SIST EN 13981-1:2004

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Aluminium and aluminium alloys - Products for structural railway applications - Technical conditions for inspection and delivery - Part 1: Extruded productsAluminium und Aluminiumlegierungen - Erzeugnisse für tragende Anwendungen im Schienenfahrzeugbau - Technische Lieferbedingungen - Teil 1: StrangpresserzeugnisseAluminium et alliages aluminium - Produits pour applications ferroviaires structurales - Conditions techniques de contrôle et de livraison - Partie 1: Produits filésAluminium and aluminium alloys - Products for structural railway applications - Technical conditions for inspection and delivery - Part 1: Extruded products77.150.10Aluminijski izdelkiAluminium products45.040Materiali in deli za železniško tehnikoMaterials and components for railway engineeringICS:Ta slovenski standard je istoveten z:EN 13981-1:2003SIST EN 13981-1:2004en01-junij-2004SIST EN 13981-1:2004SLOVENSKI
STANDARD



SIST EN 13981-1:2004



EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 13981-1August 2003ICS 77.150.10English versionAluminium and aluminium alloys - Products for structural railwayapplications - Technical conditions for inspection and delivery -Part 1: Extruded productsAluminium et alliages d'aluminium - Produits pourapplications ferroviaires structurales - Conditionstechniques de contrôle et de livraison - Partie 1: ProduitsfilésAluminium und Aluminiumlegierungen - Erzeugnisse fürtragende Anwendungen im Schienenfahrzeugbau -Technische Lieferbedingungen - Teil1:StrangpresserzeugnisseThis European Standard was approved by CEN on 7 May 2003.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and UnitedKingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2003 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 13981-1:2003 ESIST EN 13981-1:2004



EN 13981-1:2003 (E)2ContentsForeword.41Scope.52Normative references.53Terms and definitions.64Ordering information.65Requirements.75.1Production and manufacturing processes.75.2Quality assurance.75.3Alloys, chemical composition and tempers.75.4Mechanical properties of extruded products.85.4.1Mechanical properties of extruded products under static loading.85.4.2Mechanical properties of extruded products under cyclic loading.85.5Mechanical properties of welded joints.85.5.1General.85.5.2Mechanical properties of welded joints under static loading.85.5.3Mechanical properties of welded joints under cyclic loading.95.6Extrusion seams.105.7Internal walls of hollow profiles.105.8Freedom from surface defects.105.9Tolerances on dimensions and form.106Qualification procedures.106.1First-off article approval procedure.106.2Additional qualification procedure.107Sampling and test methods.117.1General.117.2Analysis of chemical composition.117.3Tensile test (longitudinal).117.4Preparation of test pieces for the testing of welded joints.127.5Tensile testing on welded joints.127.6Fatigue testing (parent material and welded joints).127.7Metallographic testing.137.8Verification of soundness of extrusion seams.137.9Verification of soundness of internal walls.137.10Visual inspection.137.11Measurement of dimensions.138Traceability.139Marking of products.1310Declaration of conformity.1411Record keeping.1412Packaging.1413Application and use.1414Complaints of non-conformity.15Annex A (normative)
Bend test procedure.16A.1Test piece for bend test.16A.2Test.16A.3Acceptance criteria.17SIST EN 13981-1:2004



EN 13981-1:2003 (E)3Annex B (normative)
Mechanical properties of alloy EN AW-6008.18Annex C (normative)
Test pieces for fatigue testing.19Annex D (informative)
Guidelines for application and use.20D.1Selection of alloys.20D.1.1EN AW-6082 and EN AW-6061.20D.1.2EN AW-6005A.20D.1.3EN AW-6005.20D.1.4EN AW-6008.20D.1.5EN AW-6060, EN AW-6063 and EN AW-6106.21D.1.6EN AW-5083.21D.1.7EN AW-5754.21D.2Fatigue Design.22D.3Welding.22Bibliography.23SIST EN 13981-1:2004



