Engineering Specification: FSE-S-PSE-0005\EN

Emissions Control Technologies Released Date: 06/15/2013

Revision Level: G

ARC WELDING REQUIRMENTS

General:
1.1 PURPOSE
To provide the minimum requirements for arc welded joints including the acceptance criteria
for visual and macroscopic cross sectional inspections.

1.2 SCOPE
This standard applies to all arc welding processes used to produce welded joints on exhaust
systems including GMAW, GTAW, and PAW. This standard is an extension of a released
drawing on which it is specified. Welded joints must be capable of meeting all the
requirements of this specification in addition to all the drawing requirements. The weld sizes
shown on the Engineering Drawing by welding symbols are for reference only. In the case
that this standard and a customer specification are both listed on a drawing and they are in
conflict, the customer requirements take precedence.

2.0 REFERENCED DOCUMENTS

This specification is within the guidelines of the following specifications:
American Welding Society
AWS A2.4 Standard Symbols for Welding, Brazing, and Nondestructive
Examination
AWS A3.0 Standard Welding Terms and Definitions
AWS A5.9 Specification for Bare Stainless Steel Welding Electrodes and Rods
AWS A5.18 Specification for Carbon Steel Electrodes and Rods for Gas
Shielded Arc Welding
AWS A5.22 Specification for Stainless Steel Flux Cored and Metal Cored Welding
Electodes and Rods
AWS A 5.15 Specification for Welding Electrodes and Rods for Cast Iron

Customers
Chrysler..............................................PS-9472 <S>, PS-9184 <S>, MS-5672 <S>
Cummins Emission Solution…………ES0044 Weld Specification
Ford................................................... ES-C8AB-1006-A, WJ-120-01
General Motors .................................GMW 14058, GM6122M, GM4491M
Harley-Davidson Motor Company…...Arc Welding Specification
HINO……………………………………TSH5603G Arc Welding Specification
John Deere…………………………… JDV20 Specification for Arc Welding
Mazda….……………………………….MESPW 4000 A B
Volkswagen…………………………….01106-1 Issue 2009-08
Volvo ……………………………………STD 181-0002 Fusion Welding

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Faurecia
NAO FSE-I-PSE-G025/EN “Weld Standardization”
NAO 00118462 “Welding of Cast Iron Manifolds”
NAO FSE-S-PSE-0006/EN “Repair of Weld Defects”
NAO FSE-S-PSE-G016/EN “Evaluation Standard for Top Hat Converter Welds”

3.0 APPLICATION

3.1 Process

This specification covers the Gas Metal Arc Welding (GMAW), Gas Tungsten Arc
Welding (GTAW), and Plasma Arc Welding (PAW) processes utilized to assemble
exhaust system from components. This specification does not cover resistance welding
processes or high energy density processes including RSW, RSEW, PW, LBW, and
EBW. This specification shall also be used for hybrid welding processes that utilize an
electric welding arc to produce fusion.

3.2 Type of Welds

The welding standard defines the quality requirements for fillet, groove, plug, slot
and edge welds made with or without the addition of filler material.

The weldments covered by the specification are described in Section 4.3 and shown
in Figures 1- 9.

3.3 Materials

This specification applies but not limited to the following materials:

3.3.1 Low Carbon Steels (1006, 1008, 1010, 1018);

3.3.2 Ferritic Stainless Steels (409, 409Ni, AL 409, 11Cr-Cb, 439, 468, 441,
18SR);
3.3.3 Austenitic Stainless Steels (304, 309);
3.3.4 SiMo Ductile Cast Iron
3.3.4 Combinations of (3.3.1), (3.3.2), (3.3.3) and (3.3.4)

Requirements for welding of cast iron manifolds are defined by Faurecia internal
standard NAO 00118462

3.4 Welding Wires

Grades of filler material used for base alloys or their combinations shall conform to
Table 1 otherwise noted on the drawing. Solid and metal cored weld wires are

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acceptable. Metal cored wires are preferential for ferritic stainless steels and thin
gages. The filler materials for stainless steels shall meet the requirements of AWS
A5.9 and A5.22 and the filler materials for carbon steels shall meet the requirement
of AWS A5.18. Nickel filler materials used to weld SiMo Cast Iron shall meet the
requirements of AWS A5.15.

