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Deliverable 6.4 – Joint acceptance criteria

Towards a REgulatory FRamework for the usE of Structural new materials in

railway passenger and freight Bodyshells

Grant Agreement no.: 605632

WP 6.4

Joint acceptance criteria

Deliverable: D6.4

Due date of deliverable: M27

Submission date: 26 02 2016

Version: Final

Project co-funded by the European Commission within the 7th Framework

Programme

Deliverable 6.4 –Joint acceptance criteria

REFRESCO Deliverable D6.4 was produced by BT and received contributions

from the following members of the consortium:

- CAF

- DLR

- UNEW

This document should be referenced as:

“REFRESCO- Joint behaviour, Deliverable 6.3, version 01”

QUALITY CONTROL INFORMATION

Issue Date Description Revising Authorship

Draft 1 06.11.2015 Draft version of REFRESCO

D6.4 for TMT COMMENT

Jan PROCKAT

(BOMBARDIER)

Final 26.11.2015 Submission of REFRESCO D6.4

final version to the EC

Hendrik SEIDLER

(BOMBARDIER)

DOCUMENT HISTORY

Issue Date Pages Comment

1 19.06.2015 All Initial issue (Draft 1)

2 06.11.2015 All Draft 1

3 26.11.2015 All Final

4 15.12.2015 13/15/16/19/29 Rev_1

DISSEMINATION LEVEL

PU Public [X]

PP Restricted to other programme participants (including the

Commission Services)

RE Restricted to a group specified by the consortium (including the


CO Confidential, only for members of the consortium (including the



EXECUTIVE SUMMARY

The Work Package 6.4 deals with acceptance criteria for joints used for new

materials.

Destructive and Non- destructive test measures have been investigated

to become able to have acceptance criteria in manufacturing

This measures have been clustered to the three most relevant joining

principles

Gaps in the Regulatory framework have been highlighted

A recommendation for the use of the different norms in relation to the

material has been given

A recommendation for the structure of a future framework for joining

principles has been made


Table of Contents

1 INTRODUCTION INTO OJECTIVE OF WP 6.4 .................................................... 6

2 TESTING PROCESSES ........................................................................................ 7

2.1 GENERAL .......................................................................................................... 7

2.2 DESTRUCTIVE TESTING ................................................................................. 8

2.3 NON DESTRUCTIVE TESTING ...................................................................... 16

2.4 RECOMMENDATION FOR THE RAIL INDUSTRY ......................................... 24

3 REGULATIVE FRAMEWORK PROPOSAL/ APPROACH ................................ 25

4 SUMMARY .......................................................................................................... 31

5 APPENDIX .......................................................................................................... 32

5.1 APPENDIX A ....................................................................................................... 32

6 REFERENCES .................................................................................................... 34


List of tables

TABLE 1 SHORTLIST OF MATERIALS CONSIDERED FOR PROCESS DETERMINATION ............................ 8

TABLE 2 ALLOWABLE TOLERANCES FOR WELDING ....................................................................... 17

TABLE 3 COMPARISON OF WALL THICKNESS VS. VOLTAGE ............................................................ 18

TABLE 4 RECOMMENDED FRAMEWORKS ..................................................................................... 30

List of figures

FIGURE 1 BENDING TEST PRINCIPLE ............................................................................................. 9

FIGURE 2 TENSILE TEST SPECIMEN ............................................................................................. 10

FIGURE 3 CREEP TENSILE TEST – EXPERIMENTAL SET UP ............................................................ 10

FIGURE 4 PEEL TEST – SET UP EXAMPLE ................................................................................... 11

FIGURE 5 TENSILE TEST FOR LOW TEMPERATURES - SPECIMEN ................................................... 11

FIGURE 6 TENSILE TEST FOR SPECIMEN WITH ROUNDED NOTCH - SPECIMEN ................................ 12

FIGURE 7 SCHEMATIC FOR TENSILE TEST ................................................................................... 13

