Ces S Manf 13 PDF

Engineering Standard
CES-S-MANF-13
This document must be reviewed for technical accuracy by: 2020-09-18
If this document is used after this date, the technical content may be INVALID
Name: Welding Requirements for Aftertreatment and Exhaust Parts
Identifier: Specification: Manufacturing
Description
This specification provides welding requirements for welds used in Cummins Emission
Solutions aftertreatment applications. All dimensions in this document are in millimeters
unless otherwise noted. Sketches in this document are not to scale. If communication is
required to the customer of the material contained within this document, please refer to
Section 5, “Customer Communication Document.”
CUMMINS CONFIDENTIAL: This information is confidential and classified CONFIDENTIAL per CORP-00-24-00-00, and shall not be disclosed to others in hard copy or
electronic form, reproduced by any means, or used for any purpose without the written consent of Cummins Inc.
CES-S-MANF-13 Page 1 of 160

Revision 13 DCR: 00002991
September 2018 THIS DOCUMENT SUPERSEDES ALL PREVIOUS VERSIONS © Copyright 2018 Cummins Inc.
CES-S-MANF-13
Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Applicable Documents and Citations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Applicable documents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Citations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Customer Communication Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6 Welding Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1 Weld Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.1 “F” and “G” Weld Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2 Direction and Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.1 U/D Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.2 1, 2, 3, 4, or 5 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3 Position descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.3.1 1F/1G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.3.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2F/2G27
6.3.3 3F/3G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3.4 4F/4G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.5 5F/5G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7 Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Variable specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.2 Development and fit-up gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.3 Key Welding Variables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.3.1 Arc Welding (GMAW, GTAW, and PAW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.3.2 Resistance Welding (RSW, PW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.3.3 Arc Stud Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.3.4 Brazing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3.5 Laser Beam Welding (LBW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1 Shielding Gas and Filler Metal Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.1.1 Welding Filler Metal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9 Inspection Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.1 Limits for Imperfections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

CES-S-MANF-13
9.1.1 CES Weld Quality Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9.1.2 Visual Inspection in Imperfection Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.3 Frequency of Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.4 Lack of Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.5 Welding Symbol Weld Class Callout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.6 Heat Input in Arc Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
9.1.7 Spatter on Marmons Per CES-S-MANF-2 and Sealing Surfaces . . . . . . . . . . . . . . 48
9.2 Inspection methods for imperfections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.2.1 Nondestructive Testing, NDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.2.2 Destructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.2.3 Inspector Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.3 Destructive Testing Methods for Strength and Toughness of Welds . . . . . . . . . . . . . . . . 71
9.3.1 Tension Testing - Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
9.3.2 Bend Testing - Butt Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
9.3.3 . . . . . . . . . . . . . . . . . . . . . . . .Ball Punch Deformation - Laser Welded Butt Joints74
9.3.4 Bend Testing - T Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
9.3.5 Peel Testing - Lap Joints and Slot Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9.3.6 . . . . . . . . . . . . . . . . . . . . . .Tension (Shear) Testing - Spot Welds and Plug Welds80
9.3.7 Peel Testing - Spot Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.3.8 Torque Testing - Annular Couplers (RPW/LBW/GMAW) . . . . . . . . . . . . . . . . . . 86
9.3.9 Dye Penetrant Testing of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.3.10 Torque Testing - Stud Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
9.3.11 Bend Testing - Stud Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
9.3.12 Bend Testing - Brazed Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
9.3.13 Peel Testing - Brazed Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
9.3.14 Metallography - Cross Sectioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10 Rework Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1.1 Weld Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
10.1.2 CAG and OFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.1.3 Affected Base Metal Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.1.4 Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.1.5 Rework Cycles Allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.1.6 Rework Method Not Listed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.2 Rework Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10.2.1 Rework of Welds Within Flared Outer Body Joint Geometry per CES-S-MANF-9
108
10.2.2 Rework of Welds Within Outer Body Joint Geometry per
CES-S-MANF-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

CES-S-MANF-13
11 Laser Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

11.1 Laser Welding Fit-Up Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12 Weldment Fabrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.1 Fabrication Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.1.1 Fit-Up Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
12.1.2 Work Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
12.1.3 Torch Angle (Travel Angle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
12.1.4 Electrode Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
12.1.5 Contact-Tip-to-Work-Distance (CTWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
12.1.6 Weld Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
12.1.7 Tack Welding Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
13 Recurring Weldment Verification (RWV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
13.1 Verification Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
13.1.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method129
13.1.2 Deviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
13.1.3 Recording Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
13.1.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Failed RWV130
14 Appendix A: Material Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
15 Appendix B: Recommended Weld Procedure Test Assembly Dimensions . . . . . . . . . . . . . 136
16 Appendix C: Recommended Spot Weld Placement for Inner Bodies . . . . . . . . . . . . . . . . . . 146
16.1 Spot weld specifications for inner bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
17 Appendix D: Document Metadata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
17.1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
17.2 Content Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
17.3 Document Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
17.3.1 Access and Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
17.4 File Names and Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
17.5 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

CES-S-MANF-13
Table of Figures
Figure 1: Lap Joint (left) and T Joint (right). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 2: Square Butt Joint (left) and Single Bevel T Joint (right) . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 3: 1F Orientation, T Joint on plate (left) and mechanically rotated pipe (right) . . . . . . . . 27
Figure 4: 2F Orientation, T Joint on plate (left) and pipe (right) . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 5: 3F Orientation, T Joint on plate (left) and mechanically rotated pipe (right) . . . . . . . . 28
Figure 6: 4F Orientation, T Joint on plate (left) and pipe (right) . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 7: 5F Orientation, T Joint (left) and Lap Joint on pipe (right) . . . . . . . . . . . . . . . . . . . . . 30
Figure 8: Transverse Rectangular Tension Test Specimen (1). . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Figure 9: Square Butt Joint (left) and after a Transverse Root Bend test (right) (3) . . . . . . . . . . 73
Figure 10: Weld fail example - 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 11: Weld fail example - 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 12: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weld pass example 75
Figure 13: Ball Punch Deformation Test Sample, Laser Welded Butt Joint . . . . . . . . . . . . . . . . 76
Figure 14: Bend Test of a T Joint (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 15: Peel Test of a Lap Joint (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Figure 16: Peel Test of a Slot Weld (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Figure 17: Transverse Rectangular Shear Test Specimen for Spot Weld. . . . . . . . . . . . . . . . . . . 81
Figure 18: Manual method of peel test for RSW (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Figure 19: Tension tester method of peel test for RSW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 20: Projection Welded Coupling Torque Test Arrangement. . . . . . . . . . . . . . . . . . . . . . . 88
Figure 21: Indications found in GTAW using Type II Dye Penetrant Testing . . . . . . . . . . . . . . 91
Figure 22: Arc Stud Welded Torque Test Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 23: Stud Welded Bend Test Arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 24: Brazed Lap Joint Test Specimen (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 25: Brazed Lap Joint Free Bend Test. Can also be used for Butt Joints (4) . . . . . . . . . . . 96
Figure 26: Brazed Joint Peel Test Specimen (4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 27: Dimensional Analysis of a Lap Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 28: Dimensional Analysis of a T Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Figure 29: Dimensional Analysis of a Resistance Spot Weld . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Figure 30: Dimensional Analysis of an annular Projection Weld. Only half of the coupling is
visible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Figure 31: Current versus WFS for 300 Series Stainless Steel Electrodes at a Fixed Stickout (1) .
106
Figure 32: Current versus WFS for 400 Series Stainless Steel Electrodes at a Fixed Stickout (9) .
107
Figure 33: Work Angle, torch perpendicular to joint in a Single-V Groove weld . . . . . . . . . . . 123
Figure 34: Work Angle, torch perpendicular to joint in a T Joint . . . . . . . . . . . . . . . . . . . . . . . 124

CES-S-MANF-13
Figure 35: Work Angle, torch perpendicular to joint in a Lap Joint . . . . . . . . . . . . . . . . . . . . . 124
Figure 36: Torch Angle, torch parallel to joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 37: Electrode placed even in the corner of a lap joint . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Figure 38: GMAW Arc Diagram - notice that CTWD does not equal Stickout in this situation 126
Figure 39: Minimum Weld Overlap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Figure 40: Spot welds on inner bodies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

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Table of Tables
Table 1: Shielding gas and filler metal requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 2: GMAW/GTAW/LBW limits for imperfections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Table 3: Arc Stud Welding Limits for Imperfections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table 4: Resistance Spot Welding Limits for Imperfections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 5: Brazed Joints Limits for Imperfections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Table 6: Projection Welding Limits for Imperfections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table 7: Minimum Weld Diameter and Peak Peel Stress Requirements . . . . . . . . . . . . . . . . . . 85
Table 8: Thermal Efficiency Factor, k, by Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Table 9: Arc Stud Welded Rework Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Table 10: Resistance Welded Rework Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Table 11: GMAW/GTAW/LBW Rework Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Table 12: RWV Test Frequency (for greater than 500 uses) . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Table 13: Base Metal CES M-Number Classification for Welding . . . . . . . . . . . . . . . . . . . . . 131
Table 14: Base Metal Type and Ultimate Tensile Strength . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Table 15: Filler Metal F-Number Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Table 16: Recommended Weld Procedure Test Assembly Dimensions . . . . . . . . . . . . . . . . . . 136
Table 17: Appendix D: Document Metadata: Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Table 18: Appendix D: Document Metadata: Content Control . . . . . . . . . . . . . . . . . . . . . . . . . 149
Table 19: Appendix D: Document Metadata: Document Control:
Access and Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
File Names and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

CES-S-MANF-13
1 Scope
1.1 This specification provides welding requirements for welds used in CES
aftertreatment applications. All dimensions in this document are in millimeters unless
otherwise noted. Sketches in this document are not to scale. The strength of the welds
shall be measured by the destructive tests.
NOTE: Requirements included in this standard override any
requirements in the reference standards where differences
exist.
1.2 If communication is required to the customer of the material contained within this
document, please refer to Section 5, “Customer Communication Document.”
1.3 “Shall” defines a dictation within this document and must be met. “Must” is equal to
“shall.” “Should” is a recommendation and is not a requirement. Although it is
preferred when possible.
2 Purpose
In order to ensure that welds are consistent and adequate, it is necessary to provide
welding requirements for welds used in CES aftertreatment applications.

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3 Applicable Documents and Citations

3.1 Applicable documents
The following documents are listed for reference purposes only and are not critical to
the processes or procedures identified in this document.
AWS A2.4: 2012, “Standard Symbols for Welding, Brazing, and Nondestructive
Examination.”
AWS A3/0: 2010, “Standard Welding Terms and Definitions.”
AWS B2.1:2014, “Specifications for Welding Procedure and Performance
Qualification.”
AWS B4.0: 2007, “Standard Methods for Mechanical Testing of Welds.”
AWS C1.1: 2012, “Recommended Practices for Resistance Welding.”
AWS C7.2: 2010, “Recommended Practices for Laser Beam Welding, Cutting, and
Allied Processes.”
AWS D1.1: 2015, “Structural Welding Code – Steel.”
AWS D1.3: 2008, “Structural Welding Code – Sheet Steel.”
AWS D1.6: 2007, “Structural Welding Code – Stainless Steel.”
AWS D8.1: 2013, “Specification for Automotive Weld Quality – Resistance Spot
Welding of Steel.”
CES 10054, “Standards Organization Addresses.”
CES 10056, “Glossary.”
CES 18095, “Items Fabricated.”
CORP-00-24-00-00, “Classification and Protections of Data Policy.”
CQI-15:2010, “Special Processes: Welding System Assessment.”
DS/EN 12797: 2000, “Brazing - Destructive Tests of Brazed Joints.”
ISBN: 0-02-3129000-5, “Machine Design: Theory and Practice,” Aaron D.
Deutschman, Walter J. Michels, Charles E Wilson.
ISBN: 0-07-100292-8, “Mechanical Engineering Design,” Joseph Edward Shigley.
ISO 15609-4: 2009, “Specification and Qualification of Welding Procedures for
Metallic Materials - Welding Procedure Specification, Part 4: Laser Beam Welding.”

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ISO 18279: 2003, “Brazing - Imperfections in Brazed Joint.”

ISO 5817: 2014, “Welding - Fusion-Welded Joint in Steel, Nickel, Titanium and their
Alloys (beam welding excluded) - Quality Levels for Imperfections.”
“Welding Handbook – Welding Processes Gas, Arc and Resistance,” American
Welding Society, Section Two – Sixth Edition.
3.2 Citations
1. ANSI/AWS B4.0 – 98, “Standard Methods for Mechanical Testing of Welds.”
2. ANSI/AWS D1.3: 2008, “Structural Welding Code – Sheet Steel.”
3. Deutschman, Aaron D., Walter J. Michels, and Charles E. Wilson. Machine
Design: Theory and Practice. New York: Maxmillan, 1975. Print.
4. DS/EN 12797: 2000, “Brazing – Destructive Tests of Brazed Joints.”
5. ISO 10447: 2015, “Resistance Welding – Testing of Welds – Peel and Chisel
Testing of Resistance Spot and Projection Welds.”
6. Armao, Frank, et al. Gas Metal Arc Welding Product and Procedure Selection.
C4.200 ed., The Lincoln Electric Company, 2014.
7. ASTM E643-15, “Standard Test Method for Ball Punch Deformation of
Metallic Sheet Material.”
8. ASTM E1417-16, “Standard Practice for Liquid Penetrant Testing.”
9. Select Arc, Inc., “Recommended Welding Parameters: Ferritic and Martensitic
Stainless Steel (4XX Series) - Metal Cored - Argon/Oxygen - DCEP.”

CES-S-MANF-13
4 Definitions
Terms used in this standard that have general definition for usage in Cummins
Engineering Standards are defined in CES 10056, “Glossary.”
Actual Throat (ta)
The shortest linear distance from the root of a weld, perpendicular to its weld
face.
American Welding Society (AWS)
The AWS is a nonprofit organization with a global mission to advance,
science, technology and application of welding and allied joining and cutting
processes, including brazing, soldering and thermal spraying. They provide
welding standards, certifications and published works and are commonly
referred to as the governing body for welding in the United States.
Arc Stud Weld (SW)
A welding technique where a fastener (threaded or not) is welded onto base
metal through the use of a drawn arc between the face of the stud and the base
metal. A protective ceramic ferrule may or may not be used.
Autogenous
A fusion weld made without filler materials. Most applicable in gas tungsten
arc welding, plasma arc welding and laser beam welding.
Automatic Weld Type
A (re)programmable machine or robot with a multi-axis articulated arm is
manipulating the welding torch with respect to the joint, or the joint is moving
with respect to the welding torch.
Brazing
A joining technique in which the base metal is not melted. Filler metals have a
melting temperature above 450°C and rely on the flow of molten filler metal
into the braze joint by capillary action.
Butt Joint
A type of groove weld in which the joint consists of base metal members being
welded end to end.
Carbon Arc Gouging (CAG)
A thermal gouging process using heat from a carbon arc and the force of
compressed air or other nonflammable gas.

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Complete Joint Penetration (CJP)

Weld metal has penetrated through the full thickness of the joint.
Concavity (Negative Reinforcement)
A surface condition in which the face of the weld bead is intruding into the
thickness of the weld. Shortening the theoretical throat length and decreasing
the weld size.
Contact Tip
A copper component of a GMAW torch in which electrical conductivity is
passed from the weld torch into the filler wire.
Contact Tip to Work Distance (CTWD)
The linear distance between the contact tip and the work (base metal to be
welded), to be measured in line with the contact tip. Used to specify weld torch
placement.
Convexity (Reinforcement)
A surface condition in which the face of the weld bead is protruding out of the
thickness of the weld. Increasing the amount of reinforcement present on the
weld bead.
Corner Joint
A type of fillet weld in which the joint consists of base metal members located
approximately at right angles to each other, creating an L shape.
Cross Section
A sectioning of the weld bead, most often perpendicular to its linear direction.
Allowing for metallography and dimensional analysis.
Cycle Time
In the context of resistance welding, cycle time is the unit of time used for
multiple resistance welding parameters, including squeeze time, hold time, and
weld time. One cycle is equal to 1/60 of one second.
Design Throat (td)
The recommended throat length for a specific weldment, based on base
member thickness and fit-up gap, not load requirements. Only applicable for
fillet welds.

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Effective Length of Weld (Lw)

The overall linear length of the weld which is effectively carrying load,
excluding imperfections as a result of the weld start or weld stop.
Effective Throat (te)
The shortest linear distance from the root of a fillet weld perpendicular to the
hypotenuse of the largest right triangle that can be sized within a fillet weld
cross-section.
Effective Weld Size
The triangular portion of the weld which is theorized to transfer most of the
load through the weldment. Only applicable for fillet joints when fit-up gaps
are present. Different from weld size, aw.
Electrode Placement
The location in the unwelded joint where the electrode is placed prior to
welding. Sometimes measured as a linear distance from the edge of the top
member of the weldment to the electrode.
Essential Variable
In the context of a Welding Procedure Specification (WPS), an Essential
Variable refers to a specific variable which if adjusted beyond its qualified
values will require a requalification of the WPS.
Expulsion
In the context of resistance welding, it is the expelling of weld metal from in
between the metal sheets being welded as a result of excess heat input.
Filler Metal (Filler Wire or Electrode)
The additional metal that is melted and consumed during welding, mixing with
the molten base metal and creating the fusion zone of the weld bead. Filler
metal, filler wire and electrode are commonly used in the same regard. It’s
important to note that all filler metals are consumables, but not all electrodes
are consumables (i.e. tungsten electrode for GTAW).
Fillet Weld
A weld type resulting in a triangular cross section (i.e. lap joint, t-joint) joining
base metal together at approximately right angles to each other.