TABLE 1: WELD WIRE SELECTION

Recommended Alternative Filler

Base Material Combination
Filler Materials Materials
Carbon Steel Carbon Steel ER70S-6, ER70S-3
409
EC70S-6, ER70C-3
409, 409Ni Mod. 409, 409Ni Mod. or 409 (409Ti) 409Nb
Carbon Steel 439 (439Ti)
AL 409 AL 409, 409, 409Ni Mod., or 409 (409Ti) 409Nb
Carbon Steel 439 (439Ti)
15CrCb (429) 15CrCb, AL 409, 409, 439 (439Ti)
409Ni Mod., or Carbon Steel
439 439, 15CrCb, AL 409, 409, 439 (439Ti)
409Ni Mod., or Carbon Steel
AL 439 AL 439, 439, 15CrCb, 439 (439Ti)
AL 409, 409, 409Ni Mod., or
Carbon Steel
441 (18CrCb) 441 (18CrCb), AL 439, 439, 439 (439Ti)
15CrCb, AL 409, 409,
409Ni Mod., or Carbon Steel
304 (304L) 304, 304L. 441 (18CrCb), 308L or 308LSi 309L or 309LSi
AL 439, 439, 15CrCb,
439 (Flexible
AL 409, 409, 409Ni Mod., or
Coupling Joints)
Carbon Steel
309 (309L) 304, 304L. 441 (18CrCb), 308L or 308LSi 309L or 309LSi
AL 439, 439, 15CrCb,
AL 409, 409, 409Ni Mod., or
Carbon Steel
309 (309L) 309 (309L) 309L or 309LSi

SiMo Ductile Cast 300 or 400 Series Stainless ERNiFeMn-Cl 309LCr-C

Iron Steel (2216)

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4.0 WELDING SYMBOLS

Welding symbols are intended for conveying the information from the designer to the
welding personnel. These symbols provide the means for placing on drawings
information to be used in making the weld. The weld sizes included in the welding
symbols should not be used for weld inspection. Characteristics of weld
geometry shall be determined according to type of joint and material thickness per
Section 10.5. The symbols used to denote fusion welds on drawings or other
documents shall be as follows:

4.1 General Notation

The welding symbol consists of several elements. Only the reference line and
arrow are required elements. Additional elements may be included to convey
specific welding information. All elements, when used, shall have specific
locations within the welding symbol as shown below.

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4.2 Symbols for Specific Types of Welds:

4.2.1 Single Fillet Weld Above Reference Line

Below Reference Line

4.2.2 Double Fillet Weld

4.2.3 Square Groove Weld

4.2.4 Vee Groove Weld

4.2.5 Bevel Groove Weld

4.2.6 Flare Vee Groove Weld

4.2.7 Flare Bevel Groove Weld

4.2.8 Seam Weld

4.2.9 Spot Weld

4.2.10 Plug or Slot Weld

4.2.11 Edge Weld

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4.3 Application of Information to Weld Symbols

4.3.1 Filet Welds

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4.3.2 Flare-Bevel and Flare-V Groove Welds

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4.3.3 Square Groove Welds

4.3.4 Plug Welds

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4.3.5 Slot Welds

4.3.6 Edge Welds

0.8

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5.0 DEFINITIONS

5.1 Fusion Welding

Joining of metal without pressure in which a significant amount of parent

metals is fused. Added filler metal may be used.

5.2 Gas Metal Arc Welding (GMAW)

Fusion welding process uses an electrical arc between a continuous filler metal
electrode and the weld pool. The process incorporates the automatic feeding of a
continuous, consumable electrode that is shielded by an externally supplied gas.

5.3 Gas Tungsten Arc Welding (GTAW)

Fusion welding process that uses an electrical arc between a nonconsumable

tungsten electrode and the work piece to create the weld pool. The process may
incorporate filler wire and is shielded by an externally supplied gas.

5.4 Plasma Arc Welding (PAW)

Fusion welding process that uses an electrical arc between a nonconsumable

tungsten electrode and the work piece to create the weld pool. The tungsten is
recessed into the torch and a constricting nozzle is used to restrict the arc into a
narrow column. The process may incorporate filler wire and is shielded by an
externally supplied gas.

5.5 Metal Cored Electrode

Metal cored electrode is a composite tubular filler metal electrode consisting of a

metal sheath and a core of various powdered materials.

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5.6 Weld Features

FEATURE DEFINITION
Exposed surface of a weld on the side from which the
FACE welding was performed
Points at which the back of the weld intersects the base
ROOT metal surface

TOE Junction between the weld face and the base metal.

Shortest distance from root to toe in a fillet weld (includes

LEG only areas where fusion is complete)

THROAT Shortest distance from root to face in a fillet weld

Maximum depth of the fusion zone which extends into the

PENETRATION base metal

WETTING Angle between the weld surface and the base metal surface
ANGLE measured at the weld toe

See Figures 1 - 7.

5.7 Effective Weld Length

Effective length is defined as that length having the minimum shape and
dimensions specified. Undersize welds at the beginning and end of weld runs and
along the weld run cannot be included in the effective weld length measurement.

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5.8 Overheating

Raising the welding temperature much higher than the normal temperature
necessary to produce a good weld and holding that temperature for sufficient time
for the parent metal structure to change to a coarse grain size and thus become
embrittled.

5.9 Burning

Similar to overheating except that the deterioration occurs in an oxidizing

environment and oxygen penetrates the grain boundaries.

5.10 Melt-through

Visible root reinforcement produced in a joint welded from one side.

