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British Standard
A single copy of this British Standard is licensed to
Tom Magee
18 June 2003
This is an uncontrolled copy. Ensure use of the most
current version of this document by searching British
Standards Online at bsonline.techindex.co.uk
a
Date: 8 March 2002
Origin: European
Latest date for receipt of comments: 31.05.2002 Project no.: 1994/01384
Responsible committee: ISE/35 Cast Iron
Interested committees: WEE/35, WEE/-/1
Title: Draft British Standard BS EN 1011-8 Welding - Recommendations for welding of metallic materials - Part 8:
Welding of cast irons
Supersession information: If this document is published as a standard, the UK implementation of it will supersede
BS4570 : 1985 . If you are aware of a current national standard which may be affected, please notify the secretary
(contact details below).
WARNING: THIS IS A DRAFT AND MUST NOT BE REGARDED OR USED AS A BRITISH STANDARD.
THIS DRAFT IS NOT CURRENT BEYOND 31.05.2002.
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Introduction
This draft standard is based on European discussions in which the UK took an active part. Your comments on this
draft are welcome and will assist in the preparation of the consequent British Standard. If no comments are received
to the contrary, then the UK will approve this draft and implement it as a British Standard. Comment is particularly
welcome on national, legislative or similar deviations that may be necessary.
Even if this draft standard is not approved by the UK, if it receives the necessary support in Europe, the UK will be
obliged to publish the official English Language text unchanged as a British Standard and to withdraw any conflicting
standard.
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Please indicate whether you consider the UK should submit a negative (with reasons) or positive vote on this draft.
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technical/editorial)
Comment (with rationale) Proposed change
3.1 1st definition Editorial Definition is ambiguous and needs
clarifying.
Amend to read ... so that the mains
connector to which no connection ...
6.4 2nd paragraph Technical The use of the UV photometer as an
alternative cannot be supported as
serious problems have been
encountered in its use in the UK.
Delete reference to UV photometer.
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EUROPEAN STANDARD
NORME EUROPENNE
EUROPISCHE NORM
DRAFT
prEN 1011-8
March 2002
ICS
English version
Welding - Recommendations for welding of metallic materials -
Part 8: Welding of cast irons
Soudage - Recommandations pour le soudage des
matriaux mtalliques - Partie 8: Soudage des fontes
Schweien - Empfehlungen zum Schweien metallischer
Werkstoffe - Teil 8: Schweien von Gusseisen
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 190.
If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a national standard without any alteration.
This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language
made by translation under the responsibility of a CEN member into its own language and notified to the Management Centre has the same
status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMI T EUROPEN DE NORMALI SATI ON
EUROPI SCHES KOMI TEE FR NORMUNG
Management Centre: rue de Stassart, 36 B-1050 Brussels
2002 CEN All rights of exploitation in any form and by any means reserved
worldwide for CEN national Members.