FIGURE 8 SCHEMATIC FOR COMPRESSION SHEAR TEST .............................................................. 13

FIGURE 9 SCHEMATIC FOR TENSILE SHEAR TEST ....................................................................... 14

FIGURE 10 SCHEMATIC FOR TORSION SHEAR TEST .................................................................... 14

FIGURE 11 SCHEMATIC FOR PEEL TEST ..................................................................................... 14

FIGURE 12 PRINCIPLE OF ULTRA SONIC TESTING FOR WELDS ..................................................... 18

FIGURE 13 PRINCIPLE OF ULTRA SONIC TESTING ....................................................................... 20

FIGURE 14 PRINCIPLE OF ELECTRICAL METHOD ......................................................................... 21

FIGURE 15 PRINCIPLE OF THERMAL METHOD .............................................................................. 21

FIGURE 16 PRINCIPLE OF X-RAY TESTING ................................................................................... 22

FIGURE 17 PRINCIPLE OF ACTOR-SENSOR SYSTEM ..................................................................... 23

FIGURE 18 FREQUENCY SHIFT IN A LOCK BOLT JOINT BETWEEN 1 AND 10KN ................................ 23

FIGURE 19 SCREENSHOT FROM EN15085 REGARDING STRESS CATEGORIES ............................... 28


1 INTRODUCTION INTO OJECTIVE OF WP 6.4

The WP 6.4 - Joint acceptance criteria is part of the REFRESCO WP 6 - Joint

and Manufacturing. Work package WP 6 is structured into the following sub packages:

WP 6.1 – Materials manufacturing and processes,

WP 6.2 – Manufacturing acceptance criteria

WP 6.3 – Joint behaviour

WP 6.4 – Joint acceptance criteria

WP 6.1 and WP 6.2 are dealing with the material and related manufacturing. WP

6.3 combines materials with joints and gives an overview about influencing process

parameters.

WP 6.4 aims to give an overview about the different testing possibilities to be

able to check if the expected and needed property of a joint connection inside of or

between components/ assemblies has been reached.

It is clustered into destructive and non-destructive testing related to the fact that

different testing processes will be used to validate different kinds of requirements.

WP 6.3 has shown in its chapter 4 that there is no rail specific regulation

framework existing for the different joining processes. To satisfy the needs of

REFRESCO the WP 6.4 will try to outline which topics such a framework should cover.

Therefore it will partly refer on existing norms which are already in use or preparation

and which can be used in one or the other way to contribute to this framework.


2 TESTING PROCESSES

2.1 GENERAL

This chapter will summarise which testing processes are available to prove that

the properties of a joint is as expected and needed to fulfil the given/ expected

specification/ requirements.

The focus is to show opportunities for testing after/ during serial production as

well for the incoming and outgoing good control.

Consequently this will be non- destructive measures with the objective to

compare their test results with the acceptance criteria to show/ document the stability

of a serial manufacturing and to support the QA process.

The acceptance criteria need to be defined in advance for each specific

connection by a combination of non-destructive and destructive methods.

To gain very specific information about the properties of joints also destructive

measures are needed. To be complete the basic tests will be mentioned too.

Therefore it will be differentiated between the three joining principles worked out

in WP 6.3.

Welding

Bonding

Mechanical fastened (Bolted/ Riveted)


The principles can be applied in connection with the following basic materials as

agreed for the project and its combinations.

„TOP“ Monolithic Sandwich

1

CFRP CFRP – Toplayer

Resin: Epoxy Resin: Epoxy

UD top-layers: UD or quasi-isotropic

Foam: Airex T90

Honeycomb: Aramid (alternative: Aluminium*)

2

GFRP GFRP – Toplayer

Resin: Epoxy Resin: Epoxy

quasi-isotropic top-layers: quasi-isotropic

Foam: Airex T90

Honeycomb: Aluminium (alternative: Aramid)

*) No direct combinaton of carbon fibres and Aluminium due to

galvanic corrosion issues. But it is possible by using at least one layer

of GFRP (100g/m² dry fabric) between Aluminium HC core and CFRP.