6.0 WELDING PROCESS

The welding process, component composition, and electrode or filler wire grade or
classification shall be chosen to alleviate the risk of cracked or brittle welds.
The welding process type, component composition, and filler wire classification used to
produce parts for DV (Design Validation) testing shall match those specified on the
prints and shall be the same as used in production.
The welding process, component composition, filler wire classification, size, and type,
welding equipment, and fixtures used in production shall be used to produce parts for
PV (Production Validation) testing. A change in any of the above conditions shall not be
made in production without obtaining a prior Product Development Deviation with the
following exceptions. Changes or improvements to the weld fixtures that do not affect
the weld position, part orientation during welding, and fixture concept are allowed.
Changes to the weld equipment that do not affect the welding process or parameters
are allowed such as changing a weld gun or nozzle type. If a GMAW-P process is
used, the power supply may be switched only if the same make and model is used. If
standard GMAW (MIG) is used, the power supply can be switched with a different make
and model as long as the same parameters are used.
The production welding process shall be validated according to the Faurecia weld
standardization process. See section 8.0.

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7.0 CONDITION OF THE SURFACES PRIOR TO WELDING
Prior to welding, the surfaces to be welded must be reasonably free from rust, dirt,
paint, pitting or other surface deposits, which will adversely interfere with the
welding.

Grease, oil, water or other Hydrogen and Carbon producing materials should be
minimized on the surfaces to be welded. If a process is used which causes scale, oxide
or flux to be left on the weld deposit surfaces, this must be removed and the surfaces
made clean before the addition of further weld deposits or any surface finishing
operation, such as painting, plating, phosphating, etc.

8.0 VERIFICATION OF WELDING PROCESS AND WELDER

8.1 Prior to the start of production welding, the process, materials, and welders must
be validated by cut and etch as defined in the Faurecia weld standardization process,
FSE-I-PSE-G025. Only validated welding parameters and torch angles shall be used to
make production welds. If the welding parameters or torch angles are changed from the
validated parameters, these new parameters and angles may not be used for
production welding until they are validated by cut and etch as defined in the weld
standardization process.

8.2 A routine quality check system must be established up and implemented. When
specified on the drawing or in the Engineering Specifications, sample weldments shall
be taken from production and fully tested. When faults are found, these must be
investigated by appropriate means, including macro and micro examination of cut
sections. A remedy for the fault shall be developed and implemented. If it is possible,
a repair procedure must be established for faulty welds (see Section 11.0). A follow-up
report shall be issued.

9.0 GENERAL REQUIREMENTS

9.1 Position, Length, Shape and Number of Welds

Position, length, shape, and number of welds will be shown on the Engineering
Drawing or chart and are minimum requirements. Any components with welds
having any obvious major oversize dimensions must be reviewed by Quality
Assurance or Materials Engineering.

Fusion shall be required for the effective length of the weld, which will be
defined as the specified length minus short allowance given in Table 1 below:

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TABLE 2: ARC WELD SHORT ALLOWANCES

Specified Weld Length, mm Short Allowance, mm

0-13 0.0
Over 13-25 2.0
Over 25-50 3.0
Over 50-100 4.0
Over 100-150 6.0
Over 150-300 8.0
Over 300 10.0

For sealing welds the short allowance is not applicable (effective length
should be equal to the specified length).
The weld profiles must conform to those shown in Figure 2.

9.2 Visual Condition

The visible surfaces of all welds shall be clean and have regular and reasonably
consistent contour. The weld surfaces shall have the appearance of welds
known to have satisfactory weld properties. When very high quality is required
and specified, boundary samples and/or photographs will be jointly produced and
agreed by Product Development, Quality Assurance, Materials Engineering and
Manufacturing to illustrate and define acceptable and non-acceptable weld
surface appearances.

9.3 Joint Quality

Overall joint quality should be verified by visual inspection and microscopic

evaluation at magnifications no less than 10X.
Visual inspection shall be performed by the operator or welder on 100% of welds.

9.3.1 Joint Fit-Up

9.3.1.1 All parts should be accurately located for welding in a manner to

ensure fusion between the parts being joined.

9.3.1.2 The maximum gap allowable between adjacent members in

the weld joint should be limited to the thickness of the
thinner member or 1. 5 mm (0.059") whichever is the smaller
dimension.

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9.3.2 Cracks

Macro cracks are not permissible.

9.3.3 Burn-through

Burn-through producing a hole completely through the weld or adjacent to

the weld in the base material is not permissible.

9.3.4 Melt-through

Melt-trough shall not exceed 150% of the affected layer thickness and do
not affect the function or fit-up of the part

Melt-through < 1.5 x T2

T1

T2

Melt-through

9.3.5 Undercut

Undercut may not exceed a depth of 10% of the thickness of the affected
member.

9.3.6 Notching

Notching (gouging of the base metal at the ends or at the edge of the joint)
is not permitted.

9.3.7 Overlap (Cold Lap)

Overlap size (L) should not exceed 0.5 mm and its length should not
exceed 20% of the weld length (Figure 2). Overlap is not allowed within 10
mm from the start or stop point of welding.

9.3.8 Gross Defects

Gross defects are not permitted.

Small and occasional defects of the following types may be allowed:

9.3.8.1 Internal scattered porosity and cavities

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Maximum pore diameter shall not exceed 1.5 mm or 0.5xT
whichever is smaller, where T is the thickness of the thinnest
member.
Internal porosity shall not exceed 25% of the area of the weld
section being examined.