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Ferrule
In the context of arc stud welding, it is a ceramic protective cylinder which
shields the operator from the arc, minimizes the atmosphere that the flux must
purge and forms the shape of the molten weld metal into a fillet.
Flare-Bevel Joint
A type of groove weld in which the joint consists of a radius meeting another
radius or a radius meeting a flat section of base metal.
Focal Spot Size
In the context of LBW, it is the size of the part of the beam beyond the focusing
system where the beam comes to a minimum cross-sectional area. The energy
density is at its highest point at this location.
Force
In the context of resistance welding, it is the amount of force (typically in
pounds) between the two faces of the welding electrodes. Force is directly
related to weld quality; too little force and expulsion will occur before a proper
nugget has formed, too much force and the resistance between the sheets of
base metal will be too low, requiring increased current to compensate.
Fusion Zone
The section of a weldment which consists of primarily filler material and some
base metal as a result of dilution (base metal has mixed with weld metal).
Commonly referred to as weld metal, or weld bead.
Gas Metal Arc Weld (GMAW or MIG)
Gas Metal Arc Welding (GMAW) is an arc welding process in which a
continuous consumable wire electrode and shielding gas are fed through the
welding gun. Also referred to as Metal Inert Gas (MIG) welding.
Gas Tungsten Arc Weld (GTAW or TIG)
Gas Tungsten Arc Welding (GTAW) is an arc welding process in which a non-
consumable tungsten electrode is used to produce the arc for welding. Filler
metal may or may not be used. Also referred to as Tungsten Inert Gas (TIG)
welding.
Groove Weld
A weld type made by depositing filler metal in a groove between base metal
members to be joined.

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Heat Affected Zone (HAZ)

The area of a weldment just adjacent to the fusion zone which has been
sufficiently heated to undergo microstructural recovery, recrystallization and
finally grain growth. The weldment is typically weakest in this region.
Hold Time
In the context of resistance welding, it is the amount of time the electrodes will
continue to apply force after current has stopped being passed. This time
allows the resistance weld to fully solidify while still under pressure between
the electrodes.
Impulse
In the context of resistance welding, it is the occurrence of current flowing
through the electrodes during a multi-pulse cycle. Impulse is categorized by
quantity of current and duration. During single pulse welding, impulse is
irrelevant since there is no need to specify an additional current pulsation
outside of the set welding parameters.
Inspector
A qualified individual responsible for evaluating the weld quality of Cummins
Emission Solutions’ products.
Joint Root (Rj)
The area of closest proximity between the members of a joint to be welded.
Lap Joint
A type of fillet weld in which the joint consists of base metal members
overlapping one another and welded along the overlapping seam.
Laser Beam Cutting (LBC)
Laser Beam Cutting is a cutting technique that is used to cut pieces of metal by
positioning the focal spot of a laser approximately towards the bottom of the
through thickness metal being cut.
Laser Beam Weld (LBW)
Laser Beam Welding is a high energy density welding process that is used to
join two or more pieces of metal by positioning the focal spot of a laser
approximately in the center of the through thickness seam to be welded. It is
typically an autogenous process.
Lux
The SI unit for illuminance, equal to one lumen per square meter.

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Manual Weld Type

A welding operator is manually manipulating the welding torch while traveling
along a fixed joint.
Manufacturer
The organization responsible for the production of Cummins Emission
Solutions products.
Mechanized Weld Type
A non-programmable, typically one or two axis machine is moving the
welding torch with respect to the joint, or the joint with respect to the torch.
Nugget
In the context of resistance welding, a nugget refers to the fusion zone of a
resistance spot weld. The term is most often used during a peel test, in which a
full button pull results in the tearing of the full nugget out of one piece of base
metal, leaving a hole, while the other section contains base metal, a fully intact
fusion zone, and the base metal that was torn from the other member.
Operator Qualification Record (OQR)
A standardized record explicitly recording the capabilities of a welding
operator as it pertains to their qualifications to weld specific Welding
Procedure Specifications.
Oxyfuel Gas Cutting (OFC)
A group of oxygen cutting processes using heat from an oxyfuel gas flame.
Partial Joint Penetration (PJP)
Weld metal has penetrated only partially through the thickness of the joint.
Percent Heat
In the context of resistance welding, percent heat is a parameter set on the
welding controller that dictates how much current, in percent, is being allowed
to pass through the electrodes during welding. Percent is relative to the TAP
setting. Some welding controllers forgo percent heat and use a direct ampere
current measurement.

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Pinch Effect
In GMAW the electro-magnetic forces, which are mathematically proportional
to the square of the applied current, affect the mode of metal transfer. The most
common term applied to the electro-magnetic force is the pinch effect. As the
molten drop forms, it is uniformly squeezed from the electrode anode end by
the electro-magnetic force. The size of the droplet transferred depends upon
this force, the applied welding current, and the shielding gas (6).
Plasma Arc Cutting (PAC)
Plasma Arc Cutting (PAC) is a cutting technique that is used to cut pieces of
metal through the use of a plasma torch. An inert gas (in some units,
compressed air) is blown at high speed out of a nozzle; at the same time an
electrical arc is formed through that gas from the nozzle to the surface being
cut, turning some of that gas to plasma. The plasma is sufficiently hot to melt
the metal being cut and moves sufficiently fast to blow molten metal away
from the cut.
Plasma Arc Weld (PAW)
Plasma Arc Welding (PAW) is an arc welding process similar to GTAW, where
the electric arc is formed between an electrode and the work piece. The key
difference from GTAW is that in PAW, the electrode is positioned within the
body of the torch, which allows the plasma arc to be separated from the
shielding gas envelope. The plasma is then forced through a fine-bore copper
nozzle which constricts the arc, and the plasma exits the orifice at high
velocities and temperatures.
Plug Weld
A Plug Weld is a weld joint type where a tapered shaped plug is welded into a
tapered hole in the base metal.
Polarity
Polarity specifies the direction of current flow during welding. Three polarities
are common in welding, direct current electrode negative (DCEN, also known
as straight polarity or DC-), direct current electrode positive (DCEP, also
known as reversed polarity or DC+), and alternating current (AC).
Consumable and process dictate the selected polarity. For example, MIG
welding almost always uses DC+, and TIG welding typically uses DC- except
for aluminum and magnesium, where AC is common.

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Power
In the context of laser welding, power, in watts, is directly related to the
amount of heat input in the weld. Analogous to current in resistance or arc
welding.
Procedure Qualification Record (PQR)
A PQR is a document containing all of the actual welding parameters and
variables used to create a test weldment. This test weldment is then used to
validate a Welding Procedure Specification and establish parameter ranges.
Pulse
In the context of resistance welding, pulse refers to an instantaneous moment
when current is passed through the electrodes to a set value, typically equal to
the welding current.
In the context of LBW, pulse refers to a discontinuation and reigniting of the
beam during welding, reducing heat input.
In the context of GTAW, pulse is used as pulse frequency to signify how many
pulsations in peak current (a higher current value than the base current) occur
each second.
In the context of GMAW, pulse refers to a mode of metal transfer (also known
as transfer mode), typically referred to as pulsed-spray. Pulse is also used to
identify specific waveforms used in the pulsed-spray transfer mode.
Qualifier
In the context of an Operator Qualification Record (OQR), the Qualifier is an
individual who provides, guides and supervises the Operator during OQR
testing. They must be trained to perform visual inspections of welds by an
Inspector for the relevant welding processes to be tested.
Reinforcement (R)
Reinforcement is the measured thickness of convexity on the face of a weld
bead perpendicular to the hypotenuse of the largest right triangle that can fit
within a cross-section of the weld bead. It is excess deposited weld metal that
can result in poor weld toe angles, unnecessary cost of materials, dimensional
obstructions and decreased fatigue life in some cases.

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Resistance Projection Welding (PW)

A resistance welding process in between two or more surfaces of metal at
predetermined, manufactured projections which concentrate the current
passing through the interface. This allows for greater thickness mismatches
and resistance welding of thicker sections.
Resistance Spot Welding (RSW)
A resistance welding process between two or more surfaces of metal. Limited
to thin sheets (up to 3 mm for one sheet typically), multiple stack ups of thin
sheets are common (maximum of 4 sheets).
Resistance Welding
A welding process in which current is supplied by an upper and lower pair of
copper electrodes which clamp the base metal together. Resistive heating
occurs in the area of highest resistance, typically at the interface of the base
metals. Resistive heating is also referred to as I2*R heating or Joule heating.
Total heat generation is derived from the power equation, P = I2*R, to create Q
= I2*R*t, where Q is total heat generation, I is current, R is resistance and t is
time.
Resistance Welding Manufacturing Alliance (RWMA)
A subdivision of the AWS, the RWMA is a network of industry professionals
and corporate leaders that fosters advances in resistance welding technologies,
while supporting the highest technical standards for the industry. The RWMA
educates the manufacturing community in the new technologies as well as in
existing resistance welding processes through welding standards and published
works.
Semiautomatic Weld Type
A welding operator is holding the welding torch in a fixed position while a
machine manipulates the joint.
Slot Weld
A weld made in an elongated hole in one member of a lap or t-joint joining that
member to that portion of the surface of the other member which is exposed
through the hole. The hole may be open at one end and may be partially or
completely filled with weld metal.

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Squeeze Time
In the context of resistance welding, it is the amount of time the electrodes will
begin to apply force before current has started to pass. This time allows the
force between the electrodes to meet the force set on the welding controller and
ensure the weld was made with proper electrode force.
Stickout (ESO)
In the context of GMAW, stickout, also referred to as Electrode Stickout
(ESO), is the linear distance from the end of exposed electrode to the end of the
nozzle on the weld torch. The nozzle is a copper component on the weld torch
which directs gas flow over the welded area.
Tap Switch
The Tap Switch can be found directly on the resistance welding power supply
and regulates the output voltages for the resistance welding transformer. It is
commonly thought of as the course mechanical heat adjustment for the
welding transformer. The higher the TAP setting, the more current can be
accessed during welding. Newer resistance welding machines may forgo the
TAP switch and control heat solely through the welding controller.
Theoretical Throat (tth)
The linear distance from the beginning of the root of the effective right triangle
sized within a fillet weld, or the backside surface of the members used in a
groove weld, perpendicular to the hypotenuse in a fillet weld or the topside
surface of the members in a groove weld that can be sized within a cross-
section.
T-Joint
A type of fillet weld in which the joint consists of base metal members located
at approximately right angles to each other in the form of a T shape.
Torch Angle (Travel Angle)
In the context of GTAW and GMAW it is the offset angle of the weld torch in
the same axis as the direction of travel. Typically less than 30°, both in the
push direction (weld troch at leading edge of molten weld pool) and pull/drag
direction (weld torch at the trailing edge of molten weld pool).

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Transfer Mode
In the context of GMAW, transfer mode (or mode of metal transfer) describes
the way in which molten metal is transferred from the electrode to the base
metal through the arc. The most common transfer modes are short circuit
(GMAW-SC), spray (GMAW-S), and pulsed-spray (GMAW-P). Globular
(GMAW-G) is also a mode of metal transfer but typically only used as a result
of incorrect welding parameters and variables.
Travel Speed
The speed at which the weld is being laid, typically in inches per minute (IPM)
or millimeters per minute or second.
Trim
In the context of GMAW-P, Trim is a replacement for the voltage variable
which directly controls the arc length during welding by adjusting inductance
as to only change the height at which the electrode begins to melt off. Voltage
is automatically regulated by the welding power supply. The arc width widens
with increasing arc length but not as a direct result of adjusting trim. The
variable which adjusts arc width is referred to as Pinch.
Tungsten
In the context of GTAW and PAW, it is a non-consumable electrode made of
alloyed tungsten which acts as the heat source to establish an arc during
welding.
Ultimate Tensile Strength (UTS)
UTS (or simply referred to as tensile strength) is the capacity of a structure or
material to withstand loads in tension. It occurs in the plastic region of a stress
versus strain curve and typically results in failure.
Validation Testing
Validation testing refers to the initial approval process that all welding
procedures must go through before they can be used for fabrication of CES
aftertreatment systems.
Verification Testing
Verification testing refers to the affirmation that the welding procedure in
question is currently meeting the requirements identified during the initial
welding validation and approval process.

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Voltage (V)
In the context of GMAW, voltage is a set variable in all transfer modes except
GMAW-P (where trim is substituted) which establishes arc stability and
indirectly controls weld bead width and penetration by changing the arc length
used for welding.
Waveform
In the context of GMAW-P or Synergic (changes in WFS proportionally adjust
V), waveform deals with the customization of the waveform output to fine tune
a welding process for a more specific situation. It adjusts the behavior of the
arc by optimizing both direct welding parameters (set on the machine by the
operator) and indirect parameters (such as inductance) to achieve a more ‘soft’
or ‘crisp’ bead.
Weld Bead
The term often used to describe the physical appearance or existence of a
deposited weld.
Weld Fusion
Weld fusion, often referred to as simply fusion, refers to the metallurgical
bonding that has taken place at the interface of weld metal and base metal (also
known as the fusion boundary).
Weld Leg (w)
The linear distance from the root of a weld to its weld toes. Measured either
from the root of a weld or the root of the joint, depending on throat
measurement selection (ta, te, tth, or td).
Weld Penetration
The depth of which the weld metal has penetrated into the base metal. Not to
be confused with weld fusion.
In the context of brazing, penetration refers to how much braze metal flowed
into the joint to be brazed.
Weld Root (Rw)
The deepest point of penetration in the fusion zone which is opposite the angle
of the hypotenuse where all weld legs converge.

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Weld Shrinkage
The volumetric shrinkage that has occurred in the fusion zone as a result of
weld solidification. Most prevalent in autogenously welded applications where
base metal has been relocated to the fusion zone.
Weld Size (aw)
Weld size is the term used to designate the minimum required size of a weld.
Taken literally, aw is the shortest of the weld legs (w).
Weld Tie-In
The location where the start of a weld is overlapped by the stop of a weld.
Weld Time
In the context of resistance welding, weld time designates the amount of time
(in cycles or milliseconds) that current is passing through the electrodes and
base metal, creating a weld.
Weld Toe
The transitional location where the edge of the weld bead converges with the
base metal. Typically quantified as Weld Toe Angle (α) in degrees or Weld Toe
Radius (r) in millimeters.
Welding Procedure Specification (WPS)
A WPS is a control document which contains the qualified ranges of all
relevant welding parameters and variables used for production and prototype
CES products. It is supported through the qualification of one or multiple
PQRs.
Weldment
The combination of joint design, base metal, HAZ and fusion zone. It is a term
used to evaluate the entire welded area and the affects that welding has created,
not just on the fusion zone but on the localized structure as a whole.

CES-S-MANF-13
Wire Feed Speed (WFS)

In the context of GMAW or any other wire fed arc welding process, WFS
refers to the rate at which wire is fed through the weld torch, typically in inches
per minute. Not to be confused with current, WFS is not current. But often
current, heat, amps and WFS are used interchangeably when discussing heat
input on a MIG weld. WFS is directly related to current but the value listed on
the welding power supply, if that power supply is set in WFS, does not equal
amperage. Tables can be used to obtain an approximation of current based on
WFS, some machines also support changing the input variable from WFS to
current on the user interface.
Work Angle
In the context of GTAW and GMAW it is the offset angle of the weld torch
perpendicular to the axis of the travel direction. Always less than 90°, ideally
between 40° and 50°.

CES-S-MANF-13
5 Customer Communication Document

5.1 A customer-facing version of this document is published in the CES Catalog of
Standards and Technical Publications:
5.2 CES-S-MANF-13-Outline, “Welding Inspection Standard for Customer
Communication.”
6 Welding Position
A symbolic representation of welding position, joint orientation for fillet and groove
welds. Common positions practiced are 1F, 2F, 3F (U/D), 4F, 5F, 1G, 2G, 3G (U/D),4G,
and 5G.
6.1 Weld Type
6.1.1 “F” and “G” Weld Type
The “F” and “G” to the right of the number signifies either a fillet or groove weld type,
respectively.
• F, a fillet weld type. See Figure 1.
Figure 1: Lap Joint (left) and T Joint (right)

CES-S-MANF-13
• G, a groove weld type. See Figure 2.

