be used by an all other sites. The welding coordinator or its deputy of the site shall validate the WPS before application on the workshop.

12.3. WPQR

12.3.1. General rule

Based on the Welded Joint List, communicated by the design office or during the design phase, the coordinator must define the type and necessary numbers of WPQRs to be carried out in order to validate the design / process conditions, the quality obtained, the industrial risk level according to the validity ranges given by reference standards, performance class of the weld to be performed and related site procedures. WPQR is required except for CPD class welding. The procedure SSC RS WMS 008 define the condition of qualification of the welding process and the form which to be employ.

12.3.2. The WPQR are recorded under a common database (when available). Manual and partly mechanized arc welding

The WPQR are realized according with EN ISO 15614-1 or 2, EN 15613. The WPQR relevant to EN288-3 and 4 stay available without additional test.

12.3.2.1. Carbon steel arc welding

Alstom transport standard is the following: Process 135 according to ISO4063 Filler metal : see chapter « consumable product » Shielding gas : M21 according to EN ISO 14175 (82%Ar + 18%CO2) Welding current : pulsed current / smooth current according application

The using of pulsed current don’t concern the manufacturing of bogies and motors (use of smooth current)

Process 141 is also used under Ar gas (I1 according to EN ISO 14175) for weld finishing (re-melting), repairs, shaped parts…

12.3.2.2. Stainless steel arc welding

The Alstom Transport standard is the following: Process 135 according to ISO4063 Filler metal : see chapter « consumable products » Shielding gas : M12 according to EN ISO 14175 (97,5% Ar + 2,5%CO2) Welding current : pulsed current / smooth current according application

Process 141 is also used under Ar gas (I1 according to EN ISO 14175) for weld finishing (re-melting), repairs, shaped parts, pipes…

12.3.2.3. Aluminium alloys arc welding

The Alstom Transport standard is the following: Process 131 according to ISO4063 Filler metal : see chapter « consumable products » Shielding gas:

I1 according to EN ISO 14175 (Ar ) for thicknesses lower than or equal to 10 mm I3 according to EN ISO 14175 (70%He + 30%Ar) for thicknesses greater than10

mm Welding current : pulsed current

Process 141 AC is also used under Ar gas (I1 according to EN ISO 14175) for the weld finishing (re-melting), repairs, shaped parts, pipes…

12.3.2.4. Fully mechanized and robotized arc welding

For welding of aluminium alloys, a WPQR qualified without brushing (or sandblasting) before welding, can be apply in production with or without brushing (or sandblasting).

12.3.3. Laser beam welding

Process 52 according to ISO4063 According to EN 15614-11

12.3.4. Laser Hybrid welding

It’s the association of laser beam welding and arc welding (with wire-electrode). Because of the absence of official standard, this process will be qualify according ISO15614 (1 or 2 dépending of the parent metal) for the characterisation of the welded assembly.

12.3.5. Stud-welding (forbidden for CPB, C1 et C2 welding)

Process 78 according to ISO4063 According to EN ISO 14555

12.3.6. Resistance welding (forbidden for CPB welding)

Process 21, 22, 23 according to ISO4063 According to EN 15614-12, completed with requirements from appendix F of EN15085-3.

12.3.7. Exchange of WPQR

According to the range of qualification related to the manufacturer as defined by relevant standard, the WPQR can be used by an all other sites (as example, see EN ISO 15614-1 §8.2)

12.4. Welding conditions

The following requirements must be respected:

Work on carbon steel / stainless steel / aluminium alloys must be carried out separately (except for heterogeneous assemblies)

The workshops / work stations are protected from weather conditions / draughts and be well aired and sufficiently lit

When the ambient temperature is below 10°C, the primary parts shall be stored into the workshop minimum 24h before welding. If not possible and if the temperature of the parent metal is below 10°C light preheating at 50/80°C of base metals is required before welding.

In the case that parts made of aluminium alloys shows a condensation of water on their surface the light preheating is also necessary.

Environmental Health and Safety Requirements Surfaces to be welded must be clean, exempt from fat, painting, calamine, dust, corrosion. They

must be prepared depending ofthe pollutant by grinding, brushing, degreasing, sandblasting, machining…. Quality of surfaces before welding are defined according with instruction SSC RS WMS 007.