9.3.8.2 Slag, flux and non-metallic inclusions

Maximum inclusion diameter shall not exceed 1.5 mm or 0.5xT

whichever is smaller, where T is the thickness of the thinnest
member.

9.3.8.3 Pinholes (pits, blowholes)

Maximum diameter shall not exceed 1.5 mm or (0.5xT)

whichever is smaller, where T is the thickness of the thinnest
member. The total length (sum of diameters) shall not exceed
6.4 mm in any 25 mm of weld. Two or more pinholes which are
separated by less than the diameter of the smaller pinhole(s) is
not permissible.

9.3.8.4 Spatter

Loose weld spatter must not be present inside components after

welding. The requirements for weld spatter on the outside
surfaces shall be defined on the Engineering Drawing for
purposes of adequate sealing, visual appearance and cosmetic
corrosion.

9.4 Distortion of Mating Components

This condition must be controlled to fall within the tolerance stated on the
Engineering Drawing.

9.5 Overheating and Burning

Neither condition is allowed. The usual method of detection of these faults in the
weld or heat affected zone is by metallographic analysis.

9.6 Surface Finish Treatments

Welds and adjacent parent metal shall not be subjected to a protective finish until
the welds have satisfactorily met the requirements of this document. If weld
repair is required, the finish treatment should not be applied until the repaired
joint is evaluated and accepted.

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10.0 WELD PROPERTIES

Sections 10.1 – 10.4 should be used for references only.

10.1 Hardness and Brittleness

The weld metal and heat affected zones of the components shall not be
excessively hard or brittle when subjected to hardness and bend tests and to
metallographic examination.
The limits shall be:
 300 HV (30 HRC) max.
 No continuous or network brittle constituents in the microstructure.
 5% maximum of small isolated brittle constituents in the microstructure
unless other limits are specified on the drawing.
 No excessively coarse columnar grain structure in weld (ASTM grain size
Number shall be higher than No.3).

The above requirements of Section 10.1 are not applicable for welding of Cast
Iron components.

10.2 Strength

The welded parts when loaded to failure by a single, slowly increasing load in
any direction must fail in the heat affected zone in one of the parent metals of the
component(s) being welded and not in the fused weld metal. Minimum load
specifications for proof tests, failure tests and fatigue tests may be specified on
the drawing or in an applicable Engineering Specification.

10.3 Crack Propagation Resistance

When a welded joint with a notch (3-5 mm length) artificially induced into the
weld is impacted by using a 5 Lb hammer with a full swing, the length of crack
propagation per each hit shall not exceed 25 mm (1.0") or 25% of the weld
length whichever is the smaller dimension.

10.4 Intergranular Corrosion Resistance

The weld metal shall not exhibit grain dropping and ditch structure after the
copper-copper sulfate-16% sulfuric acid test (ASTM A763, Practice Z). Step and
dual structures are acceptable. The ditch structure may be allowed in the heat
affected zone adjacent to an air gap between the components (root area).

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10.5 Weld Geometry

Characteristics of weld geometry shall be verified by metallographic evaluation.

Frequency of metallographic inspection should be established by Quality
Department based on the customer requirements and specifications.

10.5.1 Fillet Welds (T and Lap Joints)

Characteristics of fillet weld geometry are to be defined based on the

largest right triangle that can be inscribed within the weld cross
section and shall conform to the following requirements:

10.5.1.1 The minimum length of the leg shall be at least 90% of

the thickness of the thinnest material being welded (Figure
3a).

10.5.1.2 When gap is present, the length of both legs must be

increased by the width of the gap (Figure 3b).

10.5.1.3 For 3-member Lap welds the length of leg on the two
component side shall be no less than 0.9×(T1+T2)+G1+G2
(see Figure 3c). The length of leg on the one component
side shall be at least 2 mm. Both edges on the two
component side must be completely fused.

10.5.1.4 The minimum measurable throat thickness shall be 70% of

the thinnest material being welded (Figure 4a).

15.0.1.5 For 2-member welds with gap the throat must be increased
by 70% of the width of the gap (Figure 4b).

10.5.1.6 For 3-member fillet weld with gaps the minimum throat
thickness shall be 0.7×(T1+T2+G1+G2) (see Figures 4c).

10.5.1.7 The minimum weld penetration (depth of the fusion zone) in

each component of T joints, and the bottom layer of lap joints,
shall be no less than 20% of the material thickness for light-
gage material (T ≤ 1.0 mm (0.04")) and 0.2 mm (0.008") for
heavy-gage material (thickness above 1.0 mm, Figure 5). No
penetration is required for lap joint ends, only complete fusion.
See Figures A2 through A4 in Appendix A.

10.5.1.8 The wetting angle measured at each weld toe is

recommended to be in excess of 100 (see Figure 6a).

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10.5.1.9 There shall be no maximum convexity or concavity
requirement, provided that all other requirements to this
specification are complied with.