Figure 2: Square Butt Joint (left) and Single Bevel T Joint (right)
6.2 Direction and Orientation

6.2.1 U/D Travel
Stands for “Up” and “Down,” indicating the direction of travel. Only relevant for
vertical orientations.
6.2.2 1, 2, 3, 4, or 5 Orientation
The number in the nomenclature indicates joint orientation.
6.3 Position descriptions
Below are descriptions of each type and a relevant figure. See Figure 3, Figure 4,
Figure 5, Figure 6, and Figure 7. The arrow and position designation on the respective
figures indicate torch placement, if indication is needed. Weld throat angle measured
parallel from the ground.

CES-S-MANF-13
6.3.1 1F/1G
A fillet/groove weld in a flat orientation. See Figure 3.
• Applies to circumferential joints only if mechanically rotated. Receives an R
designation.
Figure 3: 1F Orientation, T Joint on plate (left) and mechanically rotated pipe (right)
6.3.2 2F/2G
A fillet/groove weld in a horizontal orientation. See Figure 4.
• Always applies to circumferential joints.
Figure 4: 2F Orientation, T Joint on plate (left) and pipe (right)

CES-S-MANF-13
6.3.3 3F/3G
A fillet/groove weld in a vertical orientation. See Figure 5.
• Applies to circumferential joints only if mechanically rotated and the torch is
placed along its vertical section. Receives an R designation.
• Becomes 2F if the torch is placed at the top section and 4F if the torch is placed
at the bottom section. See arrows on the mechanically rotated pipe in Figure 5
below.
Figure 5: 3F Orientation, T Joint on plate (left) and mechanically rotated pipe (right)

CES-S-MANF-13
6.3.4 4F/4G
A fillet/groove weld in an overhead orientation. See Figure 6.
• Always applies to circumferential joints.
Figure 6: 4F Orientation, T Joint on plate (left) and pipe (right)

CES-S-MANF-13
6.3.5 5F/5G
A fillet/groove weld in a vertical orientation that is fixed and circumferential. See
Figure 7.
• Encompasses the 2F, 3F, and 4F positions while traveling along the joint.
Figure 7: 5F Orientation, T Joint (left) and Lap Joint on pipe (right)

CES-S-MANF-13
7 Welding Procedures
Welding procedures shall produce welds that pass Class #1 visual and destructive
testing requirements as defined in this specification. To meet the welding
specification, welding procedures and parameters need to be developed by the
respective manufacturing facility and maintained. These welding procedures and
parameters need to be controlled and can be used for reference or training purposes.
7.1 Variable specification
Key welding variables shall be specified in the welding procedure.
7.2 Development and fit-up gap
Welding procedures shall be developed and validated in the worst case scenario as it
relates to fit-up gaps. Refer to Section 12.1.1 for information regarding maximum
fit-up allowable.

CES-S-MANF-13
7.3 Key Welding Variables

Below are essential variables which must be documented in the welding procedure
specification. Additional weldments (i.e. weldments not used for the validation of a
welding procedure) which meet the requirements of an existing welding procedure,
described as similar welding procedures in this section, do not require their own
welding procedures, they may be welded using the existing welding procedure.

CES-S-MANF-13
7.3.1 Arc Welding (GMAW, GTAW, and PAW)

• Base Metal Grade
• Base Metal Thickness
• Weld Type (fillet/groove)
• Weld Joint Type
• Wire Feed Speed (WFS)
• Current
• Voltage/Trim
• Metal Transfer Mode (Short Circuit, Pulse Spray, etc.)
• Wire Diameter
• Wire Electrode Grade
• Tungsten Grade
• Tungsten Diameter
• Waveform/Welder Mode
• Travel Speed
• Torch Angle
• Work Angle
• Direction of Travel
• Position
• CTWD
• Shielding Gas Composition
• Gas Flow Rate (in CFH)
• Polarity
• Pinch
• Weld size

CES-S-MANF-13
7.3.1.1 Similar Arc Welding Procedure Definition

Similar welding procedure specifications include the following:
• Identical:
• M-Number Classification, see Table 13
• Weld Type (fillet/groove)
• Weld Joint Type
• Metal Transfer Mode
• Wire Diameter
• F-Number Classification, see Table 15
• Tungsten Grade
• Tungsten Diameter
• Waveform/Welder Mode
• Position
• Polarity
• Range:
• +/- 15% in Base Metal Thickness
• +/- 5% in Wire Feed Speed (WFS)
• +/- 5% in Current
• +/- 5% in Voltage/Trim
• +/- 5% in Travel Speed
• +/- 10% in CTWD
• +25% or -10% in Gas Flow Rate (in CFH)
• +/- 15% in Weld Size, aw

CES-S-MANF-13
7.3.2 Resistance Welding (RSW, PW)

• Electrode RWMA Class
• Face Diameter
• Weld Size
• Base Metal Overlap Length
• Projection Type (annular, discontinuous, solid, embossed)
• Force
• Weld Time
• Current
• Squeeze Time
• Hold Time
• Number of Impulses

CES-S-MANF-13
7.3.2.1 Similar Resistance Welding Procedure Definition

• Identical:
• Electrode RWMA Class
• Face Diameter
• Projection Type (annular, discontinuous, solid, embossed)
• Number of Impulses
• Range:
• +/- 20% in Weld Size, Nugget Diameter, aw
• +/- 10% in Base Metal Overlap Length
• +/- 5% in Force
• +/- 5% in Weld Time
• +/- 5% in Squeeze Time
• +/- 5% in Hold Time

CES-S-MANF-13
7.3.3 Arc Stud Welding

• Power Supply (Make/Model)
• Stud Gun Model
• Weld Time
• Current
• Voltage
• Polarity
• Lift
• Post Weld Plunge
• Weld Cable Size/Length
• Number of Grounds (leads)
• Weld Height
• Weld Diameter
• Stud Diameter
• Gas Flow Rate
• Position
• Ferrule Description

CES-S-MANF-13
7.3.3.1 Similar Arc Stud Welding Procedure Definition

• Identical:
• Polarity
• Shielding Gas
• Position
• Range:
• +/- 5% in Weld Time
• +/- 5% in Voltage
• +/- 15% in Weld Height, h
• +/- 15% in Weld Diameter, d1
• +/- 15% in Stud Diameter
• +25% or -10% in Gas Flow Rate

CES-S-MANF-13
7.3.4 Brazing
• Gap Clearance
• Length of Overlap
• Preparation
• Atmosphere
• Temperature Range/Current
• Travel Speed
• Braze Size
• Braze Metal Composition/Grade
• Position
• Feed Rate
• Furnace Type (if applicable)
• Torch Tip Size
• Flame
• Heat Treatment for Furnace Brazing
• Flux Type
• Induction Coil Design (if applicable)
• Induction Time (if applicable)
• Gas Flow Rate for Induction Brazing
• Shielding Gas Composition for Induction Brazing

CES-S-MANF-13
7.3.4.1 Similar Brazing Procedure Definition

• Identical:
• Braze Metal Composition/Grade
• Position
• Furnace Braze (if used)
• Torch Braze (if used)
• Induction Braze (if used)
• Induction Coil Design
• Induction Time
• Induction Current
• Flux Type
• Range:
• +/- 10% in Length of Overlap
• +/- 15% in Braze Size, aw
• +/- 5% in Feed Rate

CES-S-MANF-13
7.3.5 Laser Beam Welding (LBW)

• Type of Laser Source (Nd:YAG, Gas, Fiber, etc.)
• Make/Model
• Beam Quality (K, M2, BPP)
• Position
• Working Distance
• Focal Spot Size
• Location/Orientation of Shielding Gas
• Gas Flow Rate
• Welding Sequence
• Nominal Power
• Continuous Wave or Pulsed
• Power Up/Down Slope
• Combined Lasers (if applicable)
• Travel Speed
• Weld Width
• Weld Depth

CES-S-MANF-13
7.3.5.1 Similar Laser Welding Procedure Definition

• Identical:
• Surface Condition
• Position
• Working Distance
• Focal Spot Size
• Welding Sequence
• Continuous Wave or Pulsed
• Combined Lasers (if applicable)
• Range:
• +/- 5% in Nominal Power
• +/- 5% in Power Up/Down Slope
• +25% or -10% in Gas Flow Rate (in CFH)
• +/- 15% in Weld Width, aw
• +/- 15% in Weld Depth, h

CES-S-MANF-13
8 Consumables
8.1 Shielding Gas and Filler Metal Requirements
Table 1 lists the acceptable base metal, welding process, filler metal, and shielding gas
combinations for Cummins Emission Solutions.
8.1.1 Welding Filler Metal
Welding filler material alloys used for a combination of base alloys shall conform to
Table 1 unless otherwise noted on the drawing. Either solid or metal cored wires are
acceptable. The suppliers of filler materials shall meet the requirements of AWS A5.9,
A5.22, and/or ISO 14343 and/or other equivalent AWS or ISO standard for their
specific welding process.

CES-S-MANF-13
Table 1: Shielding gas and filler metal requirements
Welding Allowable Filler Allowable

Base Metal Base Metal
Process Metal Shielding Gas
439 (UNS GMAW 409 (UNS S40920) 439Ti 95Ar - 5O2

S43035) GTAW 409Al (EC/ER439) 98Ar - 2O2
412 (UNS S41003) 307 (18-8Mn) 99Ar - 1O2
439 (UNS S43035) 308L (ER308L)
98Ar - 2CO2
CB30 (UNS J91803) 308LSi
CB6 (UNS J91804) (ER308LSi) 100Ar
1Cr17 (GB/T 1220) 309L (ER309L) 98Ar - 2H2
309LSi 90He - 7.5Ar -
(ER309LSi) 2.5CO2
309LCr
(EC309L)
316L (ER316L)
439 (UNS GMAW 316L (UNS S31603) 307 (18-8Mn)

S43035) GTAW 316Ti (UNS 308L (ER308L)
S31635) 308LSi
304 (UNS S30400) (ER308LSi)
304L (UNS S30403) 309L (ER309L)
CF3 (UNS J92500) 309LSi
CF3M (UNS (ER309LSi)
J92800) 309LCr
CF8 (UNS J92600) (EC309L)
ISO 3506-2 316L (ER316L)
A2-70
304L (UNS GMAW 316L (UNS S31603) 307 (18-8Mn)

S30403) GTAW 316Ti (UNS 308L (ER308L)
S31635) 308LSi
304 (UNS S30400) (ER308LSi)
304L (UNS S30403) 309L (ER309L)
CF3 (UNS J92500) 309LSi
CF3M (UNS (ER309LSi)
J92800) 309LCr
CF8 (UNS J92600) (EC309L)
ISO 3506-2 A2-70 316L (ER316L)

CES-S-MANF-13
Welding Allowable Filler Allowable

Base Metal Base Metal
Process Metal Shielding Gas
439 (UNS LBW 409 (UNS S40920) Autogenous 50He - 50Ar

S43035) 409Al 85He - 13.5Ar -
439 (UNS S43035) 1.5CO2
304 (UNS S30400) 100He
304L (UNSS30403) None (upon
316L (UNS S31603) approval)
316Ti (UNS
S31635)
304L (UNS LBW 409 (UNS S40920) Autogenous

S30403) 409Al
439 (UNS S43035)
304 (UNS S30400)
304L (UNSS30403)
316L (UNS S31603)
316Ti (UNS
S31635)
409 (UNS LBC None None 100N2

S40920)
409Al
439 (UNS
S43035)
304 (UNS
S30400)
304L (UNS
S30403)
Aluminum LBC None None 100O2

(Grade Not
Relevant)
End of table
• Deviations from the above table require pre-approval from the Materials
Engineering, Product Engineering, and/or Quality Engineering departments of
Cummins Emission Solutions.
• Ar = Argon, He = Helium, O2 = Oxygen, CO2 = Carbon Dioxide,
H2 = Hydrogen

CES-S-MANF-13
9 Inspection Standards
This section provides quality levels of imperfections in welded joints. It applies to
material thicknesses greater than or equal to 0.5 mm. This section also provides
inspection methods and how to perform them along with the necessary requirements to
be met.
9.1 Limits for Imperfections
This section contains quality standards for the following welding processes: gas metal
arc welds, gas tungsten arc welds, laser beam welds, arc stud welds, brazed joints,
resistance spot welds and projection welds. All welds that do not conform to these
standards must be evaluated for rework and processed according to Section 10.

CES-S-MANF-13
9.1.1 CES Weld Quality Levels

Limits are separated into three requirement levels, known as Weld Classes:
1. Class #1 – Safety Related Welds or High Stress
• Includes high stress areas (acquired through FEA and experience) and/or
welds that are directly related to safety.
NOTE: Examples include marmon-to-inlet/outlet tube welds,
lifting brackets, and mounting joints. This list is not
all-encompassing.
• Similar to ISO 5817:2014 Class B125 weld quality. This standard takes
precedence over ISO 5817.
• Symbol on drawing:
2. Class #2 – Sealing Welds or Mid Stress

• Includes mid stress areas (acquired through FEA and experience) and/or
welds that are required to seal.
NOTE: Examples include internal baffle welds and sealing
NOx wheel welds. This list is not all-encompassing.
• Similar to ISO 5817:2014 Class B90 weld quality. This standard takes

3. Class #3 – General Welds or Low Stress

• Includes low stress areas (acquired through FEA and experience) and
general welds that are not required to seal.
NOTE: Examples include non-sealing heat shield welds. This
list is not all-encompassing.
• Similar to ISO 5817:2014 Class C63 weld quality. This standard takes


CES-S-MANF-13
9.1.2 Visual Inspection in Imperfection Tables

All underlined inspection numbers found in Table 2, Table 3, Table 4, Table 5, and
Table 6 can be visually inspected without destruction of the weldment (if part
geometry permits accessibility). The rest require some form of destructive testing (i.e.
cross sectioning, peel testing).
9.1.3 Frequency of Visual Inspection
Visual inspection is to be performed by the welding operator on 100% of the welds.
More importantly, visual inspection must be performed by a qualified inspector as
dictated by the control plan on products produced during a given shift apart from the
first piece inspection. Inspection is to be performed according to Section 9.2.1.
9.1.4 Lack of Fusion
Similarly noted in AWS D1.1, fusion should be present to the root of the joint (RJ), but
is not required beyond. Penetration is not a measured variable in this standard
document. Refer to the definitions for Weld Fusion and Weld Penetration found in
Section 4 for more information on the differences between fusion and penetration.
9.1.5 Welding Symbol Weld Class Callout
All welding symbols on the CES print should have a weld class called out in the tail of
the symbol. If no weld class is listed, a default of Class #2 is to be assigned except for
non-load bearing or non-sealing weldments, which shall be considered Class #3.
9.1.6 Heat Input in Arc Welding Processes
All arc welds must remain below a heat input value of 1.5 kJ/mm. Refer to
Section 10.1.1 for the heat input equation. The values to be used for the heat input
equation can be found with the documented welding procedure information.
9.1.7 Spatter on Marmons Per CES-S-MANF-2 and Sealing Surfaces
Marmon adapters per CES-S-MANF-2, formed marmons and body flares per
CES-S-MANF-18 and CES-S-MANF-9, and all sealing surfaces shall be free of weld
spatter. Spatter is not permitted. This section overrides Inspection Number 2.9 where
applicable.

CES-S-MANF-13
Welding Requirements for Aftertreatment and Exhaust Parts

Name:
Specification: Manufacturing
Table 2: GMAW/GTAW/LBW limits for imperfections
Limits for Imperfections Strength Levels

Inspection
Imperfection Description Class #3 Class #2 Class #1 Remarks
Number
2.1 Surface D ≤ 0.15*a (or Not Permitted For fillet welds, a is effective
Porosity D ≤ 0.3*a (or t) throat thickness. For groove
Underlined t) welds, t is thinnest material
indicates thickness. For Classes #3
that the and #2, maximum surface
Inspection pore diameter (D) is 1.5 mm.
Number can For Classes #3 and #2, maxi-
be visually mum number of porosity
inspected imperfections allowed is five
per 25.4 mm of weld length.
CUMMINS CONFIDENTIAL: This information is confidential and classified CONFIDENTIAL per CORP-00-24-00-00, and shall not be disclosed to others in hard copy or electronic form, reproduced by any means, or used for any purpose without
the written consent of Cummins Inc.

CES-S-MANF-13

Name:

Inspection
Number
2.2 Lack of Fillet Welds: Fillet Welds: Fillet Welds: For fillet welds, a is effective
Fusion h ≤ 0.2*a h ≤ 0.15*a h ≤ 0.1*a throat thickness. For groove
(Fusion Groove Groove Groove welds, t is material thickness.
Boundary or Welds: Welds: Welds: See Overlap, Inspection
Root). h ≤ 0.2*t h ≤ 0.15*t h ≤ 0.1*t Number 2.7, for lack of fusion
Linear Length Linear Length Linear Length at the weld toe.
(L): (L): (L):
For L < 100 For L < 100 For L < 100 If lack of fusion is found, at
mm mm mm least one more cross section
LOF ≤ 0.2*L LOF ≤ 0.15*L LOF ≤ 0.1*L must be taken 1t away from
For L ≥ 100 For L ≥ 100 For L ≥ 100 first cross section.
mm mm mm
LOF ≤ 25 mm LOF ≤ 20 mm LOF ≤ 15 mm
(total) (total) (total)
2.3 Undercut h ≤ 0.15*t h ≤ 0.10*t Not Permitted Use calipers or some other
LBW: LBW: for GMAW/ approved, applicable gauge
h ≤ 0.3*t h ≤ 0.2*t GTAW. to measure the depth of
undercut. For GMAW/GTAW
LBW: (not LBW), when permitted,
h ≤ 0.1*t length of undercut shall not
exceed 3 mm.

