Specification

Title of the
document Requirements for ARC Welding Joints
Reference FSE-S-PSE-G057/EN
Purpose This document provides the minimum requirements for MAG (GMAW), TIG (GTAW) and Plasma
(PMA) welding joints including the acceptance criteria for visual and macroscopic cross sectional
inspections.

Scope This Specification applies to all divisions of Faurecia Emissions Control Technologies (referred to
below as FECT) as well as for suppliers. In the case that this standard and a customer specification
are both listed on a drawing and they are in conflict, the customer requirements take precedence.
Related documents EN ISO 5817

Issue n° 00

Description of Rev. 00 (27.Oct.2015)

changes First issue

Cancels and EED-S-PSE-0002

replaces ES 65.010, Part 3

Author T. ZIPFEL (CPO), D. ABERLE (COE), A. ZHANG (Asia Welding Specialist), R. KAISER (COE-
Durability), J. KOTNIK (Welding Engineer, ME-NAO), F. LUEDER (Quality Director),
P. MARCHAND (SEU Welding Specialist), M. SCHATTENKIRCHNER (NEU-Lab.),
J. STIEDL (CPL-CE), H. WIESER (COE-ES)

Owner T. ZIPFEL (CPO)

Approved by J. KISKER - Engineering Quality Manager

J. LAGARDE - Global Manufacturing Engineering Manager
A. BLUEML - CPO Director

Released by L. WRZOSEK – PLE Emissions Control Director

G. KNAUER – PLE Acoustic Performance Director
E. NICOLE – CVE PLE VP

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Content
1. Keywords ........................................................................................................................................ 3
2. Units ................................................................................................................................................ 3
3. Symbols .......................................................................................................................................... 3
4. Abbreviations ................................................................................................................................. 3
4.1 General ..................................................................................................................................... 3
4.2 Document specific ..................................................................................................................... 3
5. Definitions ....................................................................................................................................... 4
5.1 Fusion Welding ......................................................................................................................... 4
5.2 MAG (Metal Active Gas) welding or in USA GMAW (Gas Metal Arc Welding) .......................... 4
5.3 TIG (Tungsten Inert Gas) welding or in USA GTAW (Gas Tungsten Arc Welding) ................... 4
5.4 PAW (Plasma Arc Welding) ...................................................................................................... 4
6. Introduction .................................................................................................................................... 4
7. Inspection of welding seams ......................................................................................................... 4
7.1 Visual Inspection ....................................................................................................................... 4
7.2 Inspection of Sections ............................................................................................................... 5
8. Weld Features ................................................................................................................................. 5
9. Weld Evaluation and Validation .................................................................................................... 5
10. Specification for different weld joint types .................................................................................. 6
10.1 Lap weld .................................................................................................................................... 6
10.2 3-Layer Lap joint ....................................................................................................................... 6
10.3 4-Layer Lap joint ....................................................................................................................... 7
10.4 Rod to rod (tubular and solid) .................................................................................................... 7
10.5 Rod (tubular or solid) to Sheet(s) or edge welds ....................................................................... 8
10.6 Two sheet edge weld ................................................................................................................ 8
10.7 Three sheet edge weld .............................................................................................................. 9
10.8 Four sheet edge weld ................................................................................................................ 9
10.9 Plug or slot welding ................................................................................................................... 9
10.10 T-joint (fillet weld) .................................................................................................................... 10
10.11 Flex joint to pipe ...................................................................................................................... 10
11. Evaluation Criterion ..................................................................................................................... 11
12. Quantity and Position of Weld Cuts............................................................................................ 14
12.1 Linear or curved open welds ................................................................................................... 14
12.2 Circular and non-circular closed welds .................................................................................... 14

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1. Keywords
Welding, MAG, GMAW, TIG, GTAW, Plasma, PMA

2. Units
All values are expressed in SI units, all dimensions in mm, unless otherwise stated

3. Symbols
a nominal throat thickness of the fillet weld
h Minimum throat thickness
L1 Leg length
L2 Leg length
p1 Penetration depth
p2 Penetration depth
t1 Sheet wall thickness measured directly at the weld
t2 Sheet wall thickness measured directly at the weld
tmin Thinnest sheet wall thickness
d Sampling Distance
u Length of defect
α Toe angle
β angle of angular misalignment