Ref. No. prEN 1011-8:2002 E
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prEN 1011-8:2002 (E)
2
Contents
Foreword......................................................................................................................................................................3
1 Scope ..............................................................................................................................................................4
2 Normative references ....................................................................................................................................4
3 Terms and definitions....................................................................................................................................4
4 Abbreviations and symbols..........................................................................................................................5
5 Provision for quality assurance requirements ...........................................................................................5
6 Storage, handling and identification of parent metal.................................................................................5
7 Fusion welding processes............................................................................................................................5
8 Welding consumables...................................................................................................................................6
8.1 General ............................................................................................................................................................6
8.2 Supply, storage and handling.......................................................................................................................6
9 Equipment.......................................................................................................................................................6
9.1 General ............................................................................................................................................................6
9.2 Ancillary equipment.......................................................................................................................................6
10 Fabrication......................................................................................................................................................7
10.1 General ............................................................................................................................................................7
10.2 Butt welding ...................................................................................................................................................7
10.3 Fillet welding ..................................................................................................................................................7
11 Weld preparation............................................................................................................................................7
11.1 Joint welds......................................................................................................................................................7
11.2 Finishing welds and repair welds.................................................................................................................7
12 Positioning of parts to be welded ................................................................................................................7
13 Pre-heat temperature and interpass temperature ......................................................................................8
14 Tack welds......................................................................................................................................................8
15 Temporary attachments ................................................................................................................................8
16 Run-on plates and run-off plates..................................................................................................................8
17 Arcing..............................................................................................................................................................8
18 Inter-run cleaning and inter-run treatment..................................................................................................8
19 Heat input........................................................................................................................................................8
20 Welding procedure specification (WPS)......................................................................................................8
21 Traceability .....................................................................................................................................................8
22 Peening ...........................................................................................................................................................8
23 Inspection and testing...................................................................................................................................9
24 Quality requirements.....................................................................................................................................9
25 Correction of non-conformity.......................................................................................................................9
26 Distortion ........................................................................................................................................................9
27 Post weld heat treatment ..............................................................................................................................9
28 Post weld cleaning.........................................................................................................................................9
Annex A (normative) Quality assurance requirements .........................................................................................10
Annex B (informative) Welding technology for cast iron castings ......................................................................15
Bibliography ..............................................................................................................................................................19
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prEN 1011-8:2002 (E)
3
Foreword
This document (prEN 1011-8) has been prepared by Technical Committee CEN/TC 190 "Foundry Technology", the
secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
Within its programme of work, Technical Committee CEN/TC 190 requested CEN/TC 190/WG 5 "Welding of cast
iron" to prepare the following standard:
prEN 1011-8, Welding Recommendations for welding of metallic materials Part 8: Welding of cast irons.
This is one of a series of European Standards for requirements for fusion welding of metallic materials.
According to CEN/CENELEC Internal Regulations, the following countries are bound to implement this European
Standard:
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1 Scope
This draft European Standard specifies the requirements for fusion welding of unalloyed and low-alloy cast iron
castings produced in accordance with
EN 1561, Founding Grey cast irons;
EN 1562, Founding Malleable cast irons;
EN 1563, Founding Spheroidal graphite cast irons.
2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications. These
normative references are cited at the appropriate places in the text and the publications are listed hereafter. For
dated references, subsequent amendments to or revisions of any of these publications apply to this European
Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the
publication referred to applies (including amendments).
EN 288-2, Specification and approval of welding procedures for metallic materials Part 2: Welding procedure
specification for arc welding.
EN 729-1, Quality requirements for welding Fusion welding of metallic materials Part 1: Guidelines for selec-
tion and use.
EN 1011-1, Welding Recommendations for welding of metallic materials Part 1: General guidance for arc
welding.
EN 12536, Welding consumables Rods for gas welding of non alloy and creep-resisting steels Classification.
EN 25817, Arc-welded joints in steel Guidance on quality levels for imperfections (ISO 5817:1992).
EN ISO 4063, Welding and allied processes Nomenclature of processes and reference numbers
(ISO 4063:1998).
NOTE Informative references to documents used in the preparation of this standard, and cited at the appropriate places in
the text, are listed in the bibliography.
3 Terms and definitions
For the purposes of this standard, the following terms and definitions apply:
3.1
production welding
any welding carried out during manufacturing before final delivery to the end user
NOTE It includes joint welding and finishing welding (see 3.2 and 3.3).
3.2
joint welding
production welding used to assemble components together to obtain an integral unit
3.3
finishing welding
production welding carried out in order to ensure the agreed quality of the casting
3.4
repair welding
any welding carried out after final delivery of the casting to the end user
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prEN 1011-8:2002 (E)
5
3.5
homogeneous filler metal
any filler metal which results in a deposited metal with the same type of microstructure as the parent metal
3.6
semi-homogeneous filler metal
any filler metal which results in a deposited metal with a steel-type microstructure
3.7
non-homogeneous filler metal
any filler metal which results in a deposited metal with a microstructure that differs from the parent metal
3.8
cast welding
welding by pouring liquid metal into a specially prepared groove in a casting
3.9
liquid metal welding
cast welding with additional use of a metal arc welding process
4 Abbreviations and symbols
For the purposes of this standard, the abbreviations and symbols given in EN 1011-1 shall apply.