CES-S-MANF-13

Name:

Inspection
Number
Reinforce- Groove Groove Groove Use of an approved,

ment Welds: Welds: Welds: applicable measurement tool
2.4 h ≤ 2.5 mm h ≤ 2 mm h ≤ 1.5 mm is permitted for NDT. Cross
Fillet Welds: Fillet Welds: Fillet Welds: sectioning may be used for
h ≤ 3 mm h ≤ 2.5 mm h ≤ 2 mm Destructive Testing.
Positive reinforcement is
convexity. Negative
reinforcement is concavity.
Excessive Groove Groove Groove Use of an approved,

2.5 Penetration Welds: Welds: Welds: applicable measurement tool
h ≤ 1mm + h ≤ 1 mm + h ≤ 1mm + is permitted for NDT. Cross
(Melt 0.4 * b 0.2 * b 0.05 * b sectioning may be used for
Through) Fillet Welds: Fillet Welds: Fillet Welds: Destructive Testing.
h ≤ 1mm + h ≤ 1mm + h ≤ 1mm +
0.6 * b (max 0.4 * b (max 0.2 * b (max
of 4 mm) of 3 mm) of 2 mm)

CES-S-MANF-13

Name:

Inspection
Number
2.6 Incorrect α ≥ 100° Groove Groove Visually, the presence of

Weld Toe Welds: Welds: sharp weld toe angles can be
Angle α ≥ 125° α ≥ 150° noted. Measurements require
Fillet Welds: Fillet Welds: cross sectioning.
α ≥ 105° α ≥ 110°
2.7 Overlap h ≤ 0.15 * b h ≤ 0.1*b h ≤ 0.05*b Applicable to fillet and groove

welds; b represents the weld
Linear Linear Linear bead width. Overlap is essen-
Length (L): Length (L): Length (L): tially lack of fusion at the weld
For For For toe.
L < 100 mm L < 100 mm L < 100 mm
LOF ≤ 0.2 * L LOF ≤ 0.15 * LOF ≤ 0.1 * L If overlap is found, at least
For L For one more cross section must
L ≥ 100 mm For L ≥ 100 mm be taken 1b away from first
LOF ≤ 25 mm L ≥ 100 mm LOF ≤ 15 mm cross section.
(total) LOF ≤ 20 mm (total)
(total)

CES-S-MANF-13

Name:

Inspection
Number
2.8 Cracks Not Permitted Not Permitted Not Permitted Any base metal crack within
2 mm of the weld is not
permitted.
Rework may be used.
2.9 Spatter d ≤ 1.5mm, in d ≤ 1 mm, in d ≤ 0.75 mm, d is the diameter of the

the square the square in the square spatter imperfection. Only
area of 25.4 area of 25.4 area of 25.4 applicable within 60 mm of
mm x 25.4 mm x 25.4 mm x 25.4 the weld toes (to dashed line)
mm with five mm with five mm with five unless otherwise specified.
maximum maximum maximum
imperfections imperfections imperfections
allowed. allowed. allowed.

CES-S-MANF-13

Name:

Inspection
Number
2.10 Excessive T Joint: h ≤ T Joint: h ≤ T Joint: h ≤ Only in cases where an a

Asymmetry 2mm + 0.2*a 2mm + 0.15*a 1.5mm + symmetric fillet weld has not
of Fillet 0.15*a been specified.
Weld Lap Joint: h ≤ Lap Joint: h ≤ a = theoretical throat
2mm + 2*a 2mm + 1.5*a Lap Joint: h ≤ h = longer leg - shorter leg
1.5mm +
1.5*a
2.11 Root h ≤ 0.2 mm + h ≤ 0.1 * t Not Permitted Use calipers or some other
Concavity 0.1 * t approved, applicable gauge
(only for to measure the depth of root
GMAW/ concavity. Not applicable for
GTAW) welds over mat material. For
LBW, refer to Inspection
Number 2.17.
2.12 Discolor- Permitted Permitted Permitted Discoloration in the HAZ of

ation in HAZ the weld is permitted. In
excessive amounts (or by
customer request) it should
be wiped away to the best of
ability.

CES-S-MANF-13

Name:

Inspection
Number
2.13 Multiple ∑ h ≤ 0.4 * t ∑ h ≤ 0.3 * t ∑ h ≤ 0.2 * t ∑ h = h1 + h2 + h3 + h4 + …

Imperfec- + hn
tions in Any
Cross t is the thickness of the
Section thinnest material in the joint.
2.14 No Figure Missing Not Permitted Not Permitted Not Permitted

Weld

CES-S-MANF-13

Name:

Inspection
Number
2.15 Weld Not Permitted Not Permitted Not Permitted Weld missed edge of joint to
Missed Joint be fused. For instances where
the weld has missed the joint
such that a pinhole no larger
than 0.75mm in diameter
exists at the weld toe, refer to
Inspection Number 2.1 for
conformance.
2.16 Burn Hole Size Hole Size Not Permitted Hole or edge burnt away
Through ≤ 10mm2, ≤ 6mm2, during welding. Burn through
linear linear in either base metal or weld
spacing spacing metal. Leak rate failure takes
between between precedence over hole size
holes ≥ 10mm holes ≥ 10mm limits.
2.17 Shrinkage h ≤ 0.2 * t h ≤ 0.15 * t h ≤ 0.1 * t t = thinnest material. To be

Groove used for LBW when
(only for assessing the weld root.
LBW) Shrinkage occurs during
solidification.
End of table

CES-S-MANF-13

Name:
Table 3: Arc Stud Welding Limits for Imperfections
NOTE: Not applicable for other Stud Welding Processes, such as Capacitive Discharge (CD).

Stud
Inspection
Imperfection Description Diameter, d Class #3 Class #2 Class #1 Remarks
Number
(mm)
3.1 Minimum 6.4 ≤ d ≤ h ≥ 5 mm h ≥ 5 mm h ≥ 5 mm Refer to AWS

Fillet Weld 11.1 D1.6, Clause
Size h ≥ 6 mm h ≥ 6 mm h ≥ 6 mm 7, Table 7.2
d = 12.7 for increased
h ≥ 8 mm h ≥ 8 mm h ≥ 8 mm stud
15.9 ≤ d ≤ diameter
22.2 guidelines.
3.2 Weld is not 6.4 ≤ d ≤ Not Permitted Not Permitted Not Permitted
Closed 11.1
d = 12.7
15.9 ≤ d ≤
22.2

CES-S-MANF-13

Name:

Stud
Inspection
Imperfection Description Diameter, d Class #3 Class #2 Class #1 Remarks
Number
(mm)
Undercut h ≤ 0.15 * d h ≤ 0.10 * d Not

3.3 6.4 ≤ d ≤ Length of the Length of the Permitted
11.1 undercut shall undercut shall
not exceed not exceed
d = 12.7 30% along 15% along
the weld the weld
15.9 ≤ d ≤ length. length.
22.2
End of table

CES-S-MANF-13

Name:
Table 4: Resistance Spot Welding Limits for Imperfections

Inspection
Number
4.1 Full Button Permitted Permitted Permitted Obtained through a peel test.
Pull Complete weld nugget was
pulled intact with base metal.
Correct welding parameters.
4.2 Partial 60% Button 75% Button 90% Button Obtained through a peel test.
Thickness Pull Pull Pull Partial weld nugget was pulled
Fracture with intact with some thickness
Button Pull fracture.
4.3 Partial 75% Button 90% Button Not Permitted Obtained through a peel test.
Interfacial Pull Pull Partial weld nugget was pulled
Fracture with with section of interfacial
Button Pull fracture.
4.4 Full Interfacial Not Permitted Not Permitted Not Permitted Obtained through a peel test.
Fracture Complete interfacial fracture,
no nugget pulled at all.

CES-S-MANF-13

Name:

Inspection
Number
4.5 No Fusion Not Permitted Not Permitted Not Permitted Obtained through a peel test.
Complete lack of fusion.
4.6 Edge Weld Permitted Permitted Not Spot weld is not fully
Permitted, contained within all
unless by original edges of the sheet.
necessary

design.
4.7 Indentation In ≤ 0.55 * t In ≤ 0.45 * t In ≤ 0.35 * t Care must be taken if

distortion is present.
Distortion must not add value
to indentation measurement.
4.8 Penetration P ≥ 0.1 * t P ≥ 0.2 * t P ≥ 0.3 * t Full penetration is undesirable

and can result in failure.

CES-S-MANF-13

Name:

Inspection
Number
1. Sum of all areas ≤ 0.15 * Nugget Area Applicable to all weld classes.
4.9 2. Sum of all lengths ≤ 0.25 * Nugget Diameter Criteria 1, 2, and 3 apply to
Internal 3. Pores or cavities outside of the 0.7 * Nugget porosity. Criteria 2 and 3 apply
Porosity and Diameter, measured from center in all to cracks.
Cracks directions.
4.10 External Not Permitted Not Permitted Not Permitted External defects
Porosity, cannot be reworked.
Cracks and Indicative of process errors.
Holes

4.11 Off Center Approx. Approx. Approx. Approximately means within
Nugget 70-30 60-40 50-50 10% of the defined ratios.
Balance Min Balance Min Balance Ratios refer to percentage of
nugget within the upper and
lower sheets. Occurs when
heat balance is off due to
differences in resistivity of
materials (dissimilar sheet
thickness, resistance, or
conductivity for example).
End of table

CES-S-MANF-13

Name:
Table 5: Brazed Joints Limits for Imperfections

Inspection
Number
Located:
Crack Permitted Not Permitted Not Permitted A - Braze Metal
5.1 where com- B - Interface or Diffusion Zone
ponent func- C - HAZ
tion is not D - Unaffected Parent
adversely Material
affected.
5.2 Gas Pore/ Maximum of Maximum of Maximum of Maximum pore diameter/area

Cavity/Pocket 40% of 30% of 20% of may be defined for specific
brazed area. brazed area. brazed area. applications if needed.
5.3 Surface Pore Permitted Maximum of Not Permitted

where 20% of
component brazed area
function is not only if
adversely component
affected. function is not
adversely
affected.

CES-S-MANF-13

Name:

Inspection
Number
5.4 Surface Permitted Permitted Not Permitted

Bubble
5.5 Solid Maximum of Maximum of Maximum of Maximum pore diameter/area

Inclusion 40% of 30% of 20% of may be defined for specific
brazed area. brazed area. brazed area. applications if needed.
5.6 Bonding Maximum of Maximum of Maximum of Permitted where component

Imperfection 25% of 15% of 10% of function is not adversely
brazed area. brazed area. brazed area. affected and the defect does
not break the surface.
Relevant for all classes.
5.7 Filling Maximum of Maximum of Maximum of
Imperfection 40% of 30% of 20% of
brazed area. brazed area. brazed area.

CES-S-MANF-13

Name:

Inspection
Number
5.8 Incomplete Maximum of Maximum of Not Permitted Braze metal has failed to flow
Penetration 15% of 10% of through the required length of
brazed area. brazed area. the joint.
5.9 Excess Braze Permitted Permitted Not Permitted Use of an approved,

Metal where where applicable measurement tool
component component is permitted for NDT. Cross
function is not function is not sectioning may be used for
adversely adversely Destructive Testing.
affected and affected and
the defect the defect
does not does not
geometrically geometrically
interfere. interfere.
5.10 Burn Not Permitted Not Permitted Not Permitted

Through/
Localized
Melting

CES-S-MANF-13

Name:

Inspection
Number
5.11 Recessed Maximum Maximum Not Permitted Use calipers or some other
Braze Metal depth equal depth equal approved, applicable gauge to
to two times to one times measure the depth of
the brazed the brazed recession.
gap width. gap width.
5.12 Erosion t must not be t must not be t must not be Use calipers or some other
(Undercut) reduced by reduced by reduced by approved, applicable gauge to
more than more than more than measure the depth of erosion.
20%. 15%. 10%.

CES-S-MANF-13

Name:

Inspection
Number
A - Permitted A - Permitted A - Not A - Irregular Fillet Leg

where where Permitted.
5.13 Irregular/ component component B - Insufficient Fillet Size
Undersized function is not function is not B - Maximum
Fillet adversely adversely of 5% of fillet
affected. affected. size.
B - Maximum B - Maximum
of 15% of fillet of 10% of fillet
size. size.
5.14 Flux Seepage Permitted Permitted Not Permitted Flux residue has emerged at
where where surface pores.
component component
function is not function is not
adversely adversely
affected. affected.
Permitted Permitted Permitted

5.15 where where
Spatter component component
function is not function is not
adversely adversely
affected. affected.
End of table

CES-S-MANF-13

Name:
Table 6: Projection Welding Limits for Imperfections

Inspection
Number
6.1 Lack of Not Permitted Not Permitted Not Permitted 360° bonding of the entire
Bonding projection is required on
(shown as a annular projection welds.
white line at
the fusion
boundary)
6.2 Insufficient Collapse ≥ Collapse ≥ Collapse ≥ The projection failed to

Projection 60% of the 70% of the 80% of the completely collapse, either
Collapse projection projection projection from insufficient force, current
height. height. height. or time. Resulting in space
between the welded parts.
6.3 Extensive Permitted Permitted Not Permitted Excessive current, force or

Bulge/ where where time resulted in the expulsion
Expulsion component component of material out of the
function is not function is not weld area.
adversely adversely
affected. affected.
End of table

CES-S-MANF-13
9.2 Inspection methods for imperfections

9.2.1 Nondestructive Testing, NDT
Welds that are subject to nondestructive inspection are acceptable if they meet the
requirements of the tables found in Section 9.1. The inspection methods used to
identify imperfections are listed below:
• Acceptable visual inspection procedure: Perform the inspection with a
minimum of 200 to 1100 lux of illumination and no magnification.
• Testing may begin immediately after the completed welds or brazes have
cooled to ambient temperature.
• Deviations from the above mentioned inspection procedures shall be used only
after approval from Material Science and Technology, Product Engineering,
and/or Quality Engineering Department of Cummins Emission Solutions.
• Inspections must be performed by an inspector qualified in the method of
inspection (e.g. visual inspection, ultrasonic, dye penetrant, etc.). The inspector
must put his/her name to the inspection.
9.2.2 Destructive Testing
Welds that are subject to destructive inspection are acceptable if they meet the
requirements of the tables found in Section 9.1 along with the specific requirements of
the following appropriate tests found in Section 9.3. The inspection processes used to
identify strength of welds are listed below:
9.2.2.1 A destructive test is needed for the following processes:
• Weld validation:
• Qualification of a new weldment design (i.e. the initial processing of a
weld and a welding procedure specification).
• Weld verification:
• Any change in the welding process/parameters including welding
location.
• Performing a Recurring Weldment Verification (RWV).
• The implementation of a previously validated welding procedure
specification on another similar weldment in which the welding
procedure is applicable according to Section 7.3.

CES-S-MANF-13
9.2.2.2 The aforementioned processes requiring a destructive inspection test should contain
further information about the testing methods, either through this specification or the
use of an additional standard, such as a Control Plan.
9.2.2.3 The destructive test report shall be securely recorded for a minimum of three years.
9.2.2.4 Inspections must be performed by an inspector qualified in the method of inspection
(e.g. metallography, tension testing, etc.). The inspector must put his/her name to the
inspection.
9.2.2.5 The destructive testing method shall be selected based on its applicability with the
weldment being tested. The destructive testing method may be specified by an
additional standard/specification, or selected by the supplier/manufacturer.
9.2.2.6 The supplier/manufacturer is free to select whichever testing method is most
applicable to both the weldment being tested and their facilities capabilities, upon
approval from Cummins Emission Solutions or otherwise specified.
9.2.2.7 Test specimens are not to be heated or distorted by mechanical means prior to testing.
Test specimens can be coupons or taken directly from the product.
9.2.2.8 The coupons do not need to be geometrical or dimensional matches to the weldment
being tested (i.e., taken directly from the product), they only need to properly
represent the weldment by matching material thickness, surface condition, welding
process and parameters, and material type and grade.
NOTE: However, in cases where the actual weldment being tested can
come directly from the product, the test specimen dimensions
only need to approximately match the specified requirement.
This is to be addressed with Cummins Emission Solutions on a
case-by-case basis.
9.2.3 Inspector Qualification
This qualification must be obtained through Cummins Emission Solutions or a
certified qualifier (i.e. American Welding Society, American Society for Quality,
Automotive Industry Action Group, degreed educational discipline) or internally
through the Manufacturer if training is given by a qualified inspector. Continue to
Section 9.2.3.1 for the method of qualification.
NOTE: Not all certified qualifiers have been listed, these only provide
examples. Certified qualifiers include reputable organizations
which provide a relevant curriculum for weld inspection. This
documentation must be accessible at the manufacturer/supplier
facilities when requested.