Therefore this option is still possible as "Hybrid".

Table 1 Shortlist of materials considered for process determination

In addition a recommendation for a structure of a future regulatory framework in

connection with the use of new materials will be proposed.

2.2 DESTRUCTIVE TESTING

In the following destructive static tests for the different joining principles are

shown.

To get information about the fatigue behaviour of a joint it is recommended to

test the specific geometries under relevant loads and cycles for the specific situation.

WELDING


According to the findings in the report for WP6.3, this chapter limits on

composites with thermoplastic resins.

For destructive testing the following two international/ national standards have

been found:

EN 12814 - Testing of welded connections at thermoplastic material

DVS 2203 - Testing of welded connections at thermoplastic material

EN 12814 consists of the following parts:

EN 12814 – 1 Bending Test

EN 12814 – 2 Tensile Test

EN 12814 – 3 Creep Tensile Test

EN 12814 – 4 Peel Test

EN 12814 – 5 Macroscopic investigation

EN 12814 – 6 Tensile Test for low temperatures

EN 12814 – 7 Tensile Test for specimen with rounded notch

EN 12814 – 8 General requirements

In the following the different geometries of test specimen or the layouts for the

related tests are shown.

BENDING TEST

Bending angle and bending distance will be investigated.

Figure 1 Bending Test principle


TENSILE TEST

Load until failure will be investigated.

Figure 2 Tensile Test specimen

CREEP TENSILE TEST

Constant load will be applied. Time until failure of specimen will be measured.

Figure 3 Creep Tensile Test – Experimental set up


PEEL TEST

The specimen will be tested with constant feed rate until failure.

Figure 4 Peel Test – Set up example

TENSILE TEST FOR LOW TEMPERATURES

Same as normal tensile test but under low temperature conditions.

Figure 5 Tensile Test for low temperatures - specimen


TENSILE TEST FOR SPECIMEN WITH ROUNDED NOTCH

Load until failure will be investigated.

Figure 6 Tensile Test for specimen with rounded notch - specimen

The standards are not explicitly made for composite materials but it is assessed

that they can be used for thermoplastic composites too.

BONDING

In connection with bonded joints DT measures are useful for random tests.

DT measures deliver information about:

Aging

Adhesion

Cohesion.


They are used to determine characteristic values for bonded joints under static,

dynamic and chemical load.

They are relatively good regulated in different ISO, ASTM or DIN standards.

To judge a serial production these measures are typically used in connection

with specific test pieces in parallel to the real product.

Typical destructive tests for bonded connections are mentioned in the following.

All tests need to be adjusted to the real demands of a joint.

TENSILE TEST

This test is used to assess tensile strength, tear strength and elongation of a

bonded joint.

The test is standardised e.g. in the German DIN 53288 in which the typical

dimensions as material thickness, width and overlap of a specimen are

regulated.

Figure 7 Schematic for Tensile Test

COMPRESSION/ TENSILE SHEAR TEST

With the compression shear test the pure shear strength of a joint will be

identified.

The test is standardised e.g. in the German DIN 54452.

Figure 8 Schematic for Compression Shear Test


The tensile shear test gives information about the strength of the adhesion of a

bonded joint.

It is standardised e.g. in the German DIN 53283.

Figure 9 Schematic for Tensile Shear Test

TORSION SHEAR TEST

In this test the torque until failure will be measured.

It is standardised e.g. in the German DIN 54452.

Figure 10 Schematic for Torsion Shear Test

PEEL TEST

In the peel test the stresses longitudinal and rectangular to the glue joint until

failure will be evaluated.

The test is standardised e.g. in the German DIN 53282.

Figure 11 Schematic for Peel Test

BENDING TEST

Bonded joints show a specific sensibility against bending.

To judge the bending strength of a joint the test will be applied.


It is standardised e.g. in the US standard ASTM 1184-55.

Beside static tests also dynamic test as:

Creep rupture test and

Fatigue tests are in use.