EN 13981-1:2003 (E)4ForewordThis document (EN 13981-1:2003) has been prepared by Technical Committee CEN/TC 132 "Aluminium andaluminium alloys", the secretariat of which is held by AFNOR.This European Standard shall be given the status of a national standard, either by publication of an identical text orby endorsement, at the latest by February 2004, and conflicting national standards shall be withdrawn at the latestby February 2004.Within its program of work, Technical Committee CEN/TC 132 entrusted CEN/TC 132/WG 21 "Aluminium forrailway applications" to prepare the following standard :EN 13981-1, Aluminium and aluminium alloys - Products for structural railway applications - Technical conditionsfor inspection and delivery - Part 1: Extruded products.This standard is part of a set of four standards. The other standards deal with:¾ Part 2: Plates and sheets;¾ Part 3: Castings;¾ Part 4: Forgings.Annexes A, B and C are normative, Annex D is for information only.According to the CEN/CENELEC Internal Regulations, the national standards organizations of the followingcountries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal,Slovakia, Spain, Sweden, Switzerland and the United Kingdom.SIST EN 13981-1:2004



EN 13981-1:2003 (E)51 ScopeThis European Standard specifies requirements for extruded products (rod/bar, tube, profiles) which contribute tothe structural properties of the railcar bodyshell and other major structural components.The requirements on welded joints specified in this standard are not applicable to welded assemblies and sub-assemblies as they are specified for material qualification purposes only.It specifies particular requirements regarding qualification, quality control, material properties and dimensionaltolerances. Furthermore, guidelines for application and use are also given.NOTESome of the products listed in the present standard can be subject to patent or patent applications, and their listingherein does not in any way imply the granting of a licence under such patent right.CEN/TC 132 affirms that it is its policy that in the case when a patentee refuses to grant licenses on standardised standardproducts under reasonable and not discriminatory conditions, then this product is removed from the corresponding standard.2 Normative referencesThis European Standard incorporates by dated and undated reference, provisions from other publications. Thesenormative references are cited at the appropriate places in the text and the publications are listed hereafter. Fordated references, subsequent amendments to or revisions of any of these publications apply to this EuropeanStandard only when incorporated in it by amendment or revision. For undated references, the latest edition of thepublication referred to applies (including amendments).EN 515, Aluminium and aluminium alloys – Wrought products – Temper designations.EN 573-3, Aluminium and aluminium alloys – Chemical composition and form of wrought products –Part 3: Chemical composition.EN 755-1, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 1: Technical conditions forinspection and delivery.EN 755-2, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 2: Mechanical properties.EN 755-3, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 3: Round bars, toleranceson dimensions and form.EN 755-4, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 4: Square bars, toleranceson dimensions and form.EN 755-5, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 5: Rectangular bars,tolerances on dimensions and form.EN 755-6, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 6: Hexagonal bars,tolerances on dimensions and form.EN 755-7, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 7: Seamless tubes,tolerances on dimensions and form.EN 755-8, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 8: Porthole tubes,tolerances on dimensions and form.EN 755-9, Aluminium and aluminium alloys – Extruded rod/bar, tube and profiles – Part 9: Profiles, tolerances ondimensions and form.EN 895, Destructive tests on welds in metallic materials – Transverse tensile test.SIST EN 13981-1:2004