10.5.2 Groove Welds (Flare-V and Flare-Bevel Joints) for Solid hanger rods

Solid hanger rod joints shall conform to the following:

10.5.2.1 The leg length in each component shall be no less than 25%
of the hanger rod diameter (Figure 7a).

10.5.2.2 The weld throat (minimum section dimension measured at

the point that gives the shortest distance from the root of the
joint to the weld face) shall be no less than 20% of the
hanger rod diameter (Figure 7b). If there are two hanger
rods of different diameters than the smallest hanger rod
diameter would be used to determine the minimum weld
throat.

10.5.2.3 The minimum weld penetration shall be as specified in

Section 10.5.1.7 for Fillet welds.

10.5.2.4 The wetting angle shall be as specified in Section 10.5.1.8

(see Figure 6b).

10.5.2.5 When hanger rod is welded to multilayer stamped muffler

flange, at least three panels must be fused for the first 25%
and last 25% of the weld length (see Figure 1d). Deviation
from this requirement should be agreed upon by Product
Development, Quality Assurance, Materials Engineering and
Manufacturing.

10.5.3 Groove Welds (Flare-V and Flare-Bevel Joints) for Tubular hanger rods

Tubular hanger rod joints shall conform to the following:

10.5.3.1 The leg length in each component shall be no less than

150% of the thickness of the thinnest material being welded
(Figure 8a).

10.5.3.2 The weld throat (minimum section dimension measured at

the point that gives the shortest distance from the root of the
joint to the weld face) shall be no less than 125% of the
thickness of the thinnest material being welded (Figure 8b).

10.5.3.3 The minimum weld penetration shall be as specified in

Section 10.5.1.7 for Fillet welds.
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10.5.3.4 The wetting angle shall be as specified in Section 10.5.1.8

(see Figure 6b).

10.5.3.5 When hanger rod is welded to multilayer stamped muffler

flange, at least three panels must be fused for the first 25%
and last 25% of the weld length (see Figure 1d). Deviation
from this requirement should be agreed upon by Product
Development, Quality Assurance, Materials Engineering and
Manufacturing.

10.5.4 Square Groove Welds (Butt Joints)

10.5.4.1 The edges of square grove weld shall be completely fused.

10.5.4.2 The complete joint penetration shall be achieved (Figure 9a).

10.5.4.3 If due to the joint design complete penetration is not possible

to accomplish, the sum of weld penetration and weld
reinforcement shall be no less than the thickness of the
thinnest material being joined (Figure 9b).

10.5.4.4 For butt joints with offset the minimum section dimension
(the shortest distance from the root to the weld face) shall be
no less than 75% of the thinnest member (Figure 9c).

10.5.5 Plug and Slot Welds

The plug (Section 4.3.5) and slot (Section 4.3.6) welds shall conform to
the following:

10.5.5.1 The minimum hole diameter for plug welds and the minimum
width for slot welds shall be no less than shown in Table 3.

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TABLE 3: PLUG WELD HOLE DIAMETERS

AND SLOT WELD WDTHS

Thinnest Member Minimum Hole Minimum Slot

Thickness (T), mm Diameter, mm Width, mm

From 0.40 to < 1.00 3.0

From 1.00 to < 2.00 5.0 2T + 0.5

From 2.00 to 3.50 7.0

10.5.5.2 The weld interface diameter (Di) for plug welds shall be no
less than 90% of the hole diameter (Dh, see Figure 10).

10.5.5.3 The weld interface width of slot welds shall be no less than
90% of the slot original width (Figure 11).

10.5.5.4 The edges of plug or slot welds shall be completely fused.

10.5.5.5 Fusion shall be present for the effective length or area of the
weld.

10.5.5.6 The minimum weld penetration in the lowest sheet (furthest

from the torch) shall be no less than 20% of the sheet
thickness or 0.2 mm whichever is smaller.

10.5.5.7 Plug and slot welds shall be at least filled to the surface.

10.5.6 Edge Welds

The edge weldments utilized for joining of panels and sealing silencer
flange (Section 4.3.7) shall conform to the following requirements:

10.5.6.1 Minimum Section Dimension (the shortest distance from the

weld root to face) should be no less than 75% of the thinnest
material member (silencer panel, see Figure 12).

10.5.6.2 The silencer edge weld should be processed with wire

containing at least 17%Cr (439SS or higher grades).
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11.0 WELD SHIELDING GAS

The protective shielding gas utilized for joining of ferritic stainless steels and ferritic
stainless steels to low carbon steel components shall be a gas mixture of 98% Argon
and 2% Oxygen or 98% Argon and 2% Carbon Dioxide. It is allowable to use mixture
of 95% Argon and 5% Carbon Dioxide for welding of ferritic stainless steel to ductile
cast iron. Other compositions of shielding gases shall be reviewed and approved by
Manufacturing, Product and Materials Engineering.

12.0 REPAIR PROCEDURE

The allowed procedures to repair Arc welds are described in the Faurecia internal
standard Repair of Weld Defects.

Faulty welds may not be repaired unless authorized by a deviation. Manufacturing

Engineering may ask for acceptance of certain defects by submitting request for a
deviation that will be reviewed by Quality Assurance, Product Engineering and Materials
Engineering.