Tack weld shall be realized according with the same condition as the final joint (same WPS) and are of sufficient length to avoid any crack. In every case, the length of each tack weld must be longer or equals than the lowest of 2 values: 20mm or 3 x minimal thickness of the assembly with a minimum length of 10 mm

Whatever the performance class, according to the complexity of the parts the following documents shall be available :

best practices (yc geometry of edges to be welded, gives, cleanliness, brushing, inspection before and after welding, etc.)

Component plans Manufacturing process (sequencing of manufacturing operations) Definition overlengths / pre-deformations if necessary Assembly plan (order in which the parts / sub-assemblies must be assembled) and associated

methods; welding sequences if necessary Welding specifications : WPS (whatever the performance class) according to EN ISO 15609 or

14555

WPQR if required List of production weld tests according EN15085-4 chapter 4.2 List of welder / operator qualifications relevant of range of approval Special procedures such as repair by welding, straightening, heat treatment, cleaning and

passivation of stainless steel

Control plan and relevant procedures List of NDT personnel

The addition of welds not foreseen in the drawing, for reasons of supplies, workability and handling, will require an authorization from the designer and will thus appear on the plan and in the list of welded joints. The performance of these welds must be covered by the corresponding WPQR.. The temporary attachment is welded into the aeras defined by the designer whitout requirement of WPQR and is not included into the list of welded joints.

12.5. Welding sequences

The weld sequence is mandatory for the manufacturing of the following strauctural parts :

o Bolster o Head stock o Solebar o Vehicle access step o deck o Underframe o Sidewall o End wall o Roof o bogie frame o carbodyshell o cab structure o

crash elements o motor frame

12.6. Manufacturing Start-up - Repairs

The attendance of the coordinator is necessary during these phases in order to:

Capitalize on experience Take necessary measures – corrective actions Focus quickly on production process Control the manufacturing process – preventive actions

12.7. Implementation of test assemblies : before, during and after production.

Before, during and after the production, mock-up or tests assemblies can be made to guarantee:

The proper design. The verification of the WPS.

The good welding conditions in production. And to demonstrate:

The welder’s dexterity. The quality of the welded joints.

These assemblies shall be made in accordance with the EN 15085-4 and based on decision of the welding coordinator

12.8. Weld return

Weld return shall be executed when defined by the drawings. This point shall be take into account during the design review.

12.9. Weld finishing - Grinding

Finishing requirements appear on the list of welded joints and/or on the plans Re-melting: on steel, when TIG melting is used, qualification of the process must include the

measurement of hardness on the heat-affected area of the melting. Values must remain below those indicated by Standard ISO 15614-1

Grinding: In the absence of indications to the contrary, the grinding of sheet edge welds is performed without taking into account the direction of the grooves, with abrasives such as grinding discs, spindle disc grinder, abrasive disc with grain less than 50.

Guileline for choice of the method

Méthod Position Speed Qualification Possibility of later

of the process treatment

Grinding all Very low without Impossible in case of down-thickness

TIG all 10 to WPQR Yes remelting 15cm/min

13. WELDING CONSUMABLES

13.1. Designation of consumables for processes 131/135/141 –standard ALSTOM-

Type Consumable Standard

Carbon steel RCS355 G4Si1 ISO 14341

Carbon steel/ heterogeneous G 23 12 L ISO 14343 stainless steel

Wear plates C-Mn G ou W 20 10 3 ISO 14343

Ferritic stainless X2 Cr 12 G 19 9 L (Si) ISO 14343 steel

Austenitic stainless X5 CrNi19 11 G 19 9 L (Si) ISO 14343 steel

Casted aluminium S AL 4043 ISO 18273 alloy

Aluminium alloy AW5xxx / AW6xxx S AL 5xxx ISO 18273

Consumables, employed according to the WPQR, must hold a type « DB Abnahme » certificate available from the supplier. The grades of base metals and gas employed must figure there; otherwise, the consumable must not be utilized. The label must imperatively show the marking « CE » accompanied by a certification number and the name of the certifying body.

