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Engineering Specifications ENS0211 CNH Arc Welding Quality ECO REV CHANGES BY DATE STD0425 A Released referral to Case Engrg Specification ES-B211 S Hile 4MAY04 35048667 B Release for Production, Replace referral to
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    Engineering Specifications   ENS0211   ISSUED BY ECO NO. NAME GRM  35048667 6AUG07   CNH ARC WELDING QUALITY  APPROVED BY REV. PAGE CNH NUMBERJLW   6AUG07  B 1 OF 37 86979030   THE INFORMATION HEREON IS THE CONFIDENTIAL AND PROPRIETARY PROPERTY OF CNH GLOBAL N.V. AND/OR ITS SUBSIDIARIES OR DIVISIONS. ANY USE, EXCEPT THAT FOR WHICH IT MAY BE LOANED, IS PROHIBITED. UNCONTROLLED COPY  When Printed CNH Arc Welding Quality ECO REV CHANGES BY DATE STD0425 A Released referral to Case Engrg Specification ES-B211 S Hile 4MAY04 35048667 B Release for Production, Replace referral to ES-B211 G Mussell 6AUG07    Engineering Specifications   ENS0211   NAME REV.PAGE CNH NUMBER CNH ARC WELDING QUALITY B 2 OF 37 86979030   UNCONTROLLED COPY  When Printed TABLE OF CONTENTS 1.   PURPOSE ............................................................................................................................................................3   2.   SCOPE .................................................................................................................................................................3   3.   DEFINITIONS/ACRONYMS ................................................................................................................................4   3.1   DEFINITIONS..................................................................................................................................................4   3.2    ACRONYMS....................................................................................................................................................4   4.   RELATED DOCUMENTS ....................................................................................................................................4   4.1   RELATED STANDARDS.................................................................................................................................4   4.2   REPLACED STANDARDS..............................................................................................................................4   5.   CLASSIFICATION OF WELDS AND ADJACENT SURFACES ........................................................................4   5.1   CATEGORY 1 - PRIMARY FUNCTION WELDS............................................................................................5   5.2   CATEGORY 2 - COSMETIC WELDS AND ADJACENT SURFACES............................................................5   5.3   CATEGORY 3 – ALL OTHER WELDS AND (CLASS C) PROTECTIVE COATED SURFACES...................6   5.4   WELD REQUIREMENTS - CATEGORY 1 WELDS........................................................................................6   5.5   WELD AND SURFACE REQUIREMENTS – CATEGORY 2 WELDS............................................................8   5.6   WELD AND SURFACE REQUIREMENTS – CATEGORY 3 WELDS............................................................8   6.   WORKMANSHIP REQUIREMENTS FOR ALL ARC WELDING PROCESSES ................................................8   7.   FINISHED WELD QUALITY REQUIREMENTS ................................................................................................10   8.   INSPECTION AND TESTING ............................................................................................................................18   9.   REPAIR OF WELD DEFECTS ..........................................................................................................................18   9.1   WELD CRATERS..........................................................................................................................................18   9.2    ARC STRIKES OUTSIDE THE WELD JOINT, INCOMPLETE FUSION, CRACKS, POROSITY AND THREE DIMENSIONAL DEFECTS........................................................................................................................18   9.3   UNACCEPTABLE   UNDERCUT.....................................................................................................................19   9.4   OVERLAP......................................................................................................................................................19   9.5   UNDERSIZE AND SHORT WELDS..............................................................................................................19   9.6   OVERSIZE AND LONG WELDS...................................................................................................................19   9.7   MISLOCATED HOLES..................................................................................................................................19   9.8   MISLOCATED PARTS...................................................................................................................................20   9.9   EXCESS COPPER........................................................................................................................................20   10.   PROCESS CONTROL ...................................................................................................................................20   11.   IMPLEMENTATION AND LEGACY ISSUES ...............................................................................................20   APPENDIX 1 ...............................................................................................................................................................21   DETECTION AND REPAIR OF WELD DEFECTS ....................................................................................................21   WELD DEFECT:   CRACKS ................................................................................................................................22   WELD DEFECT:   WELD SPATTER ...................................................................................................................23   WELD DEFECT:   INCOMPLETE FUSION .........................................................................................................24   WELD DEFECT:   IMPROPER FILLET WELD SIZE ..........................................................................................25   WELD DEFECT:   CONCAVITY – UNDERSIZE WELD .....................................................................................26   WELD DEFECT:   CONVEXITY – OVERSIZE WELD ........................................................................................27   WELD DEFECT:   