Ens0211 PDF

Engineering Specifications ENS0211
CNH Arc Welding Quality
ECO REV CHANGES BY DATE

STD0425 A Released referral to Case Engrg Specification ES-B211 S Hile 4MAY04
35048667 B Release for Production, Replace referral to ES-B211 G Mussell 6AUG07
ISSUED BY ECO NO. NAME

GRM 6AUG07 35048667 CNH ARC WELDING QUALITY
APPROVED BY REV. PAGE CNH NUMBER
JLW 6AUG07 B 1 OF 37 86979030
THE INFORMATION HEREON IS THE CONFIDENTIAL AND PROPRIETARY PROPERTY OF CNH GLOBAL N.V. AND/OR
ITS SUBSIDIARIES OR DIVISIONS. ANY USE, EXCEPT THAT FOR WHICH IT MAY BE LOANED, IS PROHIBITED.
UNCONTROLLED COPY When Printed
TABLE OF CONTENTS
1. PURPOSE............................................................................................................................................................3
2. SCOPE.................................................................................................................................................................3
3. DEFINITIONS/ACRONYMS ................................................................................................................................4
3.1 DEFINITIONS ..................................................................................................................................................4
3.2 ACRONYMS ....................................................................................................................................................4
4. RELATED DOCUMENTS ....................................................................................................................................4
4.1 RELATED STANDARDS .................................................................................................................................4
4.2 REPLACED STANDARDS ..............................................................................................................................4
5. CLASSIFICATION OF WELDS AND ADJACENT SURFACES ........................................................................4
5.1 CATEGORY 1 - PRIMARY FUNCTION WELDS ............................................................................................5
5.2 CATEGORY 2 - COSMETIC WELDS AND ADJACENT SURFACES ............................................................5
5.3 CATEGORY 3 ALL OTHER WELDS AND (CLASS C) PROTECTIVE COATED SURFACES ...................6
5.4 WELD REQUIREMENTS - CATEGORY 1 WELDS ........................................................................................6
5.5 WELD AND SURFACE REQUIREMENTS CATEGORY 2 WELDS ............................................................8
5.6 WELD AND SURFACE REQUIREMENTS CATEGORY 3 WELDS ............................................................8
6. WORKMANSHIP REQUIREMENTS FOR ALL ARC WELDING PROCESSES ................................................8
7. FINISHED WELD QUALITY REQUIREMENTS................................................................................................10
8. INSPECTION AND TESTING............................................................................................................................18
9. REPAIR OF WELD DEFECTS ..........................................................................................................................18
9.1 WELD CRATERS ..........................................................................................................................................18
9.2 ARC STRIKES OUTSIDE THE WELD JOINT, INCOMPLETE FUSION, CRACKS, POROSITY AND
THREE DIMENSIONAL DEFECTS ........................................................................................................................18
9.3 UNACCEPTABLE UNDERCUT.....................................................................................................................19
9.4 OVERLAP ......................................................................................................................................................19
9.5 UNDERSIZE AND SHORT WELDS ..............................................................................................................19
9.6 OVERSIZE AND LONG WELDS ...................................................................................................................19
9.7 MISLOCATED HOLES ..................................................................................................................................19
9.8 MISLOCATED PARTS...................................................................................................................................20
9.9 EXCESS COPPER ........................................................................................................................................20
10. PROCESS CONTROL...................................................................................................................................20
11. IMPLEMENTATION AND LEGACY ISSUES ...............................................................................................20
APPENDIX 1...............................................................................................................................................................21
DETECTION AND REPAIR OF WELD DEFECTS ....................................................................................................21
WELD DEFECT: CRACKS ................................................................................................................................22
WELD DEFECT: WELD SPATTER...................................................................................................................23
WELD DEFECT: INCOMPLETE FUSION .........................................................................................................24
WELD DEFECT: IMPROPER FILLET WELD SIZE ..........................................................................................25
WELD DEFECT: CONCAVITY UNDERSIZE WELD .....................................................................................26
WELD DEFECT: CONVEXITY OVERSIZE WELD ........................................................................................27
WELD DEFECT: UNDERCUT ...........................................................................................................................28
WELD DEFECT: OVERLAP..............................................................................................................................29
WELD DEFECT: POROSITY.............................................................................................................................30
WELD DEFECT: UNFILLED CRATER .............................................................................................................31
WELD DEFECT: MISSING WELD ....................................................................................................................32
WELD DEFECT: MISLOCATED WELD............................................................................................................33
WELD DEFECT: MELT-THROUGH ..................................................................................................................34
WELD DEFECT: WELD DRIP (END-MELT) .....................................................................................................35
WELD DEFECT: ARC STRIKES.......................................................................................................................36
WELD DEFECT: LACK OF PENETRATION ....................................................................................................37
NAME REV. PAGE CNH NUMBER
CNH ARC WELDING QUALITY B 2 OF 37 86979030