13.2. Qualification of filler metal

The filler metal are delivered accompanied with a certificate 2.2 following one EN10204 (at least). In addition, the wire- electrodes intended for the welding of aluminium alloys are tested according to the procedure SSC RS WMS 006

13.3. Supplies, Storage, Distribution

Site procedures define the supply, storage, conservation, manipulation and utilization conditions for consumables in order to avoid any damage, degradation and error of utilization, according to the instructions of the consumable supplier.

14. BASE MATERIAL

14.1. Definition

They are specified by the following specifications:

DTRF 150201 : carbon steel sheets DTRF 150202 : aluminium profiles DTRF 150203 : casted parts aluminium DTRF 150204 : steel castings DTRF 150207 : forged parts aluminium DTRF 150208 : steel forgings DTRF 150216 : aluminium alloy sheets According to standards for austenitic and ferritic stainless steel sheets

14.2. Supplying, storage and manipulation

In all cases the base metals supplied according to the corresponding DTRF or similar standard must be delivered accompanied by a type 3.1 certificate according to EN 10204 A site procedure must define the storage and manipulation conditions for base metals, primary parts and mechanically-welded sub-assemblies in order to avoid any damage, degradation, pollution etc..

Except for indication to the contrary, primary parts are delivered in sheet without taking into account the direction of lamination.

14.3. Primary Parts

The methods department, on the basis of the drawings and the industrial process define / modify / hold up to date the drawings of the primary parts by integrating appendixes, over lengthes, the pre-deformations and according to the degree of complexity of parts the sizes to be used to control them The manufacture of the first parts and the pronunciation of the GO-series validate the quality of the primary parts. Quality of the welded edges If no tolerance is mentioned in the drawing and\or according to the manufacturing process, the quality of cut edges according to ISO9013 will have to be at least :

carbon steels and stainless steel : class 54 aluminium alloys : class 44

Except for indication to the contrary (defined by methods Department) no measurement is carried out on the cut faces. The primary parts are obtained according to the industrial process by laser cutting, plasma cutting, oxy-cutting, punching, shearing with or not grinding or machining. The edges shall be regular, exempt of wrench or bavure A repair process (according to ISO15613) is required to handle irregularities (such as start grooves) which may be detrimental to performing the weld or to its end quality. These checks are to be carried out before welding.

15. CLEANING AND PASSIVATION OF STAINLESS STEEL

Because of using acide, a specific attention is provided for overlap assembly parts and retention areas (these points shall be check during design reviews). When ask, the following operation shall be performed

15.1. Degreasing

This operation shall be perform in case of stain, paint, lubricant for machining. The products used can be : - solvent

- or detergent - or washing powder

15.2. Rinsing With

running water

15.3. Mechanical or chemical pickling

- Brushing with inox brush - or grinding with specific inox tools - or sand blasting - or bath 10%HNO3 + 2%HF at room temperature - or paste for welded joints apply with brush or sponge - or Manual electrolytic cleaning

15.4. Rinsing With

running water

15.5. Passivation

- bath of 20 to 25% HNO3 at room temperature - or paste for welded joints apply with brush or sponge

15.6. Rinsing

- With running water

15.7. Drying

With dry air and without oil

16. POST-WELD HEAT TREATMENT

16.1. For carbon steel

PWHT is perform if demanded by designer. Post-weld heat treatment is an essential variable of the WPQR. Any unauthorized addition or suppression of heat treatment is forbidden. The heat treatment applied to a sub-assembly must comply with that defined in the WPQR, to the nearest tolerance and undergo a recording (heat treatment curve) checked and approved by the welding coordinator. No straightening operations may be carried out after heat treatment. A site procedure will cover the control of PWHT The heat treatment parameters fixed are the following:

16.1.1. Loading in the oven

At ambient temperature or in every case less than 200°C, elements to be treated have to be placed so that the heat can circulate freely between them.

16.1.2. Control of temperature

The unit will be provided with enough thermocouples which will be set to indicate the temperatures at the highest and lowest stages. We shall consider the average of the readings between the recorded extreme values; the difference of temperature will have to exceed 40°C, whatever the phases of the treatment are (rate, maintain, cooling).

16.1.3. Increase of temperature

The increase will have to be made slowly : maximum speed of temperature rise 150°C / hour.