CES-S-MANF-13
9.2.3.1 Method of Qualification

Active qualifications obtained through certified qualifiers are to be accepted without
the requirement of in-house training, training is optional. CES qualifiers must be
trained engineers knowledgeable on the method of inspection or individuals who have
been trained by a certified qualifier on the method of inspection. Inspection methods
are mutually exclusive and require relevant training for each. The training must be
kept on record and contain the following relevant information (format is not standard):
• Trainer Identification.
• Trainee Identification.
• Method of Inspection Trained.
• Training Date.
• Expiration Date (default of three years from Training Date).
9.2.3.2 Training Material
Speak with CES Materials Science & Technology, specifically this document's owner,
for information regarding training material for destructive or nondestructive
inspection.

CES-S-MANF-13
9.3 Destructive Testing Methods for Strength and Toughness of

Welds
9.3.1 Tension Testing - Butt Joints
Tension testing of butt joints must comply with the following regulations:
9.3.1.1 Sample Details. A minimum of three specimens must be tested. The specimens are
not to come from the same weldment (for example, a long butt seam weld capable of
producing three specimens from the same weld). The tension specimens for welded
butt joints shall be longitudinal specimens and shall comply with Figure 8. Refer to
Table 16, Test Assembly No. B1.2 for further specimen dimension details.
9.3.1.2 Requirement. Tensile strength of weldment shall be at least 90% of ultimate tensile
strength (UTS) of base metal. See Table 14 of Appendix A for minimum base metal
ultimate tensile strength.
9.3.1.3 Calculation. The ultimate tensile strength calculation for rectangular tension tests is
as follows (2) (contact document owner with questions):
Su= Peak Load = P
Effective Area Lw * tth
Where:
P = Peak Load (lbs)
Lw = Effective Length of Weld (inch)
tth = Theoretical Throat of Weld (inch)
NOTE: In a butt joint, tth is the distance measured from the root of
the weld to its face. In complete joint penetrated (CJP) butt
joints, this is equal to the thickness of the base material.
Su = Ultimate Tensile Strength of Weld Metal (KSI)

CES-S-MANF-13
Figure 8: Transverse Rectangular Tension Test Specimen (1)

CES-S-MANF-13
9.3.2 Bend Testing - Butt Joints

Bend testing of butt joints must comply with the following regulations:
not to come from the same weldment (for example a long butt seam weld capable of
producing three specimens from the same weld). The bend specimens for welded butt
joints shall comply with Figure 9.
9.3.2.2 Testing Details. The specimen shall be bent 180° with the bend axis being coincident
with the weld axis. If the joint is a CJP then the root of the weld must be visible along
the face of the bend radius (Transverse Root Bend). If the joint is a PJP then the face of
the weld must be visible along the bend radius (Transverse Face Bend). The apparatus
used for bending is at the discretion of the Inspector but care must be taken to supply
one continuous bending motion to the specimen and the specimen is not bent
off-center.
9.3.2.3 Requirement. Upon bending, a visual examination must be performed analyzing the
root or face of the weld, located along face of the bend radius. A weld shall be
acceptable if:
• No visual cracks are detected in the fusion zone or along the weld toes.
• No inclusions (such as silica or slag) or porosity are visible in the fusion zone.
• Cracks in the base metal that are not within 2 mm of the weld toes shall be
ignored.
Figure 9: Square Butt Joint (left) and after a Transverse Root Bend test (right) (3)

CES-S-MANF-13
9.3.3 Ball Punch Deformation - Laser Welded Butt Joints

Only applicable for materials ranging from 0.2 mm to 2.0 mm thick. Deep draw testing
of laser welded butt joints using a ball punch must comply with the following
regulations:
not to come from the same weldment (for example a long butt seam weld capable of
producing three specimens from the same weld). The test specimens for laser welded
butt joints shall comply with Figure 13.
9.3.3.2 Testing Details. The specimen shall be placed in a mounting fixture capable of
stabilizing the 45 mm by 45 mm specimen while the ball punch deformation is
applied. The ball punch shall be spherical and have a diameter of 21 ± 1 mm and be
applied at a rate between 0.08 and 0.42 mm/s, with a minimum force of 9800 N (7).
The ball punch shall be pushed into the test specimen until cracking occurs. The
apparatus used for testing is at the discretion of the Inspector but must be capable of
supplying the requirements dictated above.
9.3.3.3 Requirement. Upon cracking, a visual examination must be performed analyzing the
direction and location of the crack. A weld shall be acceptable if:
• No visual cracks are detected in line with the fusion zone or along the weld
toes. See weld fail examples in Figure 10 and Figure 11.
Figure 10: Weld fail example - 1

CES-S-MANF-13
Figure 11: Weld fail example - 2
• Cracks in the base metal that are not in line with the fusion zone, but may
intersect with the weld, are acceptable. See the weld pass example in
Figure 12.
Figure 12: Weld pass example

CES-S-MANF-13
Figure 13: Ball Punch Deformation Test Sample, Laser Welded Butt Joint

CES-S-MANF-13
9.3.4 Bend Testing - T Joints

Bend testing of T joint must comply with the following regulations:
9.3.4.1 Sample Details. A minimum of three specimens must be tested. The bend specimens
for welded T joints shall comply with Figure 14.
9.3.4.2 Testing Details. The specimen shall be bent over the weld to at least 20°, using the
surface of the vertical member on the side of the weld as 90°, in the manner depicted
in Figure 14. The apparatus used for bending is at the discretion of the Inspector but
care must be taken to supply one continuous bending motion to the specimen and the
specimen is not bent off-center.
root and face of the weld. A weld shall be acceptable if:
ignored.
Figure 14: Bend Test of a T Joint (3)

CES-S-MANF-13
9.3.5 Peel Testing - Lap Joints and Slot Welds

Peel testing of lap joint must comply with the following regulations:
9.3.5.1 Sample Details. A minimum of three specimens must be tested. The peel specimens
for welded lap joints shall comply with Figure 15. Refer to Table 16, Test Assembly
No. B1.3 for further specimen dimension details.
9.3.5.2 Testing Details. The specimen shall be peeled over the weld to at least 110°, using the
surface of the base metal on the root side of the weld and under the top sheet as 0°, in
the manner depicted in Figure 15. The apparatus used for peeling is at the discretion of
the Inspector but care must be taken to supply one continuous peeling motion to the
specimen and the specimen is not peeled off-center.
9.3.5.3 Requirement. Upon peeling, a visual examination must be performed analyzing the
root and face of the weld. A weld shall be acceptable if:
ignored.
Figure 15: Peel Test of a Lap Joint (3)

CES-S-MANF-13
9.3.5.4 Slot Welds. Slot welds shall comply with the same standards as lap joints. The only
difference is instead of the top sheet being welded along its edge, the top sheet will be
welded along its slot. That weld will then be peeled to the same standards as a lap
joint, but starting in the configuration shown in Figure 16. Refer to Table 16, Test
Assembly No. B1.5 for further specimen dimension details.
Figure 16: Peel Test of a Slot Weld (3)

CES-S-MANF-13
9.3.6 Tension (Shear) Testing - Spot Welds and Plug Welds

Tension testing of spot welds and plug welds must comply with the following
regulations:
9.3.6.1 Sample Details. A minimum of 10 specimens must be tested. The tension specimens
for spot welded and plug welded joints shall be longitudinal samples and shall comply
with Figure 17.
9.3.6.2 Tensile Grip. When tested, neither tensile grip on each side of the specimen shall
contact the specimen nearer than 30 mm (1.18 inches) from the weld nugget to be
tested.
9.3.6.3 Requirement - Weld Validation. Peel testing and tensile testing are required during
the validation of welding parameters for spot welds. Refer to Section 9.3.7 for peel
testing details.
9.3.6.4 Requirement. The minimum shear strength requirement to be met shall be at least
90% of the ultimate tensile strength (UTS) of the base metal. See Table 14 of
Appendix A for minimum base metal ultimate tensile strength.
9.3.6.5 Calculation. The shear strength calculation for the rectangular tension tests is as
follows (contact document owner with questions):
τs= Peak Load P

Effective Area = πr2
Where:
P = Peak Load (lbf)
r = Radius of Average Diameter of the Weld (inch)
NOTE: Average diameter is found by taking the summation of two
perpendicular length measurements of the face of the pulled
nugget and dividing by two.
τs = Shear Strength of Weld (KSI)
9.3.6.6 Requirement - Final Validation. Before implementing the newly validated welding
process into production, a final test must be performed. At least three spot welds (that
have already met the requirements of Section 9.3.6.3 and Section 9.3.6.4) must be
welded to the intended production product or coupons (matching in both shape and
form), and weld verification performed according to Section 9.3.14.6.

CES-S-MANF-13
Figure 17: Transverse Rectangular Shear Test Specimen for Spot Weld

CES-S-MANF-13
9.3.7 Peel Testing - Spot Welds

Peel testing of spot welds must comply with the following regulations:
for resistance spot welds shall comply with Figure 18 for manual peel tests and
Figure 19 for tension tester peel tests. Refer to Table 16, Test Assembly No. B1.11 for
manual peel tests and B1.12 for tension tester peel tests for further specimen
dimension details.
9.3.7.2 Testing Details. During weld parameter development, see Section 9.3.7.3, the
specimen shall be manually peeled in the method shown in Figure 18 until the
members have been separated. Once the welding parameters have been selected and
confirmed through manual peel testing, weld validation, see Section 9.3.7.4, must be
performed with those parameters. For weld validation, the specimen shall be peeled
using a tension tester in the method shown in Figure 19. The apparatus used for
peeling is at the discretion of the Inspector but care must be taken to supply one
continuous peeling motion to the specimen, the specimen is not peeled off-center, and
the strength data can be accurately recorded.
9.3.7.3 Requirement - Weld Parameter Development. Upon manual peeling (see
Figure 18), a visual examination must be performed analyzing the fracture surface of
the weld nugget. A weld shall be acceptable if it passes the visual requirements of
Table 4.

CES-S-MANF-13
Figure 18: Manual method of peel test for RSW (5)
9.3.7.4 Requirement - Weld Validation. Upon peeling (a controlled tension testing machine
must be used, refer to Figure 19), a visual examination must be performed analyzing
the average diameter (refer to the note under Section 9.3.6.5) and the peak peel
strength of the weld nugget. A weld shall be acceptable if it passes the visual
requirements of Table 4 and the size and strength requirements of Table 7.
NOTE: If the sheet thickness is not listed in Table 7, use these
equations for Minimum Weld Diameter and Peak Peel Stress:
• Diameter = 4*√thickness of thinner sheet
• Peak Peel Stress = Peak Load/Effective Area = P/π*r2. Refer to the equation
for Shear Strength (equal to Peak Peel Stress) found in Section 9.3.6.5.
9.3.7.5 Requirement - Final Validation. Before implementing the newly validated welding
process into production, a final test must be performed. At least three spot welds (that
have already met the requirements of Section 9.3.7.4) must be welded to the intended
production product (matching in both shape and form), and weld verification
performed according to Section 9.3.14.6.

CES-S-MANF-13
Figure 19: Tension tester method of peel test for RSW

CES-S-MANF-13
Table 7: Minimum Weld Diameter and Peak Peel Stress Requirements
Approximate
Minimum Average Minimum Average
Thickness (± 10%) Minimum Average
Peak Peel Stress Peak Peel Stress
of Thinner Sheet Weld Diameter
(KSI) (MPa)
(mm)
1.00 4.00 13.79 95.08
1.20 4.50 14.98 103.28
1.48 5.00 15.73 108.45
1.81 5.50 16.94 116.80
2.20 6.00 18.47 127.35
End of table
NOTE: Average refers to the average measured value for weld

diameter and peak peel stress during weld validation testing.
9.3.7.6 Tensile Grip. When tested, neither tensile grip on each side of the specimen shall
contact the specimen nearer than 30 mm (1.18 inches) from the weld nugget to be
tested.

CES-S-MANF-13
9.3.8 Torque Testing - Annular Couplers (RPW/LBW/GMAW)

Torque testing of couplers and sensor bosses which have been either projection welded
(with an annular projection), laser beam welded, or gas metal arc welded around their
perimeter must comply with the following regulations:
9.3.8.1 Sample Details. A minimum of nine specimens must be tested, eight shall be torque
tested, one shall be cross sectioned according to Section 9.3.14. The welded specimens
shall comply with Figure 20 and be tested by applying a torque using a calibrated
torque wrench with or without a calibrated torque multiplier. Refer to Table 16, Test
Assembly No. B1.8 for further specimen dimension details. Efforts must be made to
eliminate all loading factors besides torsional (i.e. peeling) in order to obtain accurate
torque results.
9.3.8.2 Testing Details. For couplers and sensor bosses welded along their annulous:
1. Couplers shall be welded (using identical welding parameters) to a flat sheet of
matching grade and thickness to the production intended process or taken
directly from the product.
2. The flat sheet must be mounted to a bed-plate of significant stiffness as to
minimize distortion of the flat sheet during torque testing. Vice grips or clamps
must be used as needed to minimize distortion of the flat sheet during torque
testing.
3. A bolt of matching size and thread pitch must be threaded into the coupler until
the bolt head reaches the top surface of the coupler. The bolt length may be
altered to fit this requirement. Washers and/or a sleeve may be used when
necessary. It is recommended that the bolt head be TIG welded to the coupler
on at least two opposite flat sides, in order to eliminate incorrect readings as a
result of stripping the threads of the coupling.
4. A matching socket must be used when torquing the bolt head.
5. Torque must be applied (in the tightening thread direction) until the specified
level is reached or the weld fails.
Refer to CTR 00078256 for further details. Contact CES MS&T if required.
9.3.8.3 Requirement - Final Validation. When developing/changing welding parameters, a
final test must be performed. Three couplers (that have already gone through
Section 9.3.8.2) must be welded to the intended production product (matching in both
shape and form), and must be torque tested to the final three steps (3, 4, and 5) of
Section 9.3.8.2.

CES-S-MANF-13
9.3.8.4 Requirement - the minimum torque requirement to be met shall be at least 50% of the
breakaway torque of the base member.
9.3.8.5 Calculation. The shear stress calculation to establish a minimum torque value is as
follows:
(π ( Do4 - Di4 )
τs 32
T=
De
2
Where:
T = Breakaway Torque of Base Member (Nm)
τs = Shear Strength of Base Member (MPa)
• τs = 0.5 * UTS of Base Member (MPa)
• Use Table 14 of Appendix A to locate the minimum base metal ultimate tensile
strength.
• To meet the 50% of the breakaway torque of the base member requirement, the
UTS value used in the calculation of τs, shall be ½ of the UTS of the base
member. For example: τs (439 SS) = 0.5 * (0.5)(15 MPa)
Do = Outer diameter of Weld Area (mm)
Di = Inside diameter of Weld Area (mm)
De = Effective diameter of Weld Area (equal to Do) (mm)

CES-S-MANF-13
Figure 20: Projection Welded Coupling Torque Test Arrangement
NOTE: For gas metal arc welded and laser welded couplers and sensor
bosses, the measurement of inside and outside diameter does
not change, only the relative location of the weld with respect to
the bottom of the coupler or sensor boss.