13.0 WELD EVALUATION AND VALIDATION

The requirements for macroscopic evaluation of typical welded joints are shown in
Appendix A. Arc welds must meet the requirements of this specification and be
validated using the Faurecia weld standardization process in accordance with the
Faurecia weld standardization specification, see section 8.1.

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FIGURE 1a
TYPICAL WELD JOINT
TUBING / MUFFLER INTERFACE

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FIGURE 1b
TYPICAL WELD JOINT
HANGER ROD / TUBING (MUFFLER) INTERFACE

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FIGURE 1c
TYPICAL WELD JOINT
HANGER ROD / CONVENTIONAL MUFFLER HEAD

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WeldSize
Weld Size

Hanger Rod

Leg
(L1)
Hanger Rod Diameter

Muffler Throat

Leg (L2)

FIGURE 1d
TYPICAL WELD JOINT
HANGER ROD / STAMPED MUFFLER FLANGE

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FILLET WELD NOTATION

DESIRABLE WELD PROFILES

PROVISIONALLY ACCEPTABLE PROFILES

There are no convexity limitations provided Undercut not to Overlap is only

Leg and Throat are more than 100% of exceed 10% acceptable if L ≤ 0.5
thickness of sheet mm and there is fusion
between the parent
t i l d th
FIGURE 2
WELD PROFILES

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2-MEMBER JOINTS
T1
LEG2 ≥ 0.9 x T1 LEG1 ≥ 0.9 x T1
LEG1 ≥ 0.9 x T1+ G1

T1

T2 T2
GAP (G1)

LEG2 ≥ 0.9 x T1 + G1
a) Fillet weld with good fit-up b) Fillet weld with joint gap

For 2-member welds T1 is the thinner material being joined (T1<T2).

MULTI (THREE OR MORE) MEMBER JOINTS

LEG2 ≥ 0.9 x (T1 + T2) + G1 + G2 GAP (G1)

T1
T2

T3
GAP (G2)

LEG2 ≥ 2 mm
c) Fillet weld with two joint gaps

FIGURE 3
FILLET LEG SIZE

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2-MEMBER JOINTS
T1

For 2-member welds T1 is the thinner material being joined (T1<T2).

CONVEXITY CONCAVITY
T1
MULTI (THREE OR MORE) MEMBER JOINTS
T2 T2
GAP (G1)
THROAT ≥ 0.7 x T1 THROAT ≥ 0.7 x (T1 + G1)
a) Theoretical Throat for b) Theoretical Throat for
joint with good fit-up joint with gap

MULTI (THREE OR MORE) MEMBER JOINTS

GAP (G1)
T1
T2

T3
GAP (G2)

THROAT ≥ 0.7 x (T1 + T2 + G2 + G1)

c) Theoretical Throat for weld with two joint gaps

Note: Concavity reduces throat size.

FIGURE 4
THEORETICAL THROAT FOR FILLET WELD

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FUSION DEPTH ≥0.2

0.2mm
mm(0.008”)
(0.008")
T1 Determination of minimum fusion depth
Sizes larger than 0.2 x T must be specified on Engineering Drawing
FUSION DEPTH ≥0.2 x T1
FIGURE 5
DEPTH OF FUSION

T2
FUSION DEPTH ≥0.2
0.2 mm (0.008”)
(0.008")
FUSION DEPTH ≥0.2 x T1

a) Light – gage material b) Heavy – gage material

Thickness ≤ 1.0 mm (0.04") Thickness > 1.0 mm (0.04")

FIGURE 5
DEPTH OF FUSION

WETTING ANGLE ≥ 100º WETTING ANGLE ≥ 100º

WETTING ANGLE ≥ 100º

T1

T2

HANGER ROD

a) Wetting angle for fillet joint b) Wetting angle for V-groove joint

FIGURE 6
WELD WETTING ANGLE

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LEG 1 ≥ 0.25 x D

HANGER ROD

D
T

LEG 2 ≥ 0.25 x D LEG 1 ≥ 0.25 x D LEG 2 ≥ 0.25 x D

a) Determination of minimum leg length

THROAT ≥ 0.20 x D

D
T

THROAT ≥ 0.20 x D HANGER ROD

b) Determination of minimum throat (minimum section dimension)

FIGURE 7
GEOMETRY FOR GROOVE WELDS
SOLID HANGER ROD JOINTS

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LEG 1 ≥ 1.5xT
HANGER ROD

T D

T D

LEG 1 ≥ 1.5xT LEG 2 ≥ 1.5xT

LEG 2 ≥ 1.5xT
a) Determination of minimum leg length

THROAT ≥ 1.25xT

T D
T

T D

THROAT ≥ 1.25xT HANGER ROD

b) Determination of minimum throat (minimum section dimension)

FIGURE 8
GEOMETRY FOR GROOVE WELDS
TUBULAR HANGER ROD JOINTS

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a) Butt joint with complete penetration

T1 P
T2

P + R ≥ T1 (T1 < T2)

b) Butt joint with partial penetration

Minimum
Section
R Dimension
P
T1

T2

P + R ≥ T1 (T1 < T2)