EN 13981-1:2003 (E)6EN 1011-4:2000, Welding – Recommendations for welding of metallic materials – Part 4: Arc welding of aluminiumand aluminium alloys.EN 12258-1:1998, Aluminium and aluminium alloys – Terms and definitions – Part 1: General terms.EN 30042, Arc-welded joints in aluminium and its weldable alloys – Guidance on quality levels for imperfections(ISO 10042:1992).EN 45014, General criteria for supplier’s declaration of conformity (ISO/IEC Guide 22:1996).EN ISO 4287, Geometrical Product Specifications (GPS) – Surface texture: Profile method – Terms, definitions andsurface texture parameters (ISO 4287:1997).3 Terms and definitionsFor the purposes of this European Standard, the terms and definitions given in EN 12258-1:1998 and the followingapply:3.1extrusion lotquantity of products of the same grade or alloy, form, temper, thickness or cross-section, subsequently extrudedwithout die change3.2extruded lengthlength of a profile extruded in a single pushNOTEAn extruded length can be cut into several cut lengths.3.3snap ringannular mark or blemish left on the surface of the extruded profile caused by any sudden die movement3.4stop marktransverse peripheral ridge on an extruded product arising from a stoppage during extrusion3.5structural propertyproperty having a direct effect on the static and dynamic load carrying capability of a component or assembly4 Ordering informationThe order shall define the product required for structural applications and shall contain the following information:a) designation of the aluminium alloy and temper according to EN 573-3 and EN 515; for extruded productsordered in T4 temper the purchaser shall specify whether extruded products are used afterwards in T6 temper;b) drawing of extruded product, if applicable;c) reference to this European Standard (EN 13981-1);d) Quantity:¾ total mass or number of pieces;¾ tolerances on quantity if required;SIST EN 13981-1:2004



EN 13981-1:2003 (E)7e) length of the extruded product, if applicable;f) any requirements for certificates of conformity, test and/or analysis reports or inspection certificates;g) any additional requirements agreed between supplier and purchaser;If special requirements are stated in the order agreed between supplier and purchaser which differ fromrequirements specified or referenced in this European Standard, then these special requirements shall apply.5 Requirements5.1 Production and manufacturing processesUnless otherwise specified on the order, the production and manufacturing processes shall be left to the discretionof the manufacturer.Unless it is explicitly stated on the order, no obligation shall be placed on the manufacturer to use the sameprocesses for subsequent and similar orders.Billet changes within one cut length of extruded product shall not be permitted. Unless otherwise agreed themanufacturer shall define the extent to which the transition zone between two extruded lengths has to bediscarded.5.2 Quality assuranceThe manufacturer shall establish and maintain a quality management system which should be at least equivalent toEN ISO 9001.Furthermore, the ordering rail transport enterprise may require a formal approval of the manufacturer according to aspecified procedure.The manufacturer shall establish and maintain inspection plans defining all inspections and tests to be performedon the product to fulfil the requirements of this standard and any other requirement agreed according to 4. g), thefrequency of the inspections and tests and the type of record to be established. The inspection plan shall specifyfor each inspection or test whether it is to be performed per cast, per extrusion lot, per heat treatment batch, perinspection lot or per any other lot of importance. The inspection plan shall conform as a minimum to the testprocedures and test requirements stipulated in this standard (see table 4). The inspection plan shall includeadditional schemes for appropriate process control. If required the inspection plan shall be submitted to thepurchaser for approval before start of production.The manufacturer shall be responsible for carrying out all inspections and tests required by this standard, prior tothe shipment of the product. If the purchaser wishes to inspect the product at the manufacturer's works, he shallstipulate this at the time of placing the order.The extent of inspections shall be in accordance with Table 4. Unless explicitly stated quality controls andinspections shall be performed on inspection lots. Products included in one inspection lot shall be manufactured inthe same production unit.If additional bend testing according to Annex A or any other testing is required by the purchaser, this shall bespecified on the order.5.3 Alloys, chemical composition and tempersAlloys shall be selected from the following:EN AW-5754; EN AW-5083; EN AW-6005; EN AW-6005A; EN AW-6106; EN AW-6008; EN AW-6060;EN AW-6061; EN AW-6063; EN AW-6082.Any other alloy shall be qualified according to the procedure given in 6.2.SIST EN 13981-1:2004