CNH Arc Welding Quality

1. PURPOSE
The purpose of this document is to establish and maintain a weld quality level consistent with industry
standard practice at minimum cost, and maintain confidence that CNH product welds perform their
intended purpose.
2. SCOPE
This document contains workmanship and quality acceptance requirements for arc welding when
manufacturing CNH Agricultural or Construction Equipment components and shall be used by both
internal and external personnel engaged in designing, purchasing or manufacturing CNH products. Any
questions regarding interpretation of this specification should be referred to the applicable CNH Plant
Welding Engineer or to CNHs Chief Welding Engineer. In addition, personnel should refer to the
ENS02xx CNH Welding System Specifications and Standards series.
Drawings, standards, operational method sheets and other forms of instructions are used in the normal
course of conveying weld requirements to the welders. In all cases, the Product Engineering drawings
take precedence over all other forms of instructions - then the CNH Welding Specifications and
Standards apply, followed by any other documents. Where drawings and/or contracts specifically
reference ISO 5817 and the criteria of ISO 5817 for a specific weld quality attribute is more restrictive,
the more restrictive criteria shall be applied. Otherwise ENS0211 criteria shall be applied.
Specific practices and parameters used for production welding are to be based on those used to qualify
the process. This is accomplished through a qualified Welding Procedure Specification (WPS) based on
one or more Procedure Qualification Records in accordance with ENS0201. In the event a desirable
welding related practice is in conflict with this specification or ENS0201 - justification and approval of the
practice shall be pursued through CNHs Chief Welding Engineer with documented technical rationale.
Appendix 1 has been added to provide a greater understanding of the primary cause(s) of specific weld
defects and the actions that can help avoid them.
Welding personnel shall be qualified separately for each welding process and mode of transfer used in
production (i.e., separate welder qualification tests for SMAW, GMAW-spray, GMAW-Pulsed, GMAW-
globular, GMAW-Short Arc, FCAW, SAW, etc.). An effective training, qualification and process control
program is necessary to consistently apply these quality requirements. This program must include the
following elements as they apply to the processes used by each operations center (i.e. CNH Benson,
CNH Grand Island, CNH Zedelgem, Supplier XYZ, etc.) performing the work:
Process Safety
Basic Process Information
Welding Symbol & Drawing Interpretation
Review of Quality Specification Details
Hands-on Process Application and Qualification Testing
Process Control Procedure

3. DEFINITIONS/ACRONYMS
Welding Definitions and Acronyms used in this document, unless otherwise specified, are based on the
latest version of AWS A3.0. Weld symbols used to show welding and inspection requirements shall be in
accordance with CNH Drawing Standard DWGA130.
3.1 DEFINITIONS
Stops and Starts The start and stop locations of a single weld segment.
Welding Engineer Engineer with a welding technical degree responsible for supporting specific
welding/manufacturing operations.
3.2 ACRONYMS
AWSAmerican Welding Society

CECarbon Equivalent
DFSDeviation From Specification
WPSWelding Procedure Specification
4. RELATED DOCUMENTS
4.1 RELATED STANDARDS
AWS A3.0 (latest) - Standard Welding Terms and Definitions

AWS D14.3 (latest) - Specification for Welding Earthmoving, Construction and Agricultural Equipment
DWGA130 - Weldments - Symbols and Drawing Practices
ENPJ220 Deviation from Specification
ENS0201 CNH Arc Welding Procedure
ENS0301 - CNH Significant Characteristics
ISO 5817 Welding Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding
excluded) Quality levels for imperfections
MAT4125S Arc Welds, Sample Evaluation Requirements
4.2 REPLACED STANDARDS
Case ES-B211 Case Welding Quality Standard Arc Welding