16.1.4. Treatment

Motor with magnetic lamination : temperature to obtain is 590°C to be held during 5 hours

Bogie element : 590°C to be held during 3 hours Other sub-assembly : minimum hold time is 2 min/mm with a minimum of an hour.

16.1.5. Cooling

low cooling in the oven at 120°C/hour maximum. The oven will be opened when the treated load will achieve a temperature of 200°C. At this stage, stabilized elements shouldn’t be exposed to a cold draught

16.1.6. Inspection

Every stabilization operation will be registered on a graph. The graph will have to allow the reading of the treatment phases (max.-, min. temperature, duration…)

16.2. For aluminium alloys and stainless steels

No heat treatment is carried out on these base materials

17. INSPECTIONS AND TESTS

17.1. General

The applicable inspections and tests are carried out at the stages defined in the industrial process. Good practices define what the welder or operator must check before, during and after the welding operation without a record being made. The inspection plan defines the inspections to be carried out to make sure of the conformity of the product.

17.2. Good Practices

These are defined for each site and are requirements which welders must respect for welding of steel and aluminum alloy base metals ; these apply most particularly to

Welding equipment Reading of work documents Welding consumables Preparation of the parts to be welded, Tack welding run off and run on plates Preheating, post-heating and temperature between runs Sealing runs, multi-pass welding Specific welds: fillet welds, plug welds Repairs, perfection Visual inspection of CPD, CPC3, CPC2 welds Health and security

17.3. Inspection plan

Drawn up according to site procedures, this is a compilation of the destructive tests (as production weld tests), non-destructive tests and dimensional inspections to be carried out on a sub-assembly, bogie, motor, underframe… Based of the list of welded joints, it define for each welded joint the type, range, method of NDT, the levels of evaluation and acceptance for start of production and serial production. The coordinator shall define how many sub-assemblies / assemblies (according to risk, complexity, return of experience…) must be tested according start of production criteria.

Start of production :

Weld Quality level Class of Volumetric test Surface Visual performance for control

RT or UT test testing

class imperfections

CT

MT or PT VT

EN ISO 5817

CP

EN ISO

10042

B B 2 100% 100% 100%

C1 C 2 100% 100% 100%

C2 C 3 NR NR 100%

C3 C 4 NR NR 100%

D D 4 NR NR 100%

NR = not required

Inspections shall be documented

Serial production

Weld Quality level Class of Volumetric test Surface Visual performance for control

RT or UT test testing

class imperfections

CT

MT or PT VT EN ISO 5817

CP

EN ISO

10042

B B 2 10% 10% 100%

C1 C 2 10% 10% 100%

C2 C 3 NR NR 100%

C3 C 4 NR NR 100%

D D 4 NR NR 100%

NR = not required

Inspections shall be documented except for CPD It does not concern inspections carried out during the qualification of a welding process, of a welder or an operator, in finishing, during tests…

17.3.1. Dimensional and Geometric Inspections

For each vehicle, sub-assembly , on the basis of plans and manufacturing processes, the inspection plan defines the dimensional and geometric inspections to be performed, their frequency and the results to be obtained. If no tolerance is mentioned in the plan, Standard EN ISO 13920 will apply:

Class B for linear and angular dimensions Class F for straightness, flatness and parallelism.

17.3.2. Destructive Inspections

17.3.2.1. Arc welding

Welded joints CPB and CPC1 with partial penetration : Destructive tests on production weld test to demonstrate the quality of the weld are performed according EN

ISO 15613.

Or Non-destrustive testing (RT / UT) subject to demonstration by ALSTOM that the NDT method and

technique adopted can demonstrate the quality of the weld.

The inspection plan specifies the frequency

17.3.2.2. Stud welding and resistance welding

Each day before starting manufacturing In case of change of WPS After change of setting In case of non-conformity

3 studs, VT and bending test 30° according to EN ISO14555 3 spot welds, VT and chisel test according to EN ISO10447

17.3.3. Non-destructive Inspections

SSC RS WMS 001 : colored penetrant testing SSC RS WMS 003 : ultrasonic testing

SSC RS WMS 005 : magnetic particules testing SSC RS WMS 009 : visual testing

These procedure define for each NDT method the application, the precautions, the evaluation, acceptance level

and the examination report according to the quality level following standards ISO5817 / 10042.