5 Provision for quality assurance requirements
For the purposes of this standard, the provisions for quality assurance requirements given in annex A shall apply.
6 Storage, handling and identification of parent metal
Storage and handling shall be carried out in such a manner that the parent metal is not adversely affected.
Provision shall be made for correct identification, e.g. grade and storage.
7 Fusion welding processes
Fusion welding processes shall be either one or a combination of the following welding processes with their
reference number in accordance with EN ISO 4063:
111 manual metal arc welding (metal arc welding with covered electrode);
114 self-shielded tubular-cored arc welding;
12 submerged arc welding;
13 gas-shielded metal arc welding;
141 tungsten inert gas welding; TIG welding;
15 plasma arc welding;
185 magnetically impelled arc butt welding;
24 flash welding;
311 oxy-acetylene welding;
42 friction welding;
71 aluminothermic welding;
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and additionally:
cast welding;
liquid metal welding.
Other fusion welding processes shall be agreed between the manufacturer and the purchaser by the time of
acceptance of the order.
8 Welding consumables
8.1 General
An appropriate filler metal (see 3.5, 3.6 and 3.7) shall be selected in accordance with the requirements of the weld
and the welding process.
Any special recommendations given by the manufacturer and/or supplier of the welding consumables shall be
taken into account.
Welding consumables (e.g. filler metals, gases and fluxes) shall conform to the appropriate European and/or ISO
Standards, as applicable, (see annex B, Tables B.1 and B.2).
It can be necessary to manufacture appropriate filler metals, especially for oxy-acetylene and liquid metal
welding.To avoid confusion, such products shall be identified.
8.2 Supply, storage and handling
For the purposes of this standard, the supply, storage and handling requirements given in EN 1011-1 shall apply.
9 Equipment
9.1 General
For the purposes of this standard, the equipment requirements given in EN 1011-1 shall apply.
9.2 Ancillary equipment
If applicable, the ancillary equipment shall include:
a) power source for welding equipment and additional machinery;
b) facilities for joint preparation;
c) facilities for preheating and post-weld heat treatment including temperature measurement equipment;
d) cranes and other handling equipment;
e) peening equipment;
f) electrode baking ovens, electrode bags etc. for handling filler metals;
g) cleaning equipment;
h) equipment for destructive and non-destructive testing;
i) fixtures and welding jigs;
j) personal protection equipment directly connected with welding.
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10 Fabrication
10.1 General
When planning the welding of cast iron castings, consideration shall be given to the:
need for trained and approved welders;
need for a responsible welding coordinator;
casting geometry;
temperature control;
stress conditions caused by welding;
material behaviour;
working conditions;
inspection requirements.
NOTE Selection of the requirement category (see EN 729-1) is recommended and should be carried out with due consid-
eration of any special operating conditions and joint strains together with any economic factors.
Prior to welding, there shall be an agreement made between the parties concerned which includes the require-
ments for finishing welding, joint welding and repair welding, as applicable.
If applicable, finishing and/or repair welding methods to correct casting non-conformities shall be carefully planned
and prepared.
The casting surface to be welded shall be checked by a suitable non-destructive test method, in order to ensure
complete removal of any casting non-conformity.
10.2 Butt welding
Butt welding shall be in accordance with EN 1011-1.
10.3 Fillet welding
Fillet welding shall be in accordance with EN 1011-1.
11 Weld preparation
11.1 Joint welds
Preparation shall be carried out in accordance with EN 1011-1.
NOTE In addition, joint welding should meet the recommendations given in Table B.1 and Table B.2.
11.2 Finishing welds and repair welds
Preparation shall remove any crack, pore, notche and contamination. The area to be welded shall be suitable for
the welding process (see B.1 and B.2).
NOTE Recommendations on weld preparation are given in B.2.