ES 48.11 Zedelgem Standard on Arc Welding
FNHA-4-A-006.00 (86574453) New Holland Welding Quality Standard
5. CLASSIFICATION OF WELDS AND ADJACENT SURFACES
CNH divides weld joints into three categories. Category 1 welds are Primary Function Welds. Category
2 welds are Cosmetic Welds and Adjacent Surfaces. Category 3 welds comprise all Other Welds and
Protective Coated Surfaces. Category 3 welds must meet all of the requirements for Workmanship,
Quality, Repair and Process Control as defined in Sections 6-10. Category 2 welds are subdivided into
Appearance and Service Visible Surfaces, and they have several cosmetic requirements as described in
Paragraphs 5.2.1 and 5.2.2. Category 1 welds must meet all of the requirements of Category 3 welds,
and the additional requirements for fit-up gap, undercut, overlap etc. as described in Paragraph 5.4.

5.1 CATEGORY 1 - PRIMARY FUNCTION WELDS
In addition to any specific welds identified as Category 1 on a drawing, the following welds are to be
treated as Category 1 welds:
All hydraulic cylinder and fluid system welds

Fluid boundary welds
Exhaust system boundary welds
Primary structural connection welds
Primary machinery connection welds
Rollover Protection System (ROPS) structural welds
Falling Object Protection System (FOPS) structural welds
In addition to the above types of components or assemblies, Category 1 must be applied to all welds that
meet the following criteria:
failure would present a safety related concern

product must meet regulatory requirements
design safety factors are at or near their minimum limit of acceptability
failure would cause a major repair resulting in significant machine downtime
Some weld drawings with Category 1 welds, such as those listed in the above four bullet points, should
be classified as CNH1 or CNH2 drawings and the welds should display significant characteristic
designations. See ENS0301 for further details.
Welds on drawings that specify ISO 5817 level B or C requirements must meet Category 1 criteria.
5.2 CATEGORY 2 - COSMETIC WELDS AND ADJACENT SURFACES
Category 2 - Cosmetic Welds and adjacent surfaces are defined as those welds which must have
excellent appearance due to highly visible locations. These surfaces are classified into the following
three groups.
Class A - Appearance Surfaces
Class B - Service Visible Surfaces
Class C - Protective Coated Surfaces (requirements for Class C are listed within Category 3 welds)
5.2.1 Class A - Appearance Surfaces
Surfaces visible to an operator during a walk around or observed from the normal operating position of
the assembled unit.
All surfaces which are visible when walking around the finished product in a standing position.
All surfaces which are visible when sitting in the normal operating position.
All surfaces visible without opening any access doors, such as hood or battery compartment doors.

5.2.2 Class B - Service Visible Surfaces
Any surface which is visible during the performance of routine preventative maintenance.
Surfaces include but are not limited to the following: inside of battery compartment, behind grills, bottom
of frame rails, wheels and spacers, access ladders, upper portion of cab, inside of access doors,
driveline and powertrain linkage parts, steering linkage, etc., however, this does not include the bottom of
the product or components behind bolted access panels.
5.3 CATEGORY 3 ALL OTHER WELDS AND (CLASS C) PROTECTIVE COATED SURFACES
Any surface which is difficult to access once the product is completely assembled.
Surfaces located under the product or behind bolted access panels.
Surfaces include, but are not limited to inside frame rails, transmission cases, differential housings, axle
tubes, etc.
Any surface not classified as A or B.
Welds on drawings that specify ISO 5817 level D requirements must meet Category 3 criteria.
5.4 WELD REQUIREMENTS - CATEGORY 1 WELDS
This weld type has been identified on some earlier drawings as a CLASS A WELD. All Category 1 weld
applications require a representative sample be produced, evaluated and the inspection results be
properly documented. Documentation should be filed in the same manner as welding procedure
qualifications. All process/joint configuration changes (after initial successful sample completion) require
updated samples (etc.) unless otherwise approved by CNH welding engineering. Category 1 welds shall
meet all the requirements of Category 3 welds and the additional requirements specified below:
Cracks are not permitted in any part of the weld or base material. Representative sample
destructive testing (macrosection) is required to confirm tack welds incorporated into final welds
are properly fused and have no cracks below the surface.
Weld spatter is not permitted.
Incomplete (weld and sidewall) fusion (Lack of Fusion) is not permitted. See Figure 1
Improper Fillet Weld Size is not permitted. The transition angle between the weld surface and the
adjacent base or equivalent material surface at the toe of the weld shall be 135 degrees.
Concavity (Undersize weld) is not permitted.
Convexity (Oversize weld) is not permitted.
Visible undercut is not permitted.
Overlap is not permitted. See Figures 6 & 7
Visible porosity is not permitted in leak-tight welds and must be repaired.
Unfilled craters, crater pits and crater cracks are not permitted.
Missing weld is not permitted
Mislocated weld is not permitted
Melt-through (Burn-through) is not permitted.
Weld Drip (End-Melt) is not permitted
Arc strikes outside of the weld joint are not permitted.