CES-S-MANF-13
9.3.9 Dye Penetrant Testing of Welds

Dye penetrant testing of welds is only applicable for Type II (visible dye) examination,
utilizing a water washable penetrant with a non-aqueous developer. Testing must
comply with the following regulations:
9.3.9.1 Sample Details. A minimum of three specimens must be tested. All surfaces to be
examined shall be clean, dry, and free of soils, oil, grease, paint and other coatings,
corrosion products, scale, smeared metal, welding flux, chemical residues, or any
other material that could prevent the penetrant from entering discontinuities, suppress
dye performance, or produce unacceptable background. Cleaning methods selected for
a particular component shall be consistent with the contaminants to be removed and
shall not be detrimental to the component or its intended function. (8)
9.3.9.2 Testing Details. For Type II Dye Penetrant Testing of Welds, the testing sequence is as
follows:
1. Penetrant Application - Unless otherwise specified, the entire welded area of
the component shall be covered with penetrant. Large components may be
examined in sections. Penetrant shall be applied by spraying, dipping,
brushing, or other method to provide coverage as required. The component,
penetrant, and ambient temperatures shall all be in the range from 40 to 125 °F
(4 to 52 °C) unless otherwise specified. (8)
2. Penetrant Dwell Time - The dwell time, unless otherwise specified, shall be a
minimum of 10 minutes. For temperatures between 40 and 50 °F
(4.4 and 10 °C), dwell time shall be a minimum of 20 minutes. It is
recommended to rotate or otherwise move components as necessary, during
dwell to prevent pooling of the penetrant. For dwell times greater than two
hours, the penetrant shall be reapplied as required. (8)
3. Penetrant Removal - Excess penetrant shall be removed with a clean, dry, lint-
free cloth or absorbent toweling. The remainder of the surface penetrant shall
then be removed with a water-dampened cloth or towel. The surface shall not
be flushed with water and the cloth or towel shall not be saturated with water.
The component shall be examined under appropriate illumination to ensure
adequate removal of the surface penetrant. The surface shall be dried by
blotting with a clean, dry towel or cloth, or by evaporation. (8)
4. Drying Parameters - Components shall be air dried. Drying time shall only be
that necessary to adequately dry the part. (8)

CES-S-MANF-13
5. Developer Application - Components, or areas requiring examination, shall be

dry before application of the developer. Non-aqueous developer shall be
applied by spraying or wiping. For Type II penetrants, the developer shall be
applied over the entire surface to form a uniform, white coating to provide
suitable color contrast for the penetrant indications. The uniformity and
thickness of the developer coating is important. If the developer coating
thickness is too heavy such that the metallic surface is completely masked, the
component shall be cleaned and reprocessed. Unless otherwise specified, the
minimum and maximum development times for non-aqueous developers are
10 minutes and 1 hour, respectively. (8)
9.3.9.3 Requirement. All indications shall be interpreted. Components with no indications or
only non-relevant indications shall be accepted. Components with relevant indications
shall be evaluated with respect to the applicable acceptance criteria found in the limits
for imperfections tables of Section 9.1. Components with excessive background
(developer) shall be cleaned and reprocessed.
• Indication Verification - If allowed by the specific procedure, indications may
be evaluated by wiping the indication with a solvent-dampened swab or brush,
allowing the area to dry, and redeveloping. Redevelopment time shall be at
least three minutes. If no indication reappears, the original indication is
considered false. This procedure may be performed twice for any given
original indication.
• Additional Indication Verification - Indications may also be evaluated by use
of higher magnification visual inspection. Penetrant tends to congregate at
geometric convergences, allowing sharp corners or small dents to appear as
false-positive indication sites.
• Post Cleaning - Components shall be cleaned after examination to remove
developers and other examination material residues if these are detrimental to
subsequent operations or the components' intended function.

CES-S-MANF-13
Figure 21: Indications found in GTAW using Type II Dye Penetrant Testing

CES-S-MANF-13
9.3.10 Torque Testing - Stud Welds

Torque testing of stud welds must comply with the following regulations:
9.3.10.1 Sample Details. A minimum of nine specimens must be tested. The stud welded
specimens shall comply with Figure 22 and be tested by applying a torque using a
calibrated torque wrench with or without a calibrated torque multiplier. Refer to
Table 16, Test Assembly No. B1.9 for further specimen dimension details. Efforts
must be made to eliminate all loading factors besides torsional (i.e. bending) in order
to obtain accurate torque results.
NOTE: If a stud cannot be torque tested using the method defined in
this section, nor can the stud be bend tested to Section 9.3.11,
Section 9.3.14 shall replace this testing method.
9.3.10.2 Testing Details. For Arc Stud Welds:
1. Studs shall be stud welded (using identical welding parameters) to a flat sheet
of matching grade and thickness to the production intended process or taken
directly from the product.
2. The flat sheet must be mounted to a bed-plate of significant stiffness as to
minimize distortion of the flat sheet during torque testing.
3. A nut of matching size and thread pitch must be threaded onto the stud until it
reaches the welded component. Washers and/or a sleeve may be used when
necessary.
4. A matching socket must be used when torquing the nut.
5. Torque must be applied (in the tightening thread direction) until the specified
level is reached or the weld fails.
9.3.10.3 Requirement - Final Validation. When developing/changing welding parameters, a
final test must be performed. Three studs (that have already gone through
Section 9.3.10.2) must be stud welded to the intended production product (matching in
both shape and form), and must be torque tested following Section 9.3.10.2, steps 3, 4
and 5.
9.3.10.4 Requirement. The minimum torque requirement to be met shall be at least 100% of
the breakaway torque of the base member.
9.3.10.5 Calculation. The shear stress calculation to establish a minimum torque value can be
found in Section 9.3.8.5.

CES-S-MANF-13
Figure 22: Arc Stud Welded Torque Test Arrangement

CES-S-MANF-13
9.3.11 Bend Testing - Stud Welds

Bend testing of stud welds (regardless of stud welding process, for example CD or Arc
Stud Welding) must comply with the following regulations:
9.3.11.1 Sample Details. A minimum of nine specimens must be tested. Refer to Table 16, Test
Assembly No. B1.9 for further specimen dimension details.
9.3.11.2 Testing Details. The specimen shall be bent to approximately 60° from vertical, in the
manner depicted in Figure 23. The apparatus used for bending is at the discretion of
the Inspector.
structural integrity of the weld. A weld shall be acceptable if:
• Cracks in the base metal (or stud) that are not within 2 mm of the weld toes
shall be ignored.
Figure 23: Stud Welded Bend Test Arrangement

CES-S-MANF-13
9.3.12 Bend Testing - Brazed Joints

Bend testing of brazed joints must comply with the following regulations:
9.3.12.1 Sample Details. A minimum of three specimens must be tested. The bend specimens
for brazed joints shall comply with Figure 24. The dimensions to be used for the
overlap area must match the production intended joint.
9.3.12.2 Testing Details. The brazed joint specimen may be bent in a vice according to
Figure 25 or by some other effective method while still achieving the same type of
bend supplied by the use of a vice.
brazed joint. A braze shall be acceptable if:
• No visual cracks are detected in the brazed area or along the edges of the braze.
• No peeling of the brazed joint has occurred.
• No inclusions (such as flux) or porosity are visible in the brazed area.
• Cracks in the base metal that are not within 2 mm of the braze shall be ignored.
Figure 24: Brazed Lap Joint Test Specimen (4)

CES-S-MANF-13
Figure 25: Brazed Lap Joint Free Bend Test. Can also be used for Butt Joints (4)

CES-S-MANF-13
9.3.13 Peel Testing - Brazed Joints

Peel testing of brazed joints must comply with the following regulations:
for brazed joints shall comply with Figure 26. Refer to Table 16, Test Assembly No.
B1.10 for further specimen dimension details.
9.3.13.2 Testing Details. One member of the specimen may be held in a vice or by some other
effective method while the other member is peeled away so the brazed joint, location
1, may be visually examined. The specimen may also be peeled in a tensile machine,
obtaining the failure load to be measured. Note that the size of location 2 in the below
figure will influence the peel strength measurement.
9.3.13.3 Requirement. Upon peeling, the brazed joint area must pass a visual examination
against Table 5 of this standard.
Figure 26: Brazed Joint Peel Test Specimen (4)

CES-S-MANF-13
9.3.14 Metallography - Cross Sectioning

9.3.14.1 When to Use. Cross sectioning of the specimen is to be used when processing:
• Weld Validation, in the form of:
• Weld parameter development
• Weld Verification, in the form of:
• Changes to existing welding parameters
• Recurring Weldment Verification (RWV)
• Manufacturer/Supplier changes
• Welding location changes (including within the same facility)
• Implementation of a welding procedure onto a weldment which matches
the requirements of the welding procedure
• Destructive Testing Method, Section 9.3, in which cross sectioning is
specified.
9.3.14.2 Sample Details. The process involves obtaining three metallurgical samples from
three separate weldments (totaling nine), two samples taken 3 mm from each end of
the weld, and the third taken from the center of the weld. Only one section is to be
taken from welds that do not allow three (i.e. resistance spot welds, arc stud welds and
plug welds). The thickness and height of the samples must allow full view of the HAZ
and fusion zone. Sample thickness is dependent on the tester's capabilities.
• Regarding lap joints, a line should be scribed along the surface of the weld
indicating the joint root (RJ). Measurements can then be taken from the weld
toes to the edge of the scribed line. These measurements can be compared with
the leg lengths measured for Dimensional Analysis and used to determine if
the weld has fusion to the root of the joint. Refer to the yellow lines and RJ in
Figure 27 below.
• Other methods may be used to assess if the weld has penetrated past the root of
the joint if applicable.
• Refer to Section 9.1.4 for information on Lack of Fusion and root joints.
9.3.14.3 Testing Details. The cross sections must be mounted and polished to a grit no rougher
than three micrometers for dimensional analysis and one micrometer for metallurgical
analysis. The latter is optional and at the request of Cummins Emission Solutions.

CES-S-MANF-13
9.3.14.4 Dimensional Analysis. The images below provide an example but are not required to
be exactly copied. For dimensional analysis, the following variables must be
measured:
• Lap Joint, T Joint, Slot Weld:
• tth - Theoretical Throat length
• td - Design Throat length (if applicable)
• w - Weld Leg lengths
• aw - Weld Size (the shortest leg length, clearly noted on the image)
• r - Reinforcement (at its thickest/thinnest point)
• α -Weld Toe Angles (in degrees)
• LOF - Lack of Fusion length (if applicable) (seen before etching)
• Mn - Base Member Thickness
• RJ -Joint Root (if measurable)
• RW -Weld Root (only if RJ is measurable)
• G - Fit-Up Gap

CES-S-MANF-13
Figure 27: Dimensional Analysis of a Lap Joint
NOTE: The smaller red triangle indicates the effective weld size. This
effective weld size is theorized to be the only structural portion
of the weld in situations where fit-up gap exist. The shorter
horizontal weld leg, w1, extends in-line from the top of the fit-up
gap to the hypotenuse. The vertical weld leg, aw, then specifies
the weld size as it is the shortest weld leg of the effective weld
size. The clearest distinction between actual weld size and
effective weld size will be the measurements of both the design
throat (blue line), td, and theoretical throat (red line), tth.
Theoretical throat will equal design throat where no fit-up gap is
present.

CES-S-MANF-13
Figure 28: Dimensional Analysis of a T Joint
NOTE: The red triangle indicates the effective weld size. Due to the
concavity of this weld, negative reinforcement is present. The
yellow hypotenuse is used to measure negative reinforcement
by connecting both the vertical and horizontal weld toes and
measuring perpendicular from that connection to the face of the
weld. In situations where the weld is flat or convex, this yellow
hypotenuse will not be applicable. In situations where fit-up gap
is present, measure the cross section of the T-Joint just as it is
done with lap joints and record the design throat, td.

CES-S-MANF-13
• Spot Weld, Plug Weld:

• dw - Nugget Diameter (weld size aw)
• dh - Nugget Height (depth of penetration) (seen after etching)
• Pw - Diameter of Pore (if applicable)
• Ph - Height of Pore (if applicable)
• LOF - Lack of Fusion length (if applicable) (seen before etching)
• Lc - Crack Length (if applicable)
• Mn - Base Member Thickness

CES-S-MANF-13
Figure 29: Dimensional Analysis of a Resistance Spot Weld
• Projection Weld, Arc Stud Weld:

• Di - Inside Diameter
• Do - Outside Diameter (also referred to as d1 for stud welds)
• w - Weld Width
• hs - Set-Down height
• P - Penetration (at its deepest point below P)
• h - Weld Height (stud weld)

CES-S-MANF-13
Figure 30: Dimensional Analysis of an annular Projection Weld. Only half of the
coupling is visible
9.3.14.5 Requirement - Weld Validation. The following measured variables for their relevant
welding processes: tth, td (if applicable), w, aw, d1, and h, must be within a percent
difference of 15% of their respective variables across all three cross sections of each
individual specimen. Meaning that the weld start cross section taken on samples 1, 2,
and 3 must be compared with one another, and so on for the weld middle and weld
stop (if three cross sections from one weld are capable). One dimensional analysis
image must be retained with the validation documentation and its location (start,
middle, or stop) must be recorded.
9.3.14.6 Requirement - Weld Verification. Follow the sample and testing details beginning
with Section 9.3.14.2. Confirm the welds which are being verified meet the
requirements of the limits for imperfection tables found in Section 9.1 and the
validated welding procedure specification. That being all dimensions, parameters, and
other key variables must be within the acceptable ranges identified under Section 7.3
for similar welding procedures for each respective welding process.
9.3.14.7 Percent Difference Calculation. Percent difference is being applied to compare two
experimental quantities, the highest and lowest values of the measured compared
quantities, neither of which can be considered the “correct” value. The percent
difference is the absolute value of the difference over the mean multiplied by 100. See
the calculation below.
%Diff = |Highest Value - Lowest Value|

1/2 * (Highest Value + Lowest Value) *100

CES-S-MANF-13
10 Rework Welding Procedures

All welds that fail to meet Section 9.1 must be evaluated for rework procedures (only
applicable for non-destructive testing). All rework should be done according to the
guidelines specified in the following tables. This section has been broken up by
welding process and the rework methods listed under its relevant welding process
should be followed when utilizing said process. Reworked or replaced welds shall be
re-examined by the same methods and quality acceptance criteria originally specified
in Section 9.1.
10.1 General
Below are general principles to consider when utilizing rework procedures.
10.1.1 Weld Removal
The rejectable weld or portions of the weld may be removed from the base metal by
machining, grinding, chipping or plasma arc cutting. Total heat input, H, must be
monitored when plasma arc cutting and any value over 1.5 kJ/mm will result in
scrapping the part.
H – Heat input (kJ/mm)

V – Voltage (Volts)
I – Current (Amperes)
S – Travel Speed (mm/minute)
k – Thermal Efficiency Factor (unit-less)
NOTE: Thermal Efficiency Factor, k, applies to Arc Welding Processes
only. For non-arc welding processes, such as laser welding,
drop k from the heat input equation (or use a value of 1).

CES-S-MANF-13
Table 8: Thermal Efficiency Factor, k, by Process
Welding Process k
GMAW 0.8
GTAW/PAC/PAW 0.6
NOTE: Wire Feed Speed is not current. If using a machine that allows
Amps to be output versus WFS than adjust the machine
accordingly. If not, use Figure 31 as a reference.
Figure 31: Current versus WFS for 300 Series Stainless Steel Electrodes at a Fixed
Stickout (1)

CES-S-MANF-13
Figure 32: Current versus WFS for 400 Series Stainless Steel Electrodes at a Fixed
Stickout (9)

CES-S-MANF-13
10.1.2 CAG and OFC

Carbon arc gouging and oxyfuel cutting are not permitted.
10.1.3 Affected Base Metal Surface
The affected base metal surface must be thoroughly cleaned to a bright metal finish by
mechanical means and free from nicks, gouges or substantial damage to the base metal
before rewelding.
10.1.4 Heat Input
If heat input exceeds 1.5 kJ/mm during any rework procedures (i.e. weld removal or
rewelding) then the part is to be scrapped. Refer to the equation in Section 10.1.1 for
heat input calculation.
10.1.5 Rework Cycles Allowed
Only one rework is permitted on any production unit per affected area.
10.1.6 Rework Method Not Listed
If the rework method is not listed in the tables below for a given process, the
Manufacturer is capable of performing rework to their preferences. But the method
shall follow the requirements specified in Section 10, Section 10.1, and Section 10.1.1
through Section 10.1.6.
10.2 Rework Methods
See Table 9, Table 10, and Table 11.
10.2.1 Rework of Welds Within Flared Outer Body Joint Geometry per
CES-S-MANF-9
Refer to Flare Specifications found in CES-S-MANF-9 for rework procedures utilized
for half-moon and v-shaped grooves at the flared weld seam.
10.2.2 Rework of Welds Within Outer Body Joint Geometry per
CES-S-MANF-18
Refer to CES-S-MANF-18 for rework procedures utilized for formed body seams
which have cracked at the flared weld seam.

CES-S-MANF-13

Name:
Table 9: Arc Stud Welded Rework Methods
Primary Alternate
Method
Imperfection Description Defect Rework Rework Notes Settings
Number
Method Method
9.1 Fillet weld is Table 3, GMAW at GTAW (only if If repair weld Filler:
too small or Inspection least 60° fillet weld size results in ER308L(Si)
inconsis- Number 3.1 beyond each is in close undercut that GMAW: WFS
tently sized. end of the proximity to does not 120-320 ipm;
Only tip of discontinuity. obstruction) meet Voltage
stud is at least 60° Section 9.1, 16-21 V
melted. beyond each Table 3, GTAW:
end of the Inspection Current
discontinuity. Number 3.3 50-150 Amps
or the
9.2 Fillet weld is Table 3, GMAW at GTAW (only if obstruction of Filler:
not 360° Inspection least 60° fillet weld size another part ER308L
around the Number 3.2 beyond each is in close then scrap. If GMAW: WFS
stud, end of the proximity to heat input 120-320 ipm;
missing sec- discontinuity. obstruction) exceeds Voltage 16-21
tions. at least 60° value in V
beyond each Section 10.1. GTAW:
end of the 1 then scrap. Current
discontinuity. 50-150 Amps

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
9.3 Heavy Table 3, Remove stud, N/A If the surface Follow

undercut of Inspection grind surface cannot be welding
thinner stud Number 3.3 smooth and smoothed out procedure
diameter in re-stud weld without required for
the welded on a new defects then given base
area. stud. scrap. If heat metal and
input exceeds application.
value in
Section 10.1.
1 then scrap.
End of table

CES-S-MANF-13

Name:
Table 10: Resistance Welded Rework Methods
Primary Alternate
Method
Number
Method Method
10.1 Insufficient Table 6, GTAW with N/A Scrap if heat input Filler:
Projection Inspection filler metal. exceeds value in ER308L (Si)
Collapse Number 6.2 Section 10.1.1, GTAW:
burn through Current
results or 50-150
excessive Amps
thinning.
10.2 Extensive Table 6, Autogenous N/A Scrap if heat input Filler: None
Bulge/ Inspection GTAW to exceeds value in GTAW:
Expulsion Number 6.3 wash-in the Section 10.1.1, Current
expelled burn through 50-150
material. results or Amps
excessive
thinning/undercut.