Test/ Standards like

Pre-treatment of specimen for bonded joints DIN 53281

Fabrication of specimen for bonded joints DIN 53281

Conditions for temperature tests DIN 53286

Durability of adhesives DIN 53287

Tensile strength of overlap joints EN 1465

Shear testing for thick material EN 14869

Tensile testing for double shear joints ASTM D 3528

Fatigue properties for tensile loads EN ISO 9664

Ageing with thermal and humidity cycle EN ISO 9142

Shear impact test for adhesive joints EN ISO 9653

are available too.

MECHANICAL FASTENED

In general testing procedures for mechanical joints are summarised in ISO

13469.

The following DT measures are mentioned in this standard:

- Macro section

- Tensile shear test

- Cross tension test

- Mechanized peel test

- Fatigue and endurance tests

The Macro-section test is shown in the ISO 13469.


It describes where the section has to be taken from and clarifies some terms.

The tensile shear test is further specified in ISO 12996.

The Cross tension test is specified in ISO 16237.

The Mechanised peel test has to be carried out according to ISO 14270.

Fatigue and endurance tests have to follow ISO 18592 and ISO 14324.

The following additional norms are available for mechanical joints:

Test of properties of a combination of bonding and mech. joining

DVS/ EFB 3480

Lock bolt systems – mech. properties DVS/ EFB 3435

Mech. testing of blind rivets EN ISO 14589

Torque/ preload test EN ISO 16047

2.3 NON DESTRUCTIVE TESTING

Facing the growing quality requirements for structural joints compared with non-

structural, there is a need for informative and reproducible test measures.

Since destructive test measures are valid to get e.g. mechanical strength

properties under specific conditions only but without the chance to further use the

tested specimen for a product, non- destructive measures are required.

In the following NDT measures are proposed for the specific types of joints.

In connection with welding and bonding the measures need to be validated by

tests in regard to the influence of the fibre on the quality of the evaluation.

WELDING

As for the destructive testing and according to the findings in the report for

WP6.3, this chapter limits on composites with thermoplastic resins.

Therefore the two most relevant testing processes are:

- Ultrasonic Testing and

- High Voltage Testing


Also X- ray testing can be used to investigate irregularities but in connection with

this “optical” method the influence of the fibres need to be considered.

The German DVS 2206 gives a good bundle of information and shows

references to other international and national norms.

The three most relevant parts of the DVS 2206 are:

DVS 2206-1 – Check of dimensions and visual testing

DVS 2206-3 – Ultrasonic Testing

DVS 2206-4 – High Voltage Testing

DVS 2206 part 1

This part gives an overview of allowable tolerances in relation to length and heat

introduction coming from the related welding process.

See following table:

Table 2 Allowable tolerances for welding

There is a reference also to EN ISO 13920.

DVS 2206 part 3

This part describes necessary equipment, test principles and boundary

conditions for Ultrasonic Testing (US testing).

See two examples for testing principles:


Figure 12 Principle of Ultra Sonic Testing for welds

There are references to the following international standards:

- EN ISO 17025 – Form sheet for testing

- EN ISO – Qualification of welders

- EN ISO 583 – Principles

- EN ISO 1330 – Terms and conditions

- EN ISO 13100 – US testing

- EN ISO 12668 – Equipment

DVS 2206 part 4

This part describes necessary equipment, test principles and boundary

conditions for High Voltage Testing (HV testing).

Table 3 Comparison of wall thickness vs. voltage

There is a reference to the DVS 2202 – Irregularities.


BONDING

NDT for bonded joints primarily delivers information about/ recognises the

following defects in the adhesive layer and its boundary layers:

Porosities

Cavities

Insufficient wetting

Delamination (kissing bonds) etc.

NDT measures can’t deliver a related factor for a remaining mechanical strength

facing a specific defect.

They give only a YES or NO statement if there is a failure or not. The result of

this measures need to be assessed by QA and Engineering.

That’s why a combination of trained staff, save and repeatable processes, stable

environmental conditions in manufacturing, destructive and non-destructive testing

measures always in relation to the safety needs is needed for quality assurance in

companies dealing with structural bonding.