Incomplete sidewall and root penetration (Lack of Penetration) is not permitted. See Figure 2
Excessive fit-up gaps shall not be welded over without corrective action. Fit-up gaps (root
opening) greater than the thinner dimension of the parts in the joint and openings larger than 3.0
mm are considered excessive. Excessive gaps that must be welded shall use a welding
procedure qualified with a root opening equal to or greater than the most severe condition and
have Engineering approval prior to welding.
All weld stops and starts must be consistent and fully fused. See Figure 3.
Stops and starts in high-stress areas (as marked on the drawing) must be avoided.
Backside weld shrinkage is not permitted with full penetration welds. See Figure 4
Root concavity shall meet the values listed in Table 4
Grinding to meet the requirements as listed in Paragraph 5.4, 5.5 and Sections 6 thru 10, is permitted but
results must be uniform with blended contours and no notch conditions.
FIGURE 1: Example of Incomplete Fusion
FIGURE 2: Example of Lack of Penetration
FIGURE 3: Example, Weld Stops and Starts
FIGURE 4: Example of Backside Weld Shrinkage

5.5 WELD AND SURFACE REQUIREMENTS CATEGORY 2 WELDS
This weld type has been identified on some earlier drawings as a CLASS B WELD. Category 2 welds
and surfaces shall meet all the requirements of Category 3 welds and surfaces plus the additional
requirements specified below:
Category 2A (Class A, Appearance Surface)
Weld spatter is not permitted.

Visible undercut is not permitted.
Overlap is not permitted. See Figures 6 & 7
Visible porosity is not permitted.
Melt-through (Burn-through) must not exceed 10% of weld size.
Weld Drip (End-Melt) is not permitted
Arc strikes outside of the weld joint are to be removed.
Visible grinding marks are not permitted.
Category 2B (Class B, Service Visible Surface)
Undercut depth not to exceed 0.25 mm for the entire length of the weld.
Melt-through (Burn-through) must be uniform and not exceed 20% of weld size.
Slight grinding marks are acceptable as long surface meets coated surface preparation criteria.
5.6 WELD AND SURFACE REQUIREMENTS CATEGORY 3 WELDS
Category 3 welds and surfaces shall meet all of the requirements as listed in Sections 6 thru 10 of this
specification.
6. WORKMANSHIP REQUIREMENTS FOR ALL ARC WELDING PROCESSES
6.1 The surface(s) to be welded shall be free of:
Moisture or snow
Paint
Scale (a black scaly coating of oxide forming on the surface of iron or steel)
Slag (a nonmetallic material resulting from the heating of flux and impurities in some welding and
brazing processes)
Rust
Grease and oil
Any foreign material which may adversely affect weld quality. If in doubt, verify results with
representative sample tests.
Welding in-way-of any of the above is permitted only with a welding procedure that has been qualified
under worst-case conditions and is approved by the CNH Plant Welding Engineer or CNHs Chief
Welding Engineer.
6.2 Laminations in the steel are not allowed.