Minimum Section Dimension ≥ 0.75 x T1

c) Butt joint with offset

FIGURE 9
GEOMETRY FOR SQUARE-GROOVE WELDS

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Dh

Di

Di ≥ 0.90 x Dh
Minimum Hole Diameters (Dh) are shown in Table 3

FIGURE 10
PLUG WELD CROSS SECTION

Ws

Wi

Wi ≥ 0.90 x Ws

Minimum Slot Widths (Ws) are shown in Table 3

FIGURE 11
SLOT WELD CROSS SECTION
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Gas Metal Arc

Solidified
Weld Deposit

Minimum
Section
Dimension Gap
GAPS
(MSD)

Material
Thickness

MSD ≥ 0.75T

T – Thickness of the thinnest material member

MSD –Shortest distance from the root to weld face

FIGURE 12
EDGE WELDS

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APPENDIX A

MICROSCOPIC EVALUATION
TYPICAL WELDED JOINTS

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REQUIREMENTS:
T1 T - Thickness of Thinnest Member, T1 or T2
G – Joint Gap, G <T or 1.5 mm
Leg 1, L1 ≥ 0.9T+G
Leg 2, L2 ≥ 0.9T+G
P1 Throat ≥ 0.7(T+G)
P1 ≥ 0.2T or 0.2 mm
P2 ≥ 0.2T or 0.2 mm
Ø Ø ≥ 100º

THROAT

L1
Ø
G
P2
T
L2

a) Concave Weld

T1

P1
Ø

THROAT

L1

G Ø

P2
T
L2

b) Convex Weld
Figure A-1: Microscopic Examination Requirements
for Fillet Welds, T-Joints
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REQUIREMENTS:

T - Thickness of Thinnest Member, T1 or T2

G – Joint Gap, G <T or 1.5 mm
Leg 1, L1 ≥ 0.9T+G
Leg 2, L2 ≥ 0.9T+G
Throat ≥ 0.7(T+G)
P ≥ 0.2T or 0.2 mm
Ø ≥ 100º

THROAT
T1
L1
Ø
G
P

L2 T2

a) Concave Weld

Ø
THROAT

T1
L1
Ø
G
P

L2 T

b) Convex Weld

Figure A-2: Microscopic Examination Requirements

for 2-Member Fillet Welds, Lap Joints

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REQUIREMENTS:

T - Thickness of Thinnest Member, T1, T2 or T3

G1, G2 – Joint Gaps, G1, G2 <T or 1.5 mm
Leg 1, L1 ≥ 0.9(T1+T2) +G1+G2
Leg 2, L2 ≥ 2.0 mm
Throat ≥ 0.7(T1+T2+G1+G2)
P ≥ 0.2T or 0.2 mm
Ø ≥ 100º
Both edges must be fussed, T1 and T2
Ø

T1 G1 THROAT

T2 L1
T3 Ø
G2
P
T3
L2

a) Concave Weld
Ø
THROAT
T1 G1

T2 L1
Ø
G2
P

L2 T3

b) Convex Weld
Figure A-3: Microscopic Examination Requirements
for 3-Member Fillet Welds, Lap Joints
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REQUIREMENTS:

T - Thickness of Thinnest Member, T1, T2 or T3

G1, G2 – Joint Gaps, G1, G2 <T or 1.5 mm
Leg 1, L1 ≥ 0.9(T1+T2) +G1+G2
Leg 2, L2 ≥ 2.0 mm
Throat ≥ 0.7(T1+T2+G1+G2)
P ≥ 0.2T or 0.2 mm
Ø Ø ≥ 100º

T1
G1 THROAT

T2 L1
Ø
G2
P
L2 T

a) 4-Member Fillet Weld

Ø

THROAT
T1

L1

T2 G1 Ø

G2 P
L2 T

b) Flex Coupling Fillet Weld

Figure A-4: Microscopic Examination Requirements
for Multi Member Fillet Welds, Lap Joints
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D REQUIREMENTS:

T - Thickness of Member
D – Diameter of Hanger Rod
G - Joint Gap, G < T or 1.5 mm
Leg 1, L1 ≥ 0.25D
Leg 2, L2 ≥ 0.25D
P1 Throat ≥ 0.2D
P1 ≥ 0.2 mm
P2 ≥ 0.2T or 0.2 mm
Ø ≥ 100º
L1
Ø
THROAT

G
P2 T
L2

a) Flare-Bevel Groove Weld

THROAT
P1 P2
Ø Ø

L1 L2

D1 D2
b) Flare-V Groove Weld
Figure A-5: Microscopic Examination Requirements
for Solid Hanger Rod Welds
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D REQUIREMENTS:

T - Thickness of Thinnest Member, T1 or T2

D – Diameter of Hanger Rod
G - Joint Gap, G < T or 1.5 mm
Leg 1, L1 ≥ 1.5T
Leg 2, L2 ≥ 1.5T
Throat ≥ 1.2T
P1 P1 ≥ 0.2T or 0.2 mm
T P2 ≥ 0.2T or 0.2 mm
Ø ≥ 100º
L1
Ø
THROAT