To document the results of such a process often specific test pieces will be

manufactures in parallel to the serial production under exactly the same conditions/

parameters as the serial product.

This test pieces can destructively be tested parallel to the running production to

recognise problems.

The following topics cannot be detected with NDT for bonding:

Aging effects

Long term statements

Overall qualification of a bonded connection

Differences in adhesion coming from failures in manufacturing

According to the NMAB of the American Society for Non-destructive Testing

these measures can be structured into the following categories (Classification of NDT-

Methods 2002):

Mechanical Vibration

Electro- Mechanical


Thermal

Penetrative Radiation

Visual

Chemical- Electro- Chemical

This measures need to be applied at the end of the manufacturing process.

The visual measure is meaningful only for the control of the application of the

adhesive.

Chemical- Electro- Chemical measures are not applicable for bonded joints.

Techniques based on mechanical vibration are typically using ultrasonic

vibrations.

Electrical frequencies will be changed into mechanical frequencies and reverse.

Typical frequencies are between 1 and 5 MHz. If the induced wave meets a defect it

will be reflected. So the position of a defect can be determined.

Figure 13 Principle of Ultra Sonic Testing

Variations of techniques based on mechanical vibrations are:

Resonant Method

Puls- Ecco Method

Impact- Resonance Method

Spectral Analysis Method


Electrical Methods are not reasonable for industrial bonding processes and

non- conductive material like composite.

They are based on a measurement of the electrical capacity of a bonded joint of

two metals and an adhesive which are forming a kind of a condenser.

Figure 14 Principle of Electrical Method

The thermal method is using the different heat conduction through a

homogenous joints and a joint with defects. For the evaluation infrared cameras are

used.

Figure 15 Principle of thermal method

The penetrative radiation methods are clustered in the following methods:

X Ray Testing

Neutron Radiography

Holographic Method

X ray testing can be used to visualise inner structures like honeycomb structures

in sandwich panels. The thin adhesive layer cannot be checked with this method.


The Neutron radiography gives very precise information about the geometry of

defects but is extremely expensive and that’s why not eligible for a serial production.

Holographic methods are based on interference pattern in deformed bonded

panels. This method is used in the aerospace industry for thin bonding partners with

large surfaces.

Figure 16 Principle of X-ray testing

MECHANICAL FASTENED

The classic NDT approach to test a mechanical joint is the visual method as in

ISO 13469.

Therefore qualified staff in connection with specific tooling like templates is

required.

The following parameters will be checked prior to joining:

- Misalignment of holes

- Misalignment of rivet head and rivet end

- Damages on rivet or collar

After joining will be checked:

- deformation of shaft or collar

- gap between part and rivet.

In addition more precise methods are in use.

Since they are partly sensible regarding the environment for its application their use is

more or less limited to laboratories.

This methods are:

- photo elastic study of stresses

- strain gauges

- optical templates

- Vibro-acoustic with Laser Vibrometer.


For the use in an industrial environment additional systems are in development.

As an example the piezo-electrical actor-sensor system developed by “Fraunhofer

Institute” can be mentioned. With the help of this system it is possible to check the pre

load of a mechanical joint. The system uses frequency shifts in relation to inner load

conditions.

The following picture shows the use of such a system.

Figure 17 Principle of actor-sensor system

Figure 18 Frequency shift in a lock bolt joint between 1 and 10kN


2.4 RECOMMENDATION FOR THE RAIL INDUSTRY

The main objectives of testing measures for joints are the following:

- Gain parameters for validation and verification (material

characterisation)

- Ensure the required quality in the manufacturing process and in

purchasing

Therefore different international and national norms and standards are available.

They can be used also for the rail industry.

Specifically for the DT measures it should be possible to find an application

related approach.

For the NDT measures it is more difficult since there are very less norms

available which directly refer to composite material.

Solutions can be derived from existing standards for related material types but

will have to be validated by testing regarding the obtained information (e.g. influence

of fibres for the NDT results for bonding and welding).