EN 13981-1:2003 (E)8The chemical compositions of these alloys are specified in EN 573-3. In addition, the lead (Pb) content of all alloysshall be limited to max. 0,01 %. The tempers shall be selected from those specified in EN 755-2 unless otherwiseagreed upon between supplier and purchaser. Tempers are defined in EN 515.5.4 Mechanical properties of extruded products5.4.1 Mechanical properties of extruded products under static loadingTensile strength, yield strength and elongation of extruded products shall conform to the requirements of EN 755-2unless otherwise agreed upon between purchaser and supplier and stated on the order.The mechanical properties of alloy EN AW-6008 shall conform to Annex B.5.4.2 Mechanical properties of extruded products under cyclic loadingThe minimum values for the maximum stress specified in Table 1 shall be met for all alloys and wall thicknessesunder the following conditions:Percentage of non-failure:97,5 %Number of cycles:107The test pieces shall be tested according to 7.6.Table 1 — Fatigue properties of extruded products (not applicable for design purposes, see D.2)Stress ratiomaxmin/ss=R- 10,10,5Maximum stress a, bmaxs65110180a Meeting these values is a necessary condition for the use of design codes mentioned under D.2.b If maxs exceeds the yield strength as specified in 5.4.1, maxsis equal to Rp0,2.5.5 Mechanical properties of welded joints5.5.1 GeneralProducts shall be capable of providing the properties specified under 5.5.2 and 5.5.3 in the welded condition.Values specified under 5.5.2 and 5.5.3 shall be used for qualification only, and not for design purposes.5.5.2 Mechanical properties of welded joints under static loadingThe requirements on tensile strength and yield strength of welded joints between extruded products are specified inTable 2. Test pieces shall be prepared according to 7.4 and tested according to 7.5.SIST EN 13981-1:2004



EN 13981-1:2003 (E)9Table 2 — Mechanical properties of welded butt joints, EN 30042 class C, MIG weldedthickness thickness > 15mmAlloyTemper ofparentmaterialRmMPaRp0,2MPaRmMPaRp0,2MPaEN AW-5754H11218080--EN AW-5083H112270125270125EN AW-6060T66110658555EN AW-6063T6110658555EN AW-6063T6613075--EN AW-6106T616095--EN AW-6005T616090--EN AW-6005AT6165115--EN AW-6008T6165115--EN AW-6061T6175115165115 aEN AW-6082T6185125165115 aa above 20 mm wall thickness Rp0,2 is equal to 95 MPa.5.5.3 Mechanical properties of welded joints under cyclic loadingThe minimum values for the maximum stress specified in Table 3 shall be met for all alloys and wall thicknessesunder the following conditions:Percentage of non-failure:97,5 %Number of cycles:107Welded test pieces shall be prepared according to 7.4 and tested according to 7.6.Table 3 — Fatigue properties of MIG welded butt welds (not applicable for design purposes, see D.2)Stress ratiomaxmin/ss=R-10,10,5Maximum stress a, bmaxs305580aMeeting these values is a necessary condition for the use of design codes mentioned under D.2.bIf maxs exceeds the yield strength as specified in 5.5.2, maxs is equal to Rp0,2SIST EN 13981-1:2004