6.3 No welding shall be performed within 12 mm of paint or any other heavy contamination.
Deviation requires procedure qualification and prior, written approval from CNHs Chief Welding
Engineer.
6.4 Tack welds should not be seen when welded over as required on the finished part. Tack welds
used for manufacturing purposes must be inspected first, and then incorporated into the final weld. Tack
welds with any signs of cracks shall be removed and rewelded before final welding.
6.5 Welding over cracks in previously deposited weld metal or cracks in the base metal is prohibited.
All cracks shall be removed and repaired in accordance with Paragraph 9.2.
6.6 Slugging or the general use of filler sections to correct a weld joint gap condition is prohibited.
6.7 Caulking of welds (peening or sealing defects) is prohibited unless specified on the drawing.
6.8 Welding shall not be performed when the weldment is exposed to high winds, drafts, or moisture.
Winds or drafts must be limited to avoid affecting the gas shielding. Where wind and/or drafts exist at the
weld joint, demonstration of satisfactory weld quality shall be performed with a representative Weld
Break Test under worst-case conditions.
6.9 Welding shall not be performed when the temperature of the part(s) is lower than 10C (50F).
When other qualified preheat limits exist, they will be specified in the WPS. Welding shall not be
performed when the temperature of the part(s), within 150 mm of the weld joint, is lower than the
minimum temperature specified by the WPS.
6.10 Do not weld on plated material without special ventilation or instructions.
6.11 Weld Drip (End-Melt) must be avoided.
6.12 Avoid arc strikes outside of the weld joint.
6.13 Complete joint penetration groove welds that are welded without any backing must have the root
of the first pass gouged or ground out to sound metal before depositing metal from the second side. An
exception to this is the use of a qualified and approved WPS for the application.
6.14 Welding (including tack welding) of or to carbon steels, with a carbon equivalent (CE) level of
0.40 or greater requires preheat. This requirement may be waived when an alternate procedure is
qualified and approved. The minimum preheat and procedure qualification requirements are found in
ENS0201. The IIW (International Institute of Welding) formula for CE is:
CE = %C + %Mn/6 + (Cu+Ni)/15 + (Cr+Mo+V)/5
6.15 Welding on or to case hardened and carburized surface is not permitted. Any deviation will
require a qualified WPS, approved by the CNH Chief Welding Engineer.
6.16 Temporary copper or ceramic backing and weld end tabs are permitted when qualified. However,
any inclusions must be treated as a volumetric imperfection and remedied as such.

7. FINISHED WELD QUALITY REQUIREMENTS
7.1 Cracks are not permitted.
7.2 For all types of arc welds, weld craters shall be filled to at least 85% of the full cross section of the
weld (rounded to the nearest 0.5 mm) as shown in Table 1. Cracks, craters, crater pits, crater cracks,
porosity and solidification cavities (pinholes) are not allowed.
TABLE 1: Weld Crater Minimum Fill Requirements, Based on Weld Throat Size
Weld Throat Size (a) Minimum Crater Fill Equivalent Fillet Weld Leg Size (z)
2 mm 1.5 mm 3 mm
3 mm 2.5 mm 4 mm
4 mm 3.5 mm 6 mm
5 mm 4.5 mm 7 mm
6 mm 5.0 mm 8 mm
7 mm 6.0 mm 10 mm
8 mm 7.0 mm 11 mm
9 mm 7.5 mm 13 mm
10 mm 8.5 mm 14 mm
11 mm 9.5 mm 16 mm
12 mm 10.0 mm 17 mm
13 mm 11.0 mm 18 mm
14 mm 12.0 mm 20 mm
15 mm 13.0 mm 21 mm
16 mm 13.5 mm 23 mm
17 mm 14.5 mm 24 mm
18 mm 15.5 mm 25 mm
19 mm 16.0 mm 27 mm
20 mm 17.0 mm 28 mm
21 mm 18.0 mm 30 mm
22 mm 18.5 mm 31 mm
23 mm 19.5 mm 33 mm
24 mm 20.5 mm 34 mm
25 mm 21.0 mm 35 mm
7.3 The undercut limits for a weld is based on the material thickness of the thinnest piece being
joined as shown in Table 2. When the thinnest piece is more than 6 mm thick, an undercut up to 1.6 mm
deep is permissible for up to a 25 mm continuous length in any 300 mm length of weld. The cumulative
length of this deeper undercut shall not exceed 38 mm.
TABLE 2: Maximum Weld Undercut Limits, Based on Material Thickness
Material Thickness (t) Maximum Undercut