UNDERCUT ...........................................................................................................................28   WELD DEFECT:   OVERLAP ..............................................................................................................................29   WELD DEFECT:   POROSITY .............................................................................................................................30   WELD DEFECT:   UNFILLED CRATER .............................................................................................................31   WELD DEFECT:   MISSING WELD ....................................................................................................................32   WELD DEFECT:   MISLOCATED WELD ............................................................................................................33   WELD DEFECT:   MELT-THROUGH ..................................................................................................................34   WELD DEFECT:   WELD DRIP (END-MELT) .....................................................................................................35   WELD DEFECT:    ARC STRIKES .......................................................................................................................36   WELD DEFECT:   LACK OF PENETRATION ....................................................................................................37      Engineering Specifications   ENS0211   NAME REV.PAGE CNH NUMBER CNH ARC WELDING QUALITY B 3 OF 37 86979030   UNCONTROLLED COPY  When Printed CNH Arc Welding Quality 1. PURPOSE  The purpose of this document is to establish and maintain a weld quality level consistent with industry standard practice at minimum cost, and maintain confidence that CNH product welds perform their intended purpose. 2. SCOPE  This document contains workmanship and quality acceptance requirements for arc welding when manufacturing CNH Agricultural or Construction Equipment components and shall be used by both internal and external personnel engaged in designing, purchasing or manufacturing CNH products. Any questions regarding interpretation of this specification should be referred to the applicable CNH Plant Welding Engineer or to CNH’s Chief Welding Engineer. In addition, personnel should refer to the ENS02xx CNH Welding System Specifications and Standards series. Drawings, standards, operational method sheets and other forms of instructions are used in the normal course of conveying weld requirements to the welders. In all cases, the Product Engineering drawings take precedence over all other forms of instructions - then the CNH Welding Specifications and Standards apply, followed by any other documents. Where drawings and/or contracts specifically reference ISO 5817 and the criteria of ISO 5817 for a specific weld quality attribute is more restrictive, the more restrictive criteria shall be applied. Otherwise ENS0211 criteria shall be applied. Specific practices and parameters used for production welding are to be based on those used to qualify the process. This is accomplished through a qualified Welding Procedure Specification (WPS) based on one or more Procedure Qualification Records in accordance with ENS0201. In the event a desirable welding related practice is in conflict with this specification or ENS0201 - justification and approval of the practice shall be pursued through CNH’s Chief Welding Engineer with documented technical rationale.  Appendix 1 has been added to provide a greater understanding of the primary cause(s) of specific weld defects and the actions that can help avoid them. Welding personnel shall be qualified separately for each welding process and mode of transfer used in production (i.e., separate welder qualification tests for SMAW, GMAW-spray, GMAW-Pulsed, GMAW-globular, GMAW-Short Arc, FCAW, SAW, etc.). An effective training, qualification and process control program is necessary to consistently apply these quality requirements. This program must include the following elements as they apply to the processes used by each operations center (i.e. CNH Benson, CNH Grand Island, CNH Zedelgem, Supplier XYZ, etc.) performing the work: ã  Process Safety ã  Basic Process Information ã  Welding Symbol & Drawing Interpretation ã  Review of Quality Specification Details ã  Hands-on Process Application and Qualification Testing ã  Process Control Procedure    Engineering Specifications   ENS0211   NAME REV.PAGE CNH NUMBER CNH ARC WELDING QUALITY B 4 OF 37 86979030   UNCONTROLLED COPY  When Printed 3. DEFINITIONS/ACRONYMS  Welding Definitions and Acronyms used in this document, unless otherwise specified, are based on the latest version of AWS A3.0. Weld symbols used to show welding and inspection requirements shall be in accordance with CNH Drawing Standard DWGA130. 3.1 DEFINITIONS Stops and Starts – The start and stop locations of a single weld segment. Welding Engineer – Engineer with a welding technical degree responsible for supporting specific welding/manufacturing operations. 3.2 ACRONYMS  AWS––American Welding Society CE––Carbon Equivalent DFS––Deviation From Specification WPS––Welding Procedure Specification 4. RELATED DOCUMENTS  4.1 RELATED STANDARDS  AWS A3.0 (latest) - Standard Welding Terms and Definitions  AWS D14.3 (latest) - Specification for Welding Earthmoving, Construction and Agricultural Equipment DWGA130 - Weldments - Symbols and Drawing Practices ENPJ220 – Deviation from Specification ENS0201 – CNH Arc Welding Procedure ENS0301 - CNH Significant Characteristics ISO 5817 – Welding – Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) – Quality levels for imperfections MAT4125S – Arc Welds, Sample Evaluation Requirements 4.2 REPLACED STANDARDS Case ES-B211 Case Welding Quality Standard – Arc Welding ES 48.11 Zedelgem Standard on Arc Welding FNHA-4-A-006.00 (86574453) New Holland Welding Quality Standard 5. CLASSIFICATION OF WELDS AND ADJACENT SURFACES  CNH divides weld joints into three categories. Category 1 welds are Primary Function Welds. Category 2 welds are Cosmetic Welds and Adjacent Surfaces. Category 3 welds comprise all Other Welds and Protective Coated Surfaces. Category 3 welds must meet all of the requirements for Workmanship, Quality, Repair and Process Control as defined in Sections 6-10. Category 2 welds are subdivided into  Appearance and Service Visible Surfaces, and they have several cosmetic requirements as described in Paragraphs 5.2.1 and 5.2.2. Category 1 welds must meet all of the requirements of Category 3 welds, and the additional requirements for fit-up gap, undercut, overlap etc. as described in Paragraph 5.4.
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