17.3.4. Leak testing

to be define by each site according to the application.

17.3.5. Quality Level of imperfections

The NDT instructions listed on top (§17.3.3) define the quality level of imperfections (according each method and technique applied)

Spatters (except for indication to the drawing) : No spatter is accepted on :

Visible surfaces (by the passengers) Filmed surfaces Mechanical interfaces Interiors of motors, gearboxes and transmission systemes. Overlap surfaces

Other cases, spatters (Diameter < 2mm) are accepted according to the following limits : CPB 1 spatter by surface 50 x 50 mm

CPC1, CPC2, CPC3 4 spatters by surface 50 x 50 mm

CPD 8 spatters by surface 50 x 50 mm

Closed, waterproof, No limitation of diameter and quantity airproof areas

18. NON-COMPLIANCE AND CORRECTIVE ACTIONS

Each site has procedures for handling non-compliances and the implementation of corrective actions. It is to be noted that the inspection plan takes the requirements from the standard with regard to additional inspections to be carried out in the case of non-compliant welds.

19. CALIBRATION AND VALIDATION OF MEASURING, INSPECTION AND TEST EQUIPMENT

Annual calibration / verification and after maintenance and repair opération is mandatory for:

Welding : welding generators (U, I, wire speed) Resistance welding machines (current, force) PWHT : recorder of heat and associated thermocouple treatment cycle Measurement : ampermeter / voltmeter, NDT : ultrasound equipment, luxmeter, industrial radiographic illuminator, measurement devices for

tangential and residual fields

20. IDENTIFICATION AND TRACEABILITY

In the absence of contrary or additional requirements expressed by the client or by the design office / RAMS (in the case of secure parts for example), the rules hereafter will apply and will be the subject of site procedures:

20.1. Material

The different base material will be traced until the cutting. Thereafter traceability is maintained for the scrap with a view to its later use.

20.2. Personnel

The names, date and signatures of the personnel having performed the non-destructive inspections on the CPB, CPC1, C2 and C3 welds must appear on the final reports.

20.3. Sub-Assemblies, Components and Assemblies

The marking of the structural sub-assemblies (mark, serial number for example) is realized in marking aeras defined on the drawings with balls stamps

20.4. Modifications

The application of the design modifications must to be traced according site procedure

21. QUALITY RECORDS

Each site has its procedures for handling quality records. The contractual requirement additional to the Chapter 18 of Standard ISO3834-2 are included into the « Additional welding specification for the project X »

Annexe A (informative) Relationship between the chapters of standard EN ISO 3834-2 and those of document

DTRF 150221

Chapter n° of Chapter n° of standard TITLE OF THE CHAPITER OF THE STANDARD document DTRF

EN ISO 3834-2 150221

5 Requirement review and technical review 7

5.1 General 7

5.2 Requirement review 7

5.3 Technical review 7

6 Sub-contracting 8

Production transfer from one site to another 8

7 Welding Personnel 9

7.1 General 9

7.2 Welder and welding operators 9

7.3 Welding coordinating personnel 9

8 Inspection and testing personnel 10

8.1 General 10

8.2 Personnel in charge of the non destructive tests 10

9 Equipment 11

9.1 Production and test equipment 11

9.2 Equipment description 11

9.3 Equipment capacity 11

9.4 New Equipment 11

9.5 Equipment maintenance 11

10 Related welding activities 12

10.1 Production planning 12

10.2 WPS 12

10.3 WPQR 12

10.4 Work instructions 12, 15

10.5 Preparation and control procedures of documents 12

11 Welding consumable products 13

11.1 General 13

11.2 Batch inspection 13

11.3 Storage and handing 13

12 Storage of base material 14

13 Thermal treatment after welding 16

14 Inspection and tests 17

14.1 General 17

14.2 Inspections and tests before welding 17, 12

14.3 Inspections and tests during welding 17

14.4 Inspections and tests after welding 17

14.5 Inspections and tests states (inspection plan) 17

15 Non-conformities and corrective measures 18

16 Calibrations and validations of measuring, inspection and 19 testing equipment

17 Identification and traceability 20

18 Quality-related recordings 21