6 mm 10% of Material Thickness, entire length of weld
> 6 mm 0.8 mm entire length of weld plus allowance per Paragraph 7.3

7.4 Penetration shall be to the depth of the joint preparation minimum or as specified on the drawing.
Penetration can be confirmed by performing a weld break test on a representative sample produced
under production welding conditions. The test sample shall be produced with the lowest amperage
setting used for the production weld. A target penetration value of 0.5 mm beyond the required
dimension is suggested to establish a more robust welding procedure.
7.5 Weld stops, starts and tie-in areas must be consistent and fully fused. See Figure 3.
7.6 Incomplete fusion, slag inclusion and fissure (planar-type discontinuity) limits for weld cross-
sections, rounded to the closest 0.5 mm, are as shown in Table 3. This applies to any type of arc weld
and the accumulation of discontinuities applies to any cross-section. The sum of these discontinuities
shall not exceed 10% of the weld length within any 180 mm length of weld - example: 18 mm in 180 mm
length of weld, 10 mm in a weld that is 100 mm long. More stringent criteria shall apply when specified
on or referenced on the drawing. A target weld fusion level of 0.5 mm beyond the weld joint (original)
boundary is suggested (when developing or evaluation procedures) to demonstrate a more robust
procedure.
TABLE 3: Planar-type Discontinuity Limits, Based on Weld Throat Size
Weld Throat Size (a) Maximum Size of Discontinuity (25%) Equivalent Fillet Weld Leg Size (z)
2 mm 0.5 mm 3 mm
3 mm 1.0 mm 4 mm
4 mm 1.0 mm 6 mm
5 mm 1.0 mm 7 mm
6 mm 1.5 mm 8 mm
7 mm 2.0 mm 10 mm
8 mm 2.0 mm 11 mm
9 mm 2.0 mm 13 mm
10 mm 2.5 mm 14 mm
11 mm 2.5 mm 16 mm
12 mm 3.0 mm 17 mm
13 mm 3.0 mm 18 mm
14 mm 3.5 mm 20 mm
15 mm 3.5 mm 21 mm
16 mm 4.0 mm 23 mm
17 mm 4.0 mm 24 mm
18 mm 4.5 mm 25 mm
19 mm 4.5 mm 27 mm
20 mm 5.0 mm 28 mm
21 mm 5.0 mm 30 mm
22 mm 5.5 mm 31 mm
23 mm 5.5 mm 33 mm
24 mm 6.0 mm 34 mm
25 mm 6.0 mm 35 mm

7.7 Three dimensional discontinuities are permissible in discontinuous distribution, provided the
largest dimension of any single discontinuity does not exceed the following:
20% of the weld size or joint penetration for welds 10 mm.

15% of the weld size or joint penetration for welds > 10 mm.
The sum total of the largest dimensions shall not exceed 10 mm in any 25 mm length of weld, nor 10% of
the weld length. More stringent criteria shall apply when specified on or referenced on the drawing.
Root concavity shall be treated as a three dimensional discontinuity and the same criteria will be applied.
TABLE 4: Root Concavity Discontinuity Limits, Based on Weld Throat Size

Weld Throat Size (a) Category 1 Welds h ( ) Equivalent Fillet Weld Leg Size (z)
2.0 mm 0.0 mm 3 mm
3.0 mm 0.0 mm 4 mm
4.0 mm 0.2 mm 6 mm
5.0 mm 0.3 mm 7 mm
6.0 mm 0.3 mm 8 mm
7.0 mm 0.4 mm 10 mm
8.0 mm 0.4 mm 11 mm
9.0 mm 0.5 mm 13 mm
10.0 mm 0.5 mm 14 mm
11.0 mm 0.5 mm 16 mm
12.0 mm 0.5 mm 17 mm
13.0 mm 0.5 mm 18 mm
14.0 mm 0.5 mm 20 mm
15.0 mm 0.5 mm 21 mm
16.0 mm 0.5 mm 23 mm
17.0 mm 0.5 mm 24 mm
18.0 mm 0.5 mm 25 mm
19.0 mm 0.5 mm 27 mm
20.0 mm 0.5 mm 28 mm
21.0 mm 0.5 mm 30 mm
22.0 mm 0.5 mm 31 mm
23.0 mm 0.5 mm 33 mm
24.0 mm 0.5 mm 34 mm
25.0 mm 0.5 mm 35 mm