4. Abbreviations
4.1 General
AWS American Welding Society
ASTM American Society for Testing and Materials
COE Center Of Excellence
PE Product Engineering
EN European Norm
EU European Union
FECT Faurecia Emission Control Technologies
IOP International Operations (India, Brazil, Russia)
ISO International Organization for Standardization
NAO North America Operations (USA, Canada, Mexico)
ME Manufacturing Engineering
PU Purchasing
Q Quality

4.2 Document specific

MAG-welding Metal Active Gas welding
TIG-welding Tungsten Inert Gas welding
GMAW Gas Metal Arc Welding (=MAG)
GTAW Gas Tungsten Arc Welding (=TIG)

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5. Definitions
5.1 Fusion Welding
A generic term for welding processes that rely upon melting to join materials of similar compositions and melting points.

5.2 MAG (Metal Active Gas) welding or in USA GMAW (Gas Metal Arc Welding)
Fusion welding process uses an electrical arc between a continuous filler metal electrode and the weld pool. The process
incorporates the automatic feeding of a continuous, consumable electrode that is shielded by an externally supplied gas.

5.3 TIG (Tungsten Inert Gas) welding or in USA GTAW (Gas Tungsten Arc Welding)
Fusion welding process, that uses an electrical arc between a non-consumable tungsten electrode and the work piece to create
the weld pool. The process may incorporate filler wire and is shielded by an externally supplied gas.

5.4 PAW (Plasma Arc Welding)

Fusion welding process, that uses an electrical arc between a non-consumable tungsten electrode and the work piece to create
the weld pool. The tungsten is recessed into the torch and a constricting nozzle is used to restrict the arc into a narrow column.
The process may incorporate filler wire and is shielded by an externally supplied gas.

6. Introduction
The main functions of weld seams on exhaust systems of light and commercial vehicles is the transfer of forces and - except for
a few exemptions (e.g. bracket welds) – gas tightness. These functions are influenced by the two main features:

 The throat thickness

 The metallic bond between weld bead and base material

Lack of visible fusion/penetration is to be treated as high risk failure

Regarding durability of a welding seam the geometry of the seam (e.g. toe angles, notches, stiffening etc.) must be considered
as third characteristic. However, the usual process variations found in the manufacturing of exhaust systems do not allow a real
limitation of the weld seam geometry. These variations are found in the joint gaps, the welding edge, welding in forced position
due to obstructions within components and fixtures, the high part of molten material, which has to be kept in shape during
solidification. A real stable process considering the geometry can only be achieved by a (economically often unacceptable) high
effort.

7. Inspection of welding seams

Welding joints of exhaust systems are evaluated via:

 Visual control of the external appearance (non-destructive)

 Evaluation via polished and etched sections (destructive)

This standard supplies the criteria for visual control and for the evaluation of sections

7.1 Visual Inspection

 Weld must be complete according to drawing specifications, no interruptions allowed
 No spatter allowed on areas defined on drawing to be spatter free
 Pores, End craters, cracks to be rated according to Chapter 12
 Burn through or holes not allowed
 Visual fusion defects not allowed (e.g. weld misses one or more of the components locally and completely, cold weld)
 Sharp edges that could lead to bodily harm are not allowed (HSE)
 Undercut to be rated according to Chapter 12

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7.2 Inspection of Sections
A section is a weld sample cut out perpendicular to the weld with a smooth or polished plane to inspect the weld. The smooth
plane is etched to show the fusion boundaries. Sections are evaluated with an optical magnification of at least 8 fold. Sections
are cut out at a position of minimum 10 mm measured from the weld start and end point on welds longer than 20 mm. On welds
shorter than 20 mm the section is taken on half the weld length.