If contamination cannot be removed (e.g. during repair welding), other measures shall be used, such as the
selection of special filler metals.
12 Positioning of parts to be welded
Positioning of parts to be welded shall be carried out in accordance with EN 1011-1.
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13 Pre-heat temperature and interpass temperature
The pre-heat temperature T
p
and interpass temperature T
i
shall be within the recommended values given in B.4 and
Tables B.1 and B.2 for the following:
filler metal;
parent material grade;
geometry of the casting;
welding process;
welding parameters.
14 Tack welds
Tack welds shall be in accordance with EN 1011-1.
15 Temporary attachments
Temporary attachments shall be in accordance with EN 1011-1.
16 Run-on plates and run-off plates
Run-on and run-off plates shall be in accordance with EN 1011-1.
17 Arcing
Arcing shall be in accordance with EN 1011-1.
18 Inter-run cleaning and inter-run treatment
Inter-run cleaning and inter-run treatment shall be in accordance with EN 1011-1.
19 Heat input
If applicable, heat input can be estimated in accordance with EN 1011-1.
20 Welding procedure specification (WPS)
If a wleding procedure specification is required:
for arc welding its content shall be in accordance with EN 288-2;
for other welding methods, its content may be modified. In this case, its content shall be agreed in writing be-
tween the parties concerned.
21 Traceability
Traceability shall be in accordance with EN 1011-1.
22 Peening
Peening shall be in accordance with EN 1011-1.
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NOTE To minimize residual stress, when using non-homogeneous filler metal, peening is recommended immediately after
welding. For further information, see the instructions of the filler metal manufacturer.
23 Inspection and testing
Inspection and testing shall be carried out in accordance with the contract.
24 Quality requirements
Quality requirements shall be in accordance with EN 1011-1.
The requirement class and/or the quality level shall be agreed between the manufacturer and the purchaser prior to
welding. Joint welds shall conform to the requirement class given in Table A.1, and/or the quality level given in
Table A.2.
25 Correction of non-conformity
Correction of non-conformity shall be carried out in accordance with EN 1011-1.
26 Distortion
If necessary, the method of correction of castings unacceptably distorted by the welding process shall be agreed
between the manufacturer and the purchaser.
NOTE Any method used to correct distortion should not be deleterious to the casting structure.
27 Post weld heat treatment
The details of any post weld heat treatment shall be agreed between the manufacturer and the purchaser prior to
welding (see recommendations in Table B.1 and B.2).
NOTE Post weld heat treatment can be necessary because of the need to reduce residual stresses in welded castings
and/or to adjust the mechanical properties of the material.
28 Post weld cleaning
Post weld cleaning shall be in accordance with EN 1011-1.
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Annex A
(normative)
Quality assurance requirements
A.1 General
This annex gives information on the quality assurance requirements that need to be met. The requirement class,
quality level and corresponding tests shall be chosen so as to achieve the mechanical properties of the casting.
Test frequencies and test methods are not given in this annex.
The test requirements shall be agreed between the manufacturer and the purchaser by the time of acceptance of the
order.
A.2 Requirements for fusion welding
A.2.1 Agreement
In planning the welding procedure for the particular cast iron casting, the following shall be considered:
stresses caused by the welding process;
the weldability of the material;
the operating conditions;
the test procedures.
For each welded casting, only the requirements concerning the necessary conditions of use of the component shall
be defined. These requirements and the quality levels shall be agreed between the manufacturer and the purchaser
by the time of acceptance of the order (see Tables A.1 and A.2). This agreement shall be recorded.
A.2.2 Requirements
The three requirement classes and eleven criteria for fusion welding are given in table A.1.
The requirement class for weld workmanship criterion shall be selected from Table A.1. The weld workmanship (No. 1
in Table A.1) requirement class limits for external and internal imperfections shall be chosen by reference to
Table A.2.
1) excess weld metal
2) excessive convexity
3) incompletely filled groove
4) fillet weld having a throat thickness smaller than the nominal value
5) excessively asymmetric fillet weld