At least individual NDT solutions for the manufacturing process control need to

be developed.

The most important factor is the process stability.

The development of such DT/ NDT solutions need to be supported by the

generation of a “homologation approach” which clarifies which properties and

manufacturing related information for the parts of the bodyshell structure are needed

to get the homologation for a vehicle.

Such an approach need to be worked out inside FP7 e.g. in Shift2Rail.


3 REGULATIVE FRAMEWORK PROPOSAL/ APPROACH

To reach a common regulatory framework for the European rail industry it is

necessary to have a system of norms and standards which covers a whole range of

building blocks (BB).

BUILDING BLOCKS

Can be nominated as follows:

BB 1 - Concept and design

BB 2 - Safety needs for:

Supplier selection

Requirements to the manufacturing facility

Requirements to the workers in manufacturing

BB 3 - Generic QA requirements

BB 4 - Static and fatigue evaluation

BB 1) The concept and design chapter should contain:

- General accepted GO/ NO GO principles for the design of a specific

joint connection

- Definition of terms

BB 2) The safety need chapter should contain:

- Safety categories to cluster the safety need

- Related performance and inspection classes

BB 3) The generic QA requirements chapter should contain:

- Define rules for planning (min. needed documents in manufacturing, to

be documented)

- Defines rules for documentation of product

- Defines rules for documentation of repairs

BB 4) The static and fatigue evaluation chapter should contain:

- Generic rules for meshing and evaluation

- Safety factors

- Number and range of needed test to validate the FE analysis


COMPETITIVE CONTENT

Information like

- Real numbers for allowable stresses of specific material combinations

- Processes for FAI’s

- Detailed QA measures during manufacturing

- Incoming/ outgoing goods control processes

are to be seen as competitive processes which not need to be part of a

European framework.

SPECIFIC REQUIREMENTS

Norms which are defining specific requirements for rail vehicles like the EN

45545 for Fire and Smoke or the EN 12663 for Structural requirements are

not recommended to be part of the framework.

They represent requirements which have to be fulfilled for each rail vehicle,

independent from the material of the Bodyshell but it need to be discussed if

they need to be adopted to fit for composites.

EXPECTED FRAMEWORKS

Facing the principally different requirements for the different joint systems we

recommend creating a number of three of such frameworks.

- for welded connections with new materials

- for bolted/ riveted hybrid and single material solutions with involved new

materials

- for bonded hybrid and single material solutions with involved new

materials


EXISTING NORMS/ FRAMEWORKS

EN 15085

In front of the above mentioned background the existing EN 15085

gives an excellent example for a regulatory framework for welded

connections in metallic structures. The idea of the framework is to cover all

requirements for design, layout, assessment and quality assurance approach

based on the same philosophy.

This gives a clear guideline which enables supplier and customer to reach a

stable quality. It makes results and requirements transparent and secures the

comparability of welding manufacturers. It leads to the possibility of objective

cost evaluations and clear responsibilities.

The EN 15085 consists of different parts which are dealing with different

topics.

They are:

Part 1 – General

Defines Terms and gives general comments

Part 2 – Quality requirements and certification of welding manufacturers

Defines certification levels for the product and relates them to

Qualification needs to the manufacturers

Part 3 – Design requirements

Creates a relation of safety categories (LOW/ MEDIUM/ HIGH)

and stress category (Fatigue utilisation). This is related to

performance classes (CP A to CP D) for the welding seam

which are related to inspection classes (T 1 to 4).

The inspection class defines the necessary effort for testing.

Gives advises for the design engineer regarding the

arrangement of welding seams.


Figure 19 Screenshot from EN15085 regarding stress categories

Part 4 – Production requirements

Defines steps for the manufacturing of a welded connection.

Mentions documents for planning and exceptions for testing.

Defines rules for repairs.

Part 5 – Inspection, testing and documentation

It defines rules for planning and documentation of QA

measures in the manufacturing.

The EN 15085 explicitly excludes methodologies, boundaries and values for

static and fatigue analysis.