7.8 Fillet Welds
All fillet weld locations and sizes are to conform to the dimensions and requirements specified on the
engineering drawing.
7.8.1 Fillet weld size tolerances are as specified in Table 5. Weld sizes may be greater due to
compensation for excessive root opening as described in Paragraph 7.8.4. Fillet size may vary within the
stated tolerances, except that the combined length of weld at the minus tolerance shall not exceed 10%
of the total weld length. The average size for the overall length of any weld shall be equal-to or greater-
than the size specified on the drawing for that weld.
7.8.2 Fillet Weld Size Measurements
Measurement of every fillet weld is not required. Measurements must be done with enough frequency to
demonstrate compliance with the engineering drawing and this specification.
a) Fillet welds < 75 mm long
The fillet size is measured at least once. The measurement must include the apparent minimum size
weld area.
b) For welds 75 mm and 230 mm
The fillet size is measured randomly in at least two places, with a minimum separation of 35 mm between
locations. Measurement must include the apparent minimum size weld area as one of the locations.
c) For welds > 230 mm
The fillet size is measured randomly in at least three places, with a minimum of 75 mm of separation
between locations. Measurement must include the apparent minimum size weld area as one of the
locations.
TABLE 5: Fillet Weld Size Tolerance (See Note 1)
Fillet Weld Specified by Leg Size (z) Fillet Weld Specified by Throat Size (a)
Weld Size Leg Size (z) Tolerance Weld Size Throat Size (a) Tolerance
10 mm +3.0 mm -0.8 mm (10% Length Max) < 7 mm +2.0 mm -0.5 mm (10% Length Max)
(See Note 2) (See Note 2)
> 10 mm +3.0 mm -1.6 mm (10% Length Max) 7 mm +2.0 mm -1.0 mm (10% Length Max)
(See Note 3) (See Note 3)
Note 1: The combined length of weld at the minus tolerance shall not exceed 10% of the total weld length and the
average weld size shall be at or above the size specified on the drawing.
Note 2: If the full length(s) of undersize weld ( 10% total weld length) is larger than the next lowest 1 mm size weld
gage as measured by means of a standard gage, then it is acceptable for minimum size.
Note 3: If the full length(s) of undersize weld ( 10% total weld length) is larger than the gage size 2 mm below the
specified size, then it is acceptable for minimum size.

7.8.3 The maximum size fillet weld bead that may be deposited in one pass (single pass or multi-pass
weld) is shown in Table 6. Greater limits are allowed through the development and consistent
satisfactory application of a qualified and approved WPS. Each welder or operator producing welds
larger than Table 6 shall demonstrate satisfactory weld quality through the completion of a representative
weld sample appropriate for each application. Increased weld leg size required to compensate for
excessive root opening also requires additional weld passes that may be beyond the limits of Table 6, if
so, an alternate qualified and approved WPS is required.
TABLE 6: Maximum Single Pass Fillet Size Requirements
Weld Process and Maximum Single Pass Fillet Size Dimensions Leg or Throat
Weld Position SMAW GMAW (See Note 1) FCAW,GMAW-P SAW
Leg (z) Throat (a) Leg (z) Throat (a) Leg (z) Throat (a) Leg (z) Throat (a)
Flat (1F) 10 mm 7 mm 10 mm 7 mm 13 mm 9 mm 13 mm 9 mm
Horizontal (2F) 8 mm 6 mm 8 mm 6 mm 10 mm 7 mm 8 mm 6 mm
Vertical-Up (3F) Not Not