G
L2 P2 T

a) Flare-Bevel Groove Weld

P1 THROAT
P2
Ø Ø

L1 L2
T1 T2
G

D1 D2
b) Flare-V Groove Weld
Figure A-6: Microscopic Examination Requirements
for Tubular Hanger Rod Welds
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REQUIREMENTS:
T - Thickness of Member, T1 or T2
Dh – Diameter of Hole
Ws – Width of Slot
Di – Diameter of Weld at Interface
Wi – Width of Weld at Interface
G - Joint Gap, G < T or 1.5 mm
Leg 1, L1 ≥ T1 (100% Fused)
Leg 2, L2 ≥ T1 (100% Fused)
P ≥ 0.2T2 or 0.2 mm

Dh (Ws)

T1 L1 L2

G
P

Di (Wi) T

Figure A-7: Microscopic Examination Requirements

for Plug and Slot Welds

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REQUIREMENTS:

T - Thickness of Thinnest Member, T1, T2 or T3

G - Joint Gap, G < T or 1.5 mm
Leg 1, L1 ≥ T1 (if T1 > 2 mm, L1 = 2 mm)
Leg 2, L2 ≥ 1.5xT2
Leg 3, L3 ≥ T3 (100% Fused)
R - Minimum Weld Reinforcement, R ≥ 0 at some
, point along the line
P1 ≥ 0.2T or 0.2 mm
P2 ≥ 0.2T or 0.2 mm
MT – Melt-Through, MT ≤ 1.5xT2

T1

R
P1

T3 L1
L3

P2 T2
L2

MT

Figure A-8: Microscopic Examination Requirements

for Fillet-in-Slot Welds

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FECT Engineering Specifications
Change List

DATE LET REVISIONS BY

03/27/95 A Released A. Khutorsky
Added requirements for Seam, Arc Spot, Plug, and Slot
04/22/96 B Welds. A. Khutorsky
Edited to new format. Changed Weld Geometry
10/24/03 C Requirements, Section 10.5 A. Khutorsky
Added requirements for Edge Welds. Sections 4.2.11, 4.3.7,
10.5.6, and Figure 10. Modified requirements for Groove
Welds Section 10.5.2.6 and Figure 1d, Weld Penetration
Section 10.5.1.7 and Figure 5, Plug Welds Section
10.5.4.1.
Added requirements for Pin Holes Section 9.3.9.3.
07/18/06 D Added allowable shielding gases, Section 11 A. Khutorsky
Added Section 3.4 Welding Wires.
Modified Section 9.3.4 Melt-through.
Modified Requirements for Fillet Weld Leg Length (Sections
10.5.1.1, 10.5.1.2) and Weld Penetration (Section 10.5.1.7).
Added Requirements for Tubular Hanger Rod Joints
(Section 10.5.3) and Square Groove Welds (Butt Joints,
Section 10.5.4).
Omitted Requirements for Arc Spot and Seam Welds.
Modified Requirements for Plug and Slot Welds (Section
10.5.5).
Added Appendix A ”Microscopic Evaluation of Typical
04/18/11 E Welded Joints” A. Khutorsky

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Changed name to “Arc Welding Requirements”
Added new processes to the scope, “GTAW, and PAW.“
Updated reference document section 2.0 to include AWS A5.22
and A5.15.
Updated the repair spec Number in reference document section
and added the specification for top hat converter welds and weld
standardization.
Added Plasma Arc Welding to the Process Section, 3.1
Added SiMo Cast Iron to the materials section, 3.3.3.4
Updated weld wire specs in Welding Wires section, 3.4
Added ErNiFeMn-Cl to the weld wire section as well as SiMo
Cast Iron, Table 1.
Added 309LCr-C to Table 1.
Added clarification to the weld validation process for production
welding in the weld process section 8.0.
Added the requirement that both edges be fused for 3 layer lap
joints, section 10.5.1.3
Added clarification to the weld throat requirement when two
hanger rods of different thickness are welded together in section
10.5.2.2
Changed “slut weld” to “slot weld” in section 10.5.5.4.
Eliminated the repair spec number in section 12.0
Eliminated the weld standardization number in section 13.0 and
referred to section 8.1.
02/15/13 F Modified Figures A-2, and requirements of A-8 for clarification Joe Kotnik
Added clarification to section 10.5.1.7 regarding the penetration
06/15/13 G requirements of lap joints. Joe Kotnik

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FECT Engineering Specifications

Approval Sheet

DATE: 04/18/11 ORIGINATOR Alex Khutorski

CHANGE LEVEL
TITLE: Gas Metal Arc Welding (GMAW) E

X VP - Engineering Chris Wiegandt - 05/19/11

X VP - Operations Kirk Cowell – 05/17/11

X Director - Manufacturing Engineering Jim bowman - 05/16/11

X Chief Engineer – Process Engineering Mark Wassermann – 05/13/11

X Manager – Material Labs Ami Parekh – 05/03/11

X Welding Engineer - Assembly Verlin Champion – 04/25/11

X Welding Engineer - Process Joe Kotnick - 05/02/11

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