DIN 6701

The DIN 6701 represents a national framework for bonded structures in the

rail industry.

It follows the same approach as the EN 15085.

This Regulation consists of the following parts:


Part 1 – Basic terms

Defines Terms and gives general comments

Part 2 – Qualification of manufacturer of adhesive bonded materials

Classifies bonded connections in relation to the qualification of

the manufacturers. Defines qualification needs for

manufacturers.

Part 3 – Guideline for construction design and verification

Classifies bonded connections in relation to safety needs.

Gives advises for the design. Specifies testing and supports

dimensioning.

Part 4 – Manufacturing controls and quality assurance

Defines steps for the manufacturing of a bonded connection.

Mentions documents for planning and exceptions for testing.

Defines rules for repairs.

Additional parts are in preparation for manufacturing planning and quality

assurance.

Part 3 could be used as a basis for a norm describing how to do the

dimensioning of bonded connections with mixed materials/ new materials.

DVS-EFB 3435-2

This is a code of practise for the dimensioning of Lock Bolt connections in the

rail industry.

It is related to steel/ stainless steel and aluminium.

This document gives general advises for the design.

It defines rules for the structural calculation and categorises Lock Bolt

connections.

Should be extended to have a norm describing how to do the dimensioning of

bolted connections with mixed materials/ new materials.


CONCLUSION

The following table show the regulatory frameworks which are proposed to be

developed for new materials in structural approaches to get homologation in the rail

industry.

FRAMEWORK 1 FRAMEWORK 2 FRAMEWORK 3

HEADLINE

welded connections with

new materials

bolted/ riveted hybrid and single material solutions with involved new

materials

bonded hybrid and single material solutions with involved new

materials

EXAMPLE FOR RECOMMENDED FRAMEWORK ARCHITECTURE BB 1 to BB 3

EN 15085 EN 15085 DIN 6701 Part 1 to 4

EXAMPLE FOR NORM BB 4

DVS-EFB 3435-2 (adopt and make

international)

DIN 6701 part 3 (adopt and make

international)

Table 4 Recommended frameworks

At least there are approaches available which are already in use in single

countries or for metallic structures or specific processes.

It will be the task of future regulation boards to use this approaches also for new

materials.

Therefore it is recommended to use the structure of the above mentioned regulations,

to adopt them as mentioned and to give them the status of a European Norm.


4 SUMMARY

In this subtask an overview about the destructive and non- destructive testing

processes is given, based on existing norms and standards.

Some of the standards are made for similar or different base materials but the

principles should be able to be used for new materials/ composites too.

In any case it is recommended to validate this specifically for the NDT measures

by tests.

According to the agreements from the beginning of this projects tests have not

been performed.

The different testing measures have been clustered to the three essential joining

principles:

- Welding

- Bonding

- Mechanically fastened.

Test Principles and standardised geometries of specimen have been shown

exemplary.

In the last chapter a recommendation for the structure of a regulatory framework

is given.

It refers to existing regulations.

For further activities in regard to such a framework, the introduction of the related

regulation boards is strongly recommended.


5 APPENDIX

5.1 Appendix A

Additional norms and standards

DOCUMENT TITEL

DIN 27201-7 Zustand der Eisenbahnfahrzeuge - Grundlagen und Fertigungstechnologien - Teil 7: Zerstörungsfreie Prüfung

DIN 65151 Luft- und Raumfahrt - Dynamische Prüfung des Sicherungsverhaltens von Schraubverbindungen unter Querbeanspruchung (Vibrationsprüfung)

EN 1090-2 Ausführung von Stahltragwerken und Aluminiumtragwerken - Teil 2: Technische Regeln für die Ausführung von Stahltragwerken; Deutsche Fassung EN 1090-2:2008+A1:2011

EN 1090-3 Ausführung von Stahltragwerken und Aluminiumtragwerken - Teil 3: Technische Regeln für die Ausführung von Aluminiumtragwerken; Deutsche Fassung EN 1090-3:2008