8. Weld Features
Feature Definition
Flank Exposed surface of base material next to the weld
Root Point at which the back of the weld intersects the base metal surface
Toe Point at which the face of the weld intersects the base metal surface
Leg Shortest distance from root to toe in a weld (includes only areas where fusion is complete)
Minimum throat thickness Shortest distance from root to face in a weld
Penetration Maximum depth of the fusion zone which extends into the base metal
Toe angle Angle between the weld face and the base metal surface measured at the weld toe

Symbol Name Dimension

α Toe angle [°]
h Minimum throat thickness [mm]
L1 Leg length [mm]
L2 Leg length [mm]
p1 Penetration depth [mm]
p2 Penetration depth [mm]
t1 Sheet wall thickness measured directly at the weld [mm]
t2 Sheet wall thickness measured directly at the weld [mm]
u Length of defect [mm]

Figure 1: Typical weld joint

9. Weld Evaluation and Validation

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

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10. Specification for different weld joint types
10.1 Lap weld

Figure 2: Lap joint

Symbol Name Minimum required values

α Minimum toe angle 90°
h Minimum throat thickness 0.8 x tmin
L Minimum leg length tmin
p Minimum penetration depth 0.1mm

If t2/t1>1.5, 100% edge fusion not required

If n t2/t1≤1.5, 100% fusion along edge required

10.2 3-Layer Lap joint

Figure 3: 3-Layer Lap joint

Symbol Name Minimum required values

α Minimum toe angle 90°
h1 Minimum throat thickness 0.8 x (t2 + t3)
h2 Minimum throat thickness 0.8 x t3
L Minimum leg length tmin
p Minimum penetration depth 0.1 mm

If t3/t1>1.5, 100% edge fusion of upper sheet not required

If n t3/t1≤1.5, 100% fusion along edge of upper sheet required
Edge of middle sheet has to be completely fused

Note: If h distance goes through pores, then h values must be reduced by the pore length.

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10.3 4-Layer Lap joint

Figure 4: 3-Layer Lap joint

Symbol Name required values

α Minimum toe angle 90°
h1 Minimum throat thickness 0.8 x (t2 + t3 + t4)
h2 Minimum throat thickness 0.8 x (t2 + t3)
h3 Minimum throat thickness 0.8 x t4
L Leg length tmin
p penetration depth 0.1mm

If t4/t1>1.5, 100% edge fusion of upper sheet not required

If t4/t1≤1.5, 100% fusion along edge of upper sheet required

Edges of both middle sheets have to be completely fused

Note: If h distance goes through pores, then h values must be reduced by the pore length.

10.4 Rod to rod (tubular and solid)

Figure 5: Rod to rod -/pipe to pipe hanger

Symbol Name required values

α Minimum toe angle Not relevant
h Minimum throat thickness 0.2 x Dmin
L1 ; L2 Minimum straight leg length 0.2 x Dmin
p1 Minimum penetration depth 0.1 mm
p2 Minimum penetration depth 0.1 mm

Overflow into gap between rods is permitted.

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10.5 Rod (tubular or solid) to Sheet(s) or edge welds

Figure 6: Rod to rod

Symbol Name required values

α Minimum toe angle Not relevant
h Minimum throat thickness 0.2 x Dmin
L1 ; L2 Minimum straight leg length 0.2 x Dmin
p1 Minimum penetration depth 0.1 mm
p2 Minimum penetration depth 0.1 mm

Overflow into gap between rod and sheet is permitted

10.6 Two sheet edge weld

Figure 7: Two sheet edge weld

Symbol Name required values

h Minimum throat thickness 0.8 x tmin

Note: all edges have to be completely fused.

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10.7 Three sheet edge weld

Figure 8: Three sheet edge weld

Symbol Name required values

h1 Minimum throat thickness 0.8 x t1
h2 Minimum throat thickness 0.8 x t3

Note: all edges have to be completely fused.

10.8 Four sheet edge weld

Figure 9: Three sheet edge weld

Symbol Name required values

h1 Minimum throat thickness 0.8 x t1
Smallest of
h2 Minimum throat thickness 0.8 x (t1 + t2) and
0.8 x (t3 + t4)
h3 Minimum throat thickness 0.8 x t4

Note: all edges have to be completely fused

10.9 Plug or slot welding

Figure 10: Plug or slot welding

Symbol Name Minimum required values

p Minimum penetration depth 0.1mm
L Minimum leg length tmin
h1 Minimum throat thickness 0.5 x t1; min 0.5 mm
h2 Minimum throat thickness 0.5 x t1; min 0.5 mm
α1 Minimum toe angle not relevant

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 α2 Minimum toe angle not relevant

10.10 T-joint (fillet weld)

Figure 11: T-joint (fillet weld)

Symbol Name Minimum required values

α1 Minimum toe angle 90°
α2 Minimum toe angle 90°
h Minimum throat thickness 0.8 x tmin
L1 Minimum leg length tmin
L2 Minimum leg length tmin
p1 Minimum penetration depth 0.1mm
p2 Minimum penetration depth 0.1mm

Note: For β≤30° use the lap-joint specification

10.11 Flex joint to pipe

Figure 12: Flex joint to pipe

Symbol Name Minimum required values

α Toe angle Not relevant
p Minimum penetration depth 0.1mm
L Minimum leg length t1
LRing Minimum leg length t1

The edges of each layer have to be fused.