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
10.3 Lack of Table 6, GTAW with N/A Applicable only to Filler:

Bonding Inspection filler metal projection welded ER308L(Si)
Number 6.1 couplers that GTAW:
have failed dye Current
penetrant testing. 50-150
Scrap if heat input Amps
exceeds value in
Section 10.1.1,
burn through
results or
excessive
thinning.
End of table

CES-S-MANF-13

Name:
Table 11: GMAW/GTAW/LBW Rework Methods
Primary Alternate
Method
Number
Method Method
11.1 Surface Table 2, Grind out N/A Scrap if: base Filler: Same
Porosity Inspection effected metal gets as Weld
Number 2.1 area, GTAW damaged; heat Metal
using same input exceeds (ER308L(Si)
filler metal value in otherwise)
as current Section 10.1.1; GTAW:
weld metal burn through Current
results, excessive 50-150
11.2 Undercut Table 2, GTAW using N/A thinning. Copper Amps
Inspection same filler backing for heat
Number 2.3 metal as extraction is
current weld permissible.
metal.
11.3 Weld Metal Table 2, Grind out N/A

Crack Inspection effected
Number 2.8 area, GTAW
using same
filler metal
as current
weld metal

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
11.4 Inner Body Table 2, GTAW with N/A Scrap if: base metal Filler: Same
Flare Crack Inspection filler metal gets damaged; heat as Weld
as a Result Number 2.8 utilizing a input exceeds value Metal
of Forming copper in Section 10.1.1; (ER308L(Si)
backing bar burn through results, otherwise)
excessive thinning. GTAW:
Copper backing for Current
heat extraction is 50-150
permissible. Amps
11.5 Incomplete Table 2, Assumes Assumes Scrap if: base metal Filler: Same
Root Fusion Inspection access to access to gets damaged; heat as Weld
Number 2.2 weld root: weld root: input exceeds value Metal
GTAW the Autogenous in Section 10.1.1; (ER308L(Si)
root using GTAW if burn through results, otherwise)
same filler joint per- excessive thinning. GTAW:
metal as mits. This Copper backing for Current
current weld will be at the heat extraction is 50-150
metal. welder’s permissible. Amps
discretion
and must
abide by all
qualification
standards.

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
11.6 No Figure Missing Table 2, Follow No access Scrap if: base metal Follow
Weld Inspection welding to missed gets damaged; heat welding
Number procedure weld? Refer input exceeds value procedure
2.14 that should to plant in Section 10.1.1; required for
have been engineer burn through results, given
used had and materi- excessive thinning. application.
weld not als engineer Copper backing for
been for collabo- heat extraction is
missed. ration. permissible.
11.7 Spatter Table 2, Remove Remove Scrap if: base metal N/A
Inspection spatter with spatter with gets damaged
Number 2.9 chisel. Buff abrasive beyond minimal
smooth with technique. scarring; excessive
minimum Buff smooth thinning. Refer to
scarring in with mini- engineering spec if
base metal if mum scar- spatter gets on brick
occurs. ring in base face.
metal if
occurs.

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
11.8 Excessive Table 2, Grind If sharp Scrap if: base metal Filler: None
Convexity Inspection convexity to corners gets damaged; heat GTAW:
Number 2.4 a flat yet remain after input exceeds value Current
slightly primary in Section 10.1.1; 50-150
rounded rework burn through results, Amps
surface. method or excessive thinning.
weld toes Copper backing for
are not tied heat extraction is
in: Autoge- permissible.
nously
GTAW being
sure to tie in
both weld
toes. Used
in
conjunction
with primary
rework
method.

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
11.9 Incorrect Table 2, Autogenous Grind con- Scrap if: base metal Filler: None
Weld Toe Inspection GTAW being vexity down gets damaged; heat GTAW:
Angle Number 2.6 sure to tie in and follow input exceeds value Current
both weld with primary in Section 10.1.1; 50-150
toes. rework burn through results, Amps
method. excessive thinning.
Copper backing for
11.10 Weld Toe Table 2, GMAW GTAW with heat extraction is Filler: Same
Burn Inspection using filler metal. permissible. as weld
Through Number relevant Blend metal
(hole 2.16 weld reworked (ER308L(Si)
through procedure weld into otherwise)
parent mate- for given existing weld GMAW:
rial) application. with Follow
Cover brick autogenous welding
face if GTAW. procedure
applicable. If required for
brick face given
cannot be application.
covered, GTAW:
then scrap. Current
Blend with 50-150
autogenous Amps
GTAW.

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
11.11 Insufficient Section 12.1.6 GMAW GTAW with Scrap if: base metal Filler: Same
Overlap using filler metal. gets damaged; heat as weld
relevant Blend input exceeds value metal
weld reworked in Section 10.1.1; (ER308L(Si)
procedure weld into burn through results, otherwise)
for given existing weld excessive thinning. GMAW:
application. with Copper backing for Follow
Blend with autogenous heat extraction is welding
autogenous GTAW. permissible. procedure
GTAW. required for
given
application.
GTAW:
Current
50-150
Amps
11.12 Cold Weld/ Table 2, Autogenous N/A Filler: None

Cold Lap Inspection GTAW being GTAW:

Number 2.7 sure to tie in Current 50-
both weld 150 Amps
toes.

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
11.13 Weld Missed Table 2, GMAW GTAW with Scrap if: base metal Filler: Same
a Portion of Inspection using filler metal. gets damaged; heat as weld
the Joint Number relevant Blend input exceeds value metal
2.15 weld repaired in Section 10.1.1; (ER308L(Si)
procedure weld into burn through results, other-
for given existing weld excessive thinning. wise)
application. with Copper backing for GMAW:
Blend with autogenous heat extraction is Follow
autogenous GTAW. permissible. welding
GTAW. procedure
required for
given
applica-
tion.
GTAW:
Current
50-150
Amps

CES-S-MANF-13

Name:
Primary Alternate
Method
Number
Method Method
11.14 Excessive Table 2 Grind to a N/A Scrap if: base metal N/A
Penetration Inspection smooth gets damaged; heat
Number 2.5 finish input exceeds value
without in Section 10.1.1;
cutting into burn through results,
the base excessive thinning.
metal. Copper backing for
heat extraction is
permissible.
11.15 Root Table 2 Only N/A Scrap if: base metal Filler: Same
Concavity Inspection applicable if gets damaged; heat as weld
Number 2.11 capable of input exceeds value metal
root access: in Section 10.1.1; (ER308L(Si)
GTAW with burn through results, otherwise)
filler metal, excessive thinning. GTAW:
keeping in Copper backing for Current
mind total heat extraction is 50-150
heat input. permissible. Amps
End of table

CES-S-MANF-13
11 Laser Welding
Cuts and through-holes may be made through annealed laser butt joints that pass the
destructive test in Section 9.3.
NOTE: This clause applies only to annealed laser welds and
supersedes the following drawing note: “Weld seam may be at
random angular rotation, but cannot go through any additional
features.”
11.1 Laser Welding Fit-Up Gap
This section applies only to autogenously laser beam welded joints. Laser welds
which utillize filler metal shall follow the manufacturers or suppliers best practices.
• Groove weld:
• Fit-Up Gap ≤ 0.15t, where t is the thickness of the thinnest material.
• Fillet Weld:
• Fit-up Gap ≤ 0.2t, where t is the thickness of the thinnest material.

CES-S-MANF-13
12 Weldment Fabrication Requirements

12.1 Fabrication Requirements
The Manufacturer is responsible for following the weldment fabrication requirements
of this standard before and during the welding process.
12.1.1 Fit-Up Gap
Weldments must fall within the following requirements for joint gap:
• t ≤ 1.50 mm: Weld Joint Gap per Class #:
1. Gap ≤ 1.25 mm
2. Gap ≤ 1.50 mm
3. Gap ≤ 1.75 mm
• t > 1.50 mm: Weld Joint Gap per Class #:
1. Gap ≤ 1.75 mm
2. Gap ≤ 2.00 mm
3. Gap ≤ 2.25 mm

CES-S-MANF-13
12.1.2 Work Angle

Work angle for all arc welds shall be:
• Groove Weld Type: 0° - 20° from vertical. See Figure 33.
Figure 33: Work Angle, torch perpendicular to joint in a Single-V Groove weld

CES-S-MANF-13
• Fillet Weld Type (not including Lap Joints): 40° - 50° from vertical. See
Figure 34.
Figure 34: Work Angle, torch perpendicular to joint in a T Joint
• Lap Joints: 20° - 50° from vertical. See Figure 35.

Figure 35: Work Angle, torch perpendicular to joint in a Lap Joint

CES-S-MANF-13
12.1.3 Torch Angle (Travel Angle)

Torch angle for all arc welds shall be 0-30° (push/drag) from vertical. See Figure 36.
Figure 36: Torch Angle, torch parallel to joint
12.1.4 Electrode Placement

The electrode should be placed even in the corner to the best of the Manufacturer’s
ability for all relevant welds. See Figure 37.
Figure 37: Electrode placed even in the corner of a lap joint

CES-S-MANF-13
12.1.5 Contact-Tip-to-Work-Distance (CTWD)

12.1.5.1 The CTWD for all gas metal arc welds shall be between 10-16 mm, regardless of
transfer mode, waveform, or weld type (manual, semiautomatic, etc.). See Figure 38.
Figure 38: GMAW Arc Diagram - notice that CTWD does not equal Stickout in this
situation
12.1.6 Weld Overlap

12.1.6.1 The minimum weld overlap (h) for all weld tie-ins should be b ≤ h ≤ 2*b. See
Figure 39.
Figure 39: Minimum Weld Overlap

CES-S-MANF-13
12.1.7 Tack Welding Recommendations

12.1.7.1 Tack welds (individually located, small arc welds used during the fabrication process
which only temporarily hold components in place) should be made using a higher heat
input than what will be used when performing full welds on joints. This increases
penetration and reduces weld height. Resulting in a concave weld which is easily
welded over by the full weld, reducing the potential for lack of fusion.
12.1.7.2 Full welds should not start or stop on tack welds.
12.1.7.3 Tack welds should not be placed on corners, geometric convergences, or any potential
stress concentration point on the weldment.

CES-S-MANF-13
13 Recurring Weldment Verification (RWV)

In order to ensure consistent, high quality weldments on CES Current Products, a
weldment verification schedule was constructed to define the interval over which
welding procedures are to be verified. Table 12 below describes the minimum
requirement for welding procedures to be tested and their frequency depending on
their usage volume in the manufacturing facility. Table 12 only applies to production
lines which result in more than 500 completed uses of any specific welding procedure.
For welding procedures which create less than 500 completed welds per given run,
only first piece inspection is required, following the procedure outlined in Section
9.3.14.6.
Table 12: RWV Test Frequency (for greater than 500 uses)
Weld Procedure Usage Number of Welding Testing Frequency

Volume (V) Procedures Testing (Weeks)
V ≥ 50% 1 1
25% ≤ V < 50% 1 2
V < 25% 1 3
Remarks
Volume to be selected by percentage used in manufacturing.

Where 100% = all welding procedures used in the facility per welding process.
End of table
NOTE: If the welding procedure is not actively running, it is not required

to undergo recurring weld verification to any set schedule and
shall be omitted from the weld procedure usage volume within
the facility. Once the welding procedure begins being used, it
then must be evaluated for RWV testing frequency.

CES-S-MANF-13
13.1 Verification Testing

13.1.1 Method
The verification method to be utilized can be found in Section 9.3.14.6 of this
standard. However, when specifically performing an RWV, the following additional
actions must be followed:
13.1.1.1 Welding Procedure Identification. Identify the welding procedure that will undergo
verification testing. Locate the area and weldment where this procedure is being
actively used.
13.1.1.2 Obtain Samples. Gather three sample specimens (or actual production parts if
desired) which correctly represent the weldment being tested, specifically matching in
joint type (lap joint, t-joint or spot weld for example), material thickness, surface
condition, and material type and grade. These samples shall have the maximum
specified fit-up gap if not the actual production product part. Have these samples
welded directly at the location where the welding procedure undergoing verification
testing is being welded and with the exact parameters dictated in the welding
procedure, including joint orientation.
NOTE: If it is found that the parameters currently being utilized at the
location where the welding procedure in question is being
welded do not match the welding procedure, note the deviation
from the correct process, DO NOT adjust the parameters and
obtain three additional samples using the deviated welding
process. These additional samples are to be compared
according to Section 9.3.14.6 with the welding procedure being
verified in addition to the samples obtained in Section 13.1.1.2.
13.1.1.3 Repeat Testing. Example: for welding procedures with a usage volume of 75%, they
are to undergo RWV once per week, according to Table 12. It is required that upon
repeat testing of the same welding procedure the following week that the test be
performed in a different area and on a different weldment where this welding
procedure is being actively used. This requirement also applies to welding procedures
with lower usage volumes.

CES-S-MANF-13
13.1.2 Deviations
Deviations from this testing frequency may take place where permitted, but deviations
which reduce the frequency shall be backed by data clearly supporting the reduction in
verification testing. Deviations which increase either the frequency or welding
procedures tested are permitted and at the discretion of the manufacturing/supplier
without the need for supporting documentation. Deviations in testing method are
acceptable as well and can be implemented at the development of the welding
procedure, these being a deviation from cross sectioning to another destructive form of
testing. For example, bend testing of a stud weld instead of cross sectioning. These
deviations are to be handled on a case-by-case basis with a Cummins Emission
Solutions representative, meaning a production engineer or supplier quality engineer.
13.1.3 Recording Results
The verification results must be recorded and kept on record for a minimum of three
years.
13.1.4 Failed RWV
Welding procedures that fail verification will trigger an investigation based on the
following method:
13.1.4.1 Sample Size. Repeat Section 13.1.1 identically and undergo the same verification
method described in Section 9.3.14.6.
13.1.4.2 Acceptance Criteria. If the repeated verification test meets the criteria found in
Section 9.3.14.6, the investigation may be completed and recorded as a pass.
13.1.4.3 Failure Criteria. If the repeated verification test does not meet the criteria found in
Section 9.3.14.6, the problem must be identified and temporary corrective actions
taken place within an appropriately determined time period. Proposed short term and
long term fixes must be documented and implemented as determined by the internal
quality plan, unless otherwise specified by another specification.
13.1.4.4 Retesting. Once the long-term corrective action has been implemented, repeat
Section 13.1.1 identically and undergo the same verification method described in
Section 9.3.14.6. If the repeated verification test passes, the investigation may be
completed and recorded as a pass. If the repeated verification test fails, begin again at
Section 13.1.4 and repeat this process until the investigation can be successfully
completed.

CES-S-MANF-13
14 Appendix A: Material Data

This section contains information related to the mechanical properties and
classifications of relevant CES materials through the use of tables as it strictly relates
to welding or brazing. This data is to be referenced where necessary throughout this
standard. Contact CES Materials Science and Technology for questions or inquiries
regarding materials listed or material information. See Table 13, Table 14, and
Table 15.
Table 13: Base Metal CES M-Number Classification for Welding
M-Number Type of Stainless Steel Applicable Grades
1 Ferritic (C ≤ 0.08%) 405, 409, 409Al, 412, 430L,

436L, 439, 441, 444, CB6
2 Ferritic CB30, 1Cr17

(0.08%< C ≤0.35%)
3 Austenitic (C ≤ 0.08%) 304, 304L, 316, 316L, 316Ti,

CF3, CF3M, CF8
4 Austenitic (Cr ≥ 22%) 904L
5 Martensitic (Cr ≥ 15%) 431
6 Martensitic (Cr < 15%) 410
7 Precipitation Hardened 17-4PH
End of table
NOTE: For any material not noted above, please consult CES Materials
Science and Technology.