EN 1999-1-1 Eurocode 9: Bemessung und Konstruktion von Aluminiumtragwerken - Teil 1-1: Allgemeine Bemessungsregeln; Deutsche Fassung EN 1999-1-1:2007 + A1:2009 + A2:2013

EN 1999-1-3 Eurocode 9: Bemessung und Konstruktion von Aluminiumtragwerken - Teil 1-3: Ermüdungsbeanspruchte Tragwerke; Deutsche Fassung EN 1999-1-3:2007 + A1:2011

EN ISO 12996 Mechanisches Fügen - Zerstörende Prüfung von Verbindungen - Probenmaße und Prüfverfahren für die Scherzugprüfung von Einpunktproben (ISO 12996:2013); Deutsche Fassung EN ISO 12996:2013

DVS 2240-1 Gewindeeinsätze zum Fügen von Formteilen aus Kunststoffen

DVS 2241-1 Direktverschraubung von Formteilen aus Kunststoffen

DVS 2241-1 BEIBLATT 1

Beispiele - Direktverschraubung von Formteilen aus Kunststoffen und Zusatzelemente für dünnwandige Bauteile

DVS-EFB 3410 Stanznieten - Überblick

DVS-EFB 3410-2 Stanznieten - Sonderverfahren

DVS-EFB 3420 Clinchen - Überblick - Clinching - basics

DVS-EFB 3430 Blindnieten (blind rivets)

DVS-EFB 3435-1 Schließringbolzensysteme

DVS-EFB 3440-1 Funktionselemente - Überblick

DVS-EFB 3440-2 Funktionselemente - Einstanz-, Einniet-, Einpresselemente (pierce-, riveting- and pressform elements)

DVS-EFB 3440-3 Funktionselemente - Blindnietelemente (blind rivet elements)

DVS-EFB 3440-4 Funktionselemente - Loch- u. gewindeformende Schrauben (hole- and threadforming screws)


DVS-EFB 3450-1 Hybridfügen - Clinch Kleben - Stanznietkleben - Überblick

DVS-EFB 3460 Nacharbeit und Reparatur von unlösbar mechanisch gefügten Verbindungen

DVS-EFB 3470 Mechanisches Fügen - Konstruktion und Auslegung - Grundlagen/Überblick

DVS-EFB 3480-1 Prüfung von Verbindungseigenschaften - Prüfung der Eigenschaften mechanisch und kombiniert mittels Kleben gefertigter Verbindungen

DVS-EFB 3480-1 BEIBLATT 1

Prüfung von Verbindungseigenschaften - Prüfung der Eigenschaften mechanisch und kombiniert mittels Kleben gefertigter Verbindungen - Steifigkeitsermittlung elementar mechanisch gefügter Verbindungen

DVS-EFB 3490 Anlagen zum Stanznieten

ISO 13469 Mechanisches Fügen - Formschlüssiges Blindniete und Schließringbolzen - Festlegungen und Bewertung von Prüfverfahren

VDI 2014 BLATT 3 Entwicklung von Bauteilen aus Faser-Kunststoff-Verbund - Berechnungen

ISO 11003-1 Klebstoffe - Bestimmung des Scherverhaltens von Strukturklebstoffen - Teil 1: Torsionsprüfverfahren unter Verwendung stumpfgeklebter Hohlzylinder

ISO 11003-2 Klebstoffe - Bestimmung des Scherverhaltens von Strukturklebstoffen - Teil 2: Scherprüfverfahren für dicke Fügeteile


6 REFERENCES

[1] DAkkS – Deutsche Akkreditierungsstelle

[2] Fraunhofer Institute – Anwendungszentrum Rostock

[3] Normmaster

[4] DVS – Deutscher Verband für Schweißen und verwandte Verfahren

[5] Handbook DVS – Merkblätter „Kunststoffe, Schweißen und Kleben“

[6] M. Rasch; Handbuch Klebetechnik

[7] G. Habenicht; Grundlagen Kleben

wp 6.4 joint acceptance criteria - refresco - towards a ... · figure 6 tensile test for specimen...

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