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11. Evaluation Criterion
EN ISO
No. Evaluation Criterion Specification
5817 No.
1 100 Welding related cracks into bead facing surface

Welding related cracks: into bead opposing surface

u ≤ 0,1 mm

Internal cracks induced by welding (length u)

2 104 End crater crack (external defect) permissible

3 2017 Surface pores (external defect) Max diameter 1mm
4 2025 Open end crater cavity (external defect)

Not relevant

5 401 Fusion defect (external defect, incomplete fusion) Not relevant

6 401 Micro fusion defect (external defect, only detectable by
Not relevant
microscopic analysis)
7 4021 Insufficient root fusion
Not relevant

8 5012

u ≤ 0,1 mm

Partial or complete undercut

9 5013

u ≤ 0,1 mm
Root notch

10 502 Excessive bead height (butt weld)

Not relevant

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 11 503 Excessive bead height (fillet weld)

Not relevant

12 504

u ≤ 1,5 mm

Excessive root protrusion (over slip seats no root is permitted)

13 505 Toe angle, measured from toe to a point at radius 1mm from toe
intersecting with weld face

α ≥ 90°

14 506

u ≤ 0,1

Spilled weld bead

15 509

Not relevant
Undulated bead

16 511 Root not fused completely Not relevant

17 510 Burn through (=hole) Not permissible
18 512
Excessive asymmetry of fillet weld (excessive unequal leg length) Not relevant

19 515 Root retraction

u ≤ 0,1 mm

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 For all welds on covers housing a compressed mat (converters,
DPFs, etc.) the following rule applies

Criterion: the root concavity caused by the mat pushing the

cover during welding is allowed if the remaining weld thickness is
equal to the cover thickness and the step in the cover is less
than 0,3 t1.

20 516 Root porosity Not relevant

21 517 Arc start defect Not relevant
22 5213 Fillet weld too thin

Not relevant

23 5214

Not relevant

Fillet weld too thick

24 601 Arc misfiring defect Not relevant

25 602 Weld spatter consult drawing
26 1001 Micro crack (only visible with 50 fold magnification) Max 0.1 mm
27 2011,2012, Internal pores throat thickness or
2013, 2014, weld height still in
2015, 2016 spec
28 202 Cavity

u ≤ 0.1 mm

29 2024

Not relevant

End crater cavity

30 300, 301, Solid inclusion, Flux inclusion, slag inclusion, oxide include Not relevant
31 304 Metallic inclusion except copper Not relevant
32 3042 Copper inclusion Not relevant

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 33 401 (4011, Fusion defect (incomplete fusion), do not confuse with spilled
4012, 4013) weld bead

uf ≤ 0,1 mm

34 401 (4011, Fusion defect (incomplete fusion

4012, 4013) Needs to meet h-
requirements if
subtracted from weld
thickness

35 402

u ≤ 0,1 mm

Insufficient root penetration

36 507, 508, Limits relate to deviations from the correct position. Gap
Not relevant
617 between the parts to be joined.
37 - Throat or weld height (h) too thin at MAG welded welds Not relevant

12. Quantity and Position of Weld Cuts

12.1 Linear or curved open welds
Weld length Number of sections and their Position
Length < 50mm 1 cut section at position of half way between start and stop
50mm ≤ Length ≤ 300mm 2 cut sections at position 1/3 and 2/3 of length between start and stop
Length > 300mm 3 cut sections at position ¼, ½ and ¾ of length between start and stop

12.2 Circular and non-circular closed welds

Circular weld per diameter Number of sections and their Position
Diameter < 30mm 1 cut section at position of half radian between start and stop
30mm ≤ Diameter ≤ 70mm 2 cut sections at position 1/3 and 2/3 of radian between start and stop
Diameter > 70mm 3 cut sections at position ¼, ½ and ¾ of radian between start and stop

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