EN 13981-1:2003 (E)105.6 Extrusion seamsExtrusion seams shall be metallurgically sound and free from metal separations or non-metallic inclusions whichcan affect the required mechanical properties. Mechanical properties (static and dynamic) of metallurgically soundextrusion seams are close to those of the parent metal. The soundness of the extrusion seams shall be testedaccording to 7.8. If a transverse tensile test is performed, the minimum values shall be agreed between supplierand purchaser. However, the elongation A shall exceed 4 % for all thicknesses, alloys and tempers.5.7 Internal walls of hollow profilesInternal walls shall be continuous over the whole length of profile and free from surface cracks.5.8 Freedom from surface defectsThe surface extruded of the product shall be free from defects prejudicial to its suitable and proper use.The product shall have a smooth and clean surface. However, small surface defects such as light scratches,indentations, snap rings, discolourations and non-uniform surface appearance resulting from heat-treatment, etc.,which cannot always be totally avoided, are permitted on the product surface unless the purchaser specifies themas unacceptable in his order.Whilst an operation designed to mask a defect is not permitted, the elimination of a superficial defect is permissibleprovided that the dimensional tolerances and mechanical properties continue to meet the requirements.Visible surfaces and surfaces which will be subject to a surface treatment shall be indicated on the drawing. If notstated otherwise on the order, the roughness value Ra according to EN ISO 4287 shall not exceed the value of8 mm for visible surfaces. If a special surface treatment is agreed between supplier and purchaser, superficialdefects shall not impair the decorative appearance of the surface after this treatment. Limiting samples may beagreed between supplier and purchaser.Repair welding shall not be permitted.5.9 Tolerances on dimensions and formFor the different forms of extruded products, the tolerances on dimensions and form are specified in EN 755-3;EN 755-4; EN 755-5; EN 755-6; EN 755-7; EN 755-8 and EN 755-9. If other tolerances are required, this shall beindicated in the drawing.6 Qualification procedures6.1 First-off article approval procedureAny extruded product of a given alloy produced for the first time in the extrusion plant
shall be qualified by tests tobe performed on a representative extrusion lot. The test methods, the sampling and minimum test frequency andthe acceptance criteria shall be as specified in Table 4.All test results of the "first-off" approval procedure shall be recorded and included in a first-off test report. The testreport shall be approved by the purchaser.6.2 Additional qualification procedureQualification tests shall be performed by the manufacturer when setting up the production of any alloy for the firsttime.The test methods, the sampling, the minimum test frequency and the acceptance criteria shall be as specified inTable 4.SIST EN 13981-1:2004



EN 13981-1:2003 (E)11Table 4 — Product inspection and testing proceduresSampling and minimum test frequencyTestTestmethodquality control forserial productionaccording to 5.2first-off approvalaccording to 6.1additionalqualificationaccording to 6.2AcceptancecriteriaChemical analysissee 7.2each casteach casteach castsee 5.3Tensile testing onparent material(longitudinal)seeEN 755-1see EN 755-1three times as perEN 755-1three times as perEN 755-1see 5.4.1Tensile testing onwelded jointssee 7.4and 7.5--see 7.4see 5.5.2Fatigue testing onparent materialsee 7.6--see 7.5see 5.4.2Fatigue testing onwelded jointssee 7.4and 7.6--see 7.5see 5.5.3Metallographic testingsee 7.7100% at both ends100% at both ends100% at both endsno internaldefectsVerification ofsoundness ofextrusion seamssee 7.8100% at both ends100% at both ends100% at both endssee 5.6Verification ofsoundness of internalwallssee 7.9one extruded lengthper extrusion lot100%100%see 5.7Visual inspection ofsurface qualitysee 7.10according toinspection planaccording toinspection planaccording toinspection plansee 5.8Measurement ofdimensionssee 7.11at random oneper inspection lotat random one perinspection lotat random one perinspection lotsee 5.9If the purchaser requests further qualification tests he shall specify this when asking for a quotation. Thequalification procedure shall be agreed between supplier and purchaser.7 Sampling and test methods7.1 GeneralSampling, test methods, test frequency and the acceptance criteria for the different qualification procedures and forthe quality control for serial production shall be as specified in Table 4. Where appropriate two or more tests can beperformed on the same sample.7.2 Analysis of chemical compositionEach cast shall be analysed. The test procedure shall be in accordance with the requirements of EN 755-1.7.3 Tensile test (longitudinal)The sampling and preparation of test-pieces, the test method and the re-test procedure for tensile testing shall bein accordance with EN 755-1.SIST EN 13981-1:2004



EN 13981-1:2003 (E)127.4 Preparation of test pieces for the testing of welded jointsFor the testing of welded joints, MIG butt welds of class C according to EN 30042 shall be performed between thespecimens to be tested. The specimens shall be weld
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