CES-S-MANF-13

Name:
Table 14: Base Metal Type and Ultimate Tensile Strength
Base Metal Ultimate Tensile Strength Cummins

Base Metal Type
(minimum) Engineering
Type
Standard
US Number UNS Number KSI MPa Number
304 S30400 Bars/Shapes 90A (cold-finished) 620A (cold-finished) 33081
316 S31600 75A (hot-finished) 515A (hot-finished) N/A
316Ti S31635 N/A
302 S30200 N/A
304L S30403 A
90 (cold-finished) A
620 (cold-finished) N/A
316L S31603 70A (hot-finished) 485A (hot-finished) 33035
431 S43100 140E (cold-finished) 965E (cold-finished) N/A
1Cr17 S11710 65F 65F N/A

CES-S-MANF-13

Name:

Base Metal Type
Type
Standard
304 S30400 Plate/Sheet/ 75C 515C 33081
316 S31600 Strip N/A
316Ti S31635 N/A
302 S30200 N/A
304L S30403 70 C
485 C N/A
316L S31603 33035
405 S40500 60C 415C N/A
439 S43035 33065
444 S44400 N/A
409 S40920 55C 380C 33055
409Al N/A 60D 414D N/A
410 S41000 65C 450C N/A
436 S43600 N/A
412 S41003 66C 455C N/A
436L N/A 71D 490D N/A
904L N08904 71C 490C N/A
441 S44100 71D 489D 33068
17-4PH S17400 160D 1103D N/A

CES-S-MANF-13

Name:

Base Metal Type
Type
Standard
CB6 J91804 Castings 115B 790B N/A
CB30 J91803 65B 450B N/A
CF3 J92500 70B 485B N/A
CF3M J92800 N/A
CF8 J92600 N/A
A:
Data sourced from ASTM A276-13; annealed condition.
B:
Data sourced from ASTM A743/A743M-12; UTS values measured in the condition for which the casting it represents is
specified.
C:
Data sourced from ASTM A240/A240M-12a; annealed condition.
D:
Data sourced from AK Steel Data Bulletin; annealed condition.
E:
Data sourced from ASM Metals Reference Book, Third edition, 1993; annealed condition.
F: Data sourced from GB/T 1220-2007; annealed condition.
End of table
NOTE: For any material not noted above, please consult CES Materials Science and Technology.

CES-S-MANF-13
Table 15: Filler Metal F-Number Classification
F-Number Type of Stainless Steel Applicable Grades
1 Ferritic EC439, ER439, ER430LNb
2 Austenitic (22% ≥ Cr) ER307, ER308L, ER308LSi,

ER316L
3 Austenitic (23% ≤ Cr) ER309L, ER309LSi,

EC309L
ER: Electrode Rod (Solid), AWS A5.9; EC: Electrode Cored (Tubular),
AWS A5.22
End of table
NOTE: For any material not noted above, please consult CES Materials
Science and Technology.

CES-S-MANF-13

Name:
15 Appendix B: Recommended Weld Procedure Test Assembly

Dimensions
See Table 16.
Table 16: Recommended Weld Procedure Test Assembly Dimensions
Test Assembly Figure and

Test Assembly No. Test Assembly Dimensions
Description
B1.1

Flare Bevel

CES-S-MANF-13

Name:

Description
B1.2

Butt Joint

CES-S-MANF-13

Name:

Description
B1.3
Lap Joint

CES-S-MANF-13

Name:

Description
B1.4

T Joint

CES-S-MANF-13

Name:

Description
B1.5
Slot Weld

CES-S-MANF-13

Name:

Description
B1.6
Plug Weld
B1.7

Spot Weld

CES-S-MANF-13

Name:

Description
B1.8
Coupler (RPW/LBW/
GMAW)

CES-S-MANF-13

Name:

Description
B1.9
Stud Weld

CES-S-MANF-13

Name:

Description
B1.10
Brazed Joint
B1.11
Spot Weld

CES-S-MANF-13

Name:

Description
B1.12
Spot Weld
End of table

CES-S-MANF-13
16 Appendix C: Recommended Spot Weld

Placement for Inner Bodies
16.1 Spot weld specifications for inner bodies
Figure 40: Spot welds on inner bodies
“A” is the distance between start of the body and the undercut. It is calculated from the
following equation:
A = Maximum flare width of the inner bodies + clearance of 5 mm (0.2 inch)
“B” is the distance from the start and end of the body to the center of the first and last
spot weld. It is calculated from the following equation:
B = A + 5 mm (clearance from the flare) + Radius of the spot weld
“C” is the nominal diameter of the spot weld, which is 6 +0.5/-0 mm
(0.24 +0.02/-0 inch). If the peak load (P) is known, the diameter of the spot weld is
calculated by the following equation:
C= 4P
τs * π

CES-S-MANF-13
Where:
P = Peak load (lb)
C = Diameter of the spot weld (inch)
τs = Shear strength of spot weld (PSI)
“D” is the maximum distance between the centers of two spot welds. It is calculated by
the following equation:
D = ----------------
F-2B -
 N+1 
“E” is the overlap width. It is calculated from the following equation:
E = Diameter of the spot weld + 8 mm (0.31 inch)
“F” is the width of the flat detail of the body.
“N” is the number of spot welds. It is calculated by the following equation:
N = ----------------
F-2B - + 2
25.4
NOTE: “N” is rounded up to the next integer.
NOTE: The maximum spacing between the spot welds can be increased to a
value greater than 25.4 mm (1 inch) if the load exerted on the joint is known or
can be determined.

CES-S-MANF-13
17 Appendix D: Document Metadata

17.1 Identification
Table 17: Appendix D: Document Metadata: Identification
Publication Identification CES-S-MANF-13

Number (PID):
Document Type: Engineering Standard
Business Unit: Cummins Emission Solutions
Publication Category: Specification
Publication Title: Welding Requirements for Aftertreatment and Exhaust

Parts
Publication Identifier: Manufacturing
Revision: 13
Status: Published
DCR: 00002991
Proper Citation: CES-S-MANF-13, “Welding Requirements for

Aftertreatment and Exhaust Parts”

CES-S-MANF-13
17.2 Content Control

Table 18: Appendix D: Document Metadata: Content Control
Authority: No addition or unique authority beyond the scope of this

publication category.
Ownership and Maintenance: This Content is owned, developed and maintained by the
Cummins Emission Solutions, Materials Engineering
group.
The following persons were the caretakers of this
document and the content within, at the time of
development and publication:
• Owner: Logan M. Rohaley
OB281, CES
• Author: Michael J. Warwick
AL153, CES
• Technical Writer: Bobby R. Carney
JI667, CES
Review Schedule: This content shall be formally reviewed within two years
after the publication of the most recent version. More
frequent reviews and revisions may be called for at any
time by the Document Owner or the CES Technical Editor.
This content shall be formally reviewed no later than
2020-09-18. If not reviewed by this date, the technical
content of this document may be INVALID.
Primary Approver 1: • Michael J. Warwick

Primary Approver 2: • David A. Nickel
Supplemental Approver: • Rajeev Lamba

CES-S-MANF-13
17.3 Document Control

17.3.1 Access and Security
Access and Security
Cummins Data Classification: CONFIDENTIAL
Access, Use and Distribution: Safeguarding this information is your responsibility.

Access to this document is authorized for Cummins
employees and approved business partners on a
need-to know basis per CORP-00-24-00-00. This
document and the content therein are considered internal
and shall not be distributed outside the company unless a
Supplier Confidentiality Agreement has been signed and
approved by both Cummins Emission Solutions and the
receiving party, wherein all parties shall be bound by the
terms set forth in the agreement.
This is a controlled document. Copies of this document
may be created and distributed by CES EKM only.

CES-S-MANF-13
17.4 File Names and Locations

File Names and Locations
Draft File Names: CES-S-MANF-13_r13_DRAFT_v1.fm
Draft File Type: Adobe FrameMaker
Draft File Location: K:\ces\ESS\EKM\Projects by DCR\00002991\r13\v1
Final Draft received by 2018-09-18

CES EKM:
Writable File Name CES-S-MANF-13_r13.fm
Writable File Type: Adobe FrameMaker Document
Writable File Location: K:\cesd\specification\CES-S-MANF-13\writable
Writable File Access: EKM Leader, CES Global Engineering Services Manager,
Senior Technical Writer
Read-only File Name: CES-S-MANF-13_r13.pdf
Read-only File Type: Adobe Acrobat Document
Read-only File Location: K:\cesd\specification\CES-S-MANF-13\
Read-only File Access: http://ces.cummins.com/knowledgemanagement/

catalog.html

CES-S-MANF-13
17.5 Revision History

Rev. DCR Description Date By
0 00000540 • Initial release. Cloned 2010-02-15 Marland Pittman

from CFBU ES0044.
• Definitions added. Peter J. VerDuin
• “Should” replaced with Stan Maddox

“Shall” throughout the
document.
1 00000884 • Added Purpose 2012-05-22 Jay Narasimhan

statement: “In order to
ensure that welds are
consistent and adequate,
it is necessary to provide
standard strength and size
requirements for welds
used in CES
aftertreatment
applications.”
• Updated Table 1 and
Table 2.
• Changed first bullet under
Section 7.2 to:
“Acceptable inspection
procedures; perform the
inspection with a minimum
of 45 lumens of
illumination and no
magnification.”
2 00001037 • Added ASTM UNS 2012-09-28 Nikhil S.

S31635 to Material Kodgule
column of Table 5.
• Added 316 Ti reference to
NOTE at the end of Table
5.
3 00001056 • Table 3 and Table 5: 2012-10-16 Nikhil S.

Added information to Kodgule
include 904L; revised
notes.
CES-S-MANF-13 Page 152 of 160 160

CES-S-MANF-13
4 00001074 • Revised Scope to include 2013-01-16 Chetna Negi

testing of welds.
• Added Section 7.3.
• Added description before
Section 8.1.
5 00001103 • Added Section 5.1. 2013-10-08 Divaagar

• Added Table 6. Natarajan
• Section 5.1: Added Figure
1.
• Appendix C added along
with Figure 6.
• Added new Section 8.5,
body Section 8.5.1, body
Section 8.5.3, body
Section 8.5.4, body
Section 8.5.5, and body
Section 8.5.6.
• Previous Section 8.5
changed to Section 8.6.
• Minimum shear stress
values in Table 4 and
• Table 5 updated.
• Table 3: Updated text for
Inspection number 6.1.4
to “...in the square area of
25 mm x 25 mm with 5
maximum imperfections
allowed.”
• Table 3: Replaced
Inspection number 6.1.9
with information from ISO
5817, section 1.12.
6 00001391 • Changed ownership to 2014-03-26 Eric W. Fusner

Eric W. Fusner.

CES-S-MANF-13
7 00001405 • New approvers added. 2014-09-03 Eric W. Fusner

• Added 316 and 316L
combinations to Table 1
and Table 2.
• Remove Nitronic 60
entries from Table 1, Table
2, Table 4, Table 5, and
Table 6.
• Changed instance of “439”
to “439 or UNS S43932” in
Table 1 and Table 2.
• Revised information for
Class #2 and Class #3 in
row 6.1.4 of Table 3.
• Remove 6.1.6 “Axial/
longitudinal overlap” from
Table 3.
• Added 6.1.9 to Table 3.
• Added Section 8.5.1.
• Revised “Minimum
measured weldment
ultimate shear stress
(KSI)” column in Table 6.
• Added Section 10.
• Added deviation pre-
approval to include
Materials Engineering.
• Added Note to end of
Section 9.4.
• Added Section 11.

CES-S-MANF-13
8 00001543 • Revised title and 2015-01-05 Eric W. Fusner

references in Description,
Scope, and Purpose.
• Added AWS A3.0
reference to Section 3.
• Added new definitions to
Section 4 (ESO, electrode
extension, and work
angle), removed
Submerged Arc Welding
definition. Changed text in
“Fillet Weld,” “Lap Weld,”
“Plug Weld,” and “T-Fillet
Weld” definitions.
• Added Section 6 "Welding
Position" with
accompanying figures.
• Added travel speed, torch
angle, work angle,
electrode stickout (ESO),
and shielding gas flow rate
(GFR) to Section 7.
• Updated Table 2 and
Table 3.
• Removed "D < 0.15*t"
from 8.1.1 in Table 2.
• Revised bullets in
Section 9.2.
• Removed “Fillet welds”
section.
• Removed "Fillet weld
break test" section.
• Removed "Test reports for
destructive testing"
section.
• Added text to Section 12.
• Removed Appendix B:
Destructive Test Criteria.

CES-S-MANF-13
9 00001639 • Added “autogenous” to 2015-07-31 Eric W. Fusner

Section 4 - Definitions.
• Revised “Gas Metal Arc
Welding” and “Gas
Tungsten Arc Welding”
definitions in Section 4.
• Revised bullets in
Section 7.
• Revised equation in
Section 7.1 and note at
end of section.
• Revised Section 8.1 and
Table 2.
• Removed Section 7.2 and
Table 2.
• Revised Table 2.
• Revised Table 3.
• Revised title for
Section 10.3.
• Revised text and equation
in Section 10.3.6.
• Added Table 4, Table 5,
Table 6, and Table 7.
• Revised text in
Section 13.2 and
Section 13.3.
• Revised Figure 10.
10 00001692 • Made corrections to 2016-01-15 Eric W. Fusner

formatting in Table of
Figures and Table 5.
• Revised title of Table 7.
11 00002057 • Added new Section 5, 2017-03-20 Peter C.

“Customer Christianson
Communication
Document” to refer to
CES-S-MANF-13-Outline
and updated Description
and Scope with
references.

CES-S-MANF-13
12 00002783 • Document significantly 2018-08-29 Logan M.

revised in order to parallel Rohaley
new welding standards.
• Section 3 renamed to
Applicable Documents
and Citations and several
reference standards and
sources were added.
• Numerous definitions
added to Section 4.
• Welding positions
reclassified in Section 6
• More key welding
variables added to
Section 7 along with
Resistance Welding, Arc
Stud Welding, Brazing,
and Laser Beam Welding.
• Section 7.3 moved to
Appendix C and retitled to
Recommended Spot Weld
Placement for SCR Inner
Bodies.
• Revised Section 8 and
Table 1.
• Revised Section 9.1 and
expanded Table 2.
• Revised CES Weld
Classes in Section 9.
• Added Limits for
Imperfections tables for
Arc Stud Welding,
Resistance Spot Welding,
Brazed Joints, and
Projection Welding.
• Revised Section 9.2 to
include Section 9.2.1 -
Nondestructive Testing,
NDT and Section 9.2.2 -
Destructive Testing.

CES-S-MANF-13
• Added the terms Weld

Validation and Weld
Verification Section 9.2.
• Included wording which
gives suppliers/
manufacturers flexibility in
testing methods.
• Added Section 9.2.3 -
Inspection Qualification
and Section 9.2.3.1 -
Method of Qualification to
Section 9.2.
• Moved Section 10 -
Destructive Testing
Methods to Section 9.3 -
Destructive Testing
Methods for Strength and
Toughness of Welds.
• Added several more
destructive weld testing
methods.
• Moved Section 11 - Repair
Welding to Section 10 -
Rework Welding
Procedures.
• Included total heat input in
rework procedures.
• Limited rework cycles in
any given area to one.
• Revised rework methods
for Laser Welds and Arc
Welds.
• Added rework methods for
Arc Stud Welding and
Resistance Welding.
• Removed Section 13 -
Weldment Design
Requirements.
• Added Section 12 -
Weldment Fabrication
Requirements.

CES-S-MANF-13
• Expanded fit-up gap and

work angle for more
specific situations.
• Removed stickout in favor
of Contact-Tip-to-Work-
Distance, CTWD.
• Revised Section 14 -
Recurring Current Product
Weldment Validation to
Section 13 - Recurring
Current Product
Weldment Verification.
• Renamed Appendix A:
Transverse Rectangular
Tension Test Specimen to
Appendix A: Material
Data.
• Added Table 13: Base
Metal M-Number
Classifications for
Welding.
• Added Table 14: Base
Metal Type and Ultimate
Tensile Strength.
• Added Table 15: Filler
Metal F-Number
Classification.
• Renamed Appendix B:
Transverse Rectangular
Shear Test Specimen for
Spot Weld to Appendix B:
Recommended Weld
Procedure Test Assembly
Dimensions.
• Added Table 16:
Recommended Weld
Procedure Test Assembly
Dimensions.
• Changed approver 2 to
Duane Toay to expedite
release during Tim
Buchanan’s absence.

CES-S-MANF-13
13 00002991 • Technical Content 2018-09-18 Michael J.

Validation Review Warwick
completed. No technical
content altered.
• Republished with Michael
Warwick and Material
Engineering ownership.
End of table


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Engineering Standard

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 1 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 2 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

9.1.1 CES Weld Quality Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

CES-S-MANF-13 Page 3 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

11 Laser Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

CES-S-MANF-13 Page 4 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 5 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 6 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 7 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 8 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

3 Applicable Documents and Citations

CES-S-MANF-13 Page 9 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

ISO 18279: 2003, “Brazing - Imperfections in Brazed Joint.”

CES-S-MANF-13 Page 10 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 11 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

Complete Joint Penetration (CJP)

CES-S-MANF-13 Page 12 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

Effective Length of Weld (Lw)

CES-S-MANF-13 Page 13 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 14 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

Heat Affected Zone (HAZ)

CES-S-MANF-13 Page 15 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

Manual Weld Type

CES-S-MANF-13 Page 16 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 17 of 160

Name: Welding Requirements for Aftertreatment and Exhaust Parts

Identifier: Specification: Manufacturing

CES-S-MANF-13 Page 18 of 160