13 mm 9 mm 10 mm 7 mm 13 mm 9 mm
(See Note 2) Applicable Applicable
Not Not
Overhead (4F) 8 mm 6 mm 6 mm 4 mm 8 mm 6 mm
Applicable Applicable
Note 1: GMAW (other than pulsed transfer)

Note 2: Vertical-Down progression requires approval from the CNH Chief Welding Engineer
7.8.4 If fillet weld root openings greater than those specified on the drawing are continually
encountered, the following procedure shall be observed:
For root openings greater than 1.5 mm but less than 3.0 mm the fillet leg size must be increased by the
size of the gap to ensure the desired weld throat is maintained, as shown in Figure 5. For root openings
greater than 3.0 mm, a special welding procedure is required to handle each individual case. The
applicable CNH Plant Welding Engineer and Product Engineering shall define the required corrective
action.
Note that increased weld sizes are

required to compensate for
excessive root opening and may
require additional welding passes.
FIGURE 5: Compensation for Excess Root Opening of Fillet Welded Parts

7.8.5 Leg sizes for a given fillet weld shall be as listed in Table 7 unless otherwise specified on the
drawing.
TABLE 7: Unequal Fillet Weld Leg Size Dimension
Maximum h (z1 z2) Maximum h (z1 z2)

Minimum leg size (z2) Minimum leg size (z2)
All weld categories All weld categories
3 mm 2.0 mm 15 mm 3.0 mm
4 mm 2.0 mm 16 mm 3.0 mm
5 mm 2.0 mm 17 mm 3.0 mm
6 mm 2.0 mm 18 mm 3.0 mm
7 mm 2.0 mm 19 mm 3.0 mm
8 mm 2.0 mm 20 mm 4.0 mm
9 mm 3.0 mm 21 mm 4.0 mm
10 mm 3.0 mm 22 mm 4.0 mm
11 mm 3.0 mm 23 mm 4.0 mm
12 mm 3.0 mm 24 mm 4.0 mm
13 mm 3.0 mm 25 mm 4.0 mm
14 mm 3.0 mm
FIGURE 6: Desirable, Acceptable and Unacceptable Fillet Weld Profiles

7.8.6 Fillet weld profiles should be flat or have only slight reinforcement and comply with values listed in
Table 8, unless otherwise specified on the drawing. See Figure 6.
TABLE 8: Maximum Convexity (h)

Minimum leg size (z) Minimum throat size (a) h ( ) Category 1 Welds h ( ) Category 2 & 3 Welds
3 mm 2.1 mm 1.0 mm 1.6 mm
4 mm 2.8 mm 1.0 mm 1.6 mm
5 mm 3.5 mm 1.0 mm 1.6 mm
6 mm 4.2 mm 2.0 mm 3 mm
7 mm 4.9 mm 2.0 mm 3 mm
8 mm 5.7 mm 2.0 mm 3 mm
9 mm 6.4 mm 2.0 mm 3 mm
10 mm 7.1 mm 2.0 mm 3 mm
11 mm 7.8 mm 2.0 mm 3 mm
12 mm 8.5 mm 2.0 mm 3 mm
13 mm 9.2 mm 2.0 mm 3 mm
14 mm 9.9 mm 3.0 mm 3 mm
15 mm 10.6 mm 3.0 mm 3 mm
16 mm 11.3 mm 3.0 mm 3 mm
17 mm 12.0 mm 3.0 mm 3 mm
18 mm 12.7 mm 3.0 mm 5 mm
7.9 Groove Welds
All groove weld locations, lengths and sizes are to conform to the dimensions and requirements specified
on the engineering drawing.
7.9.1 Groove welds should be made with minimum reinforcement unless otherwise specified on the
drawing. Reinforcement shall not exceed 3 mm and shall be repaired if determined unacceptable per
Figure 7.
7.9.2 Flare-V-Groove Welds and Flare-Bevel-Groove Welds shall be filled to the top of the groove
unless otherwise specified on the drawing by a weld size or a weld face-width designation.

FIGURE 7: Acceptable and Unacceptable Groove Weld Profiles
7.10 Weld overlap (cold-lap) shall not exceed 0.8 mm beyond the fusion line of the weld in any cross-
section, as shown in Figure 6 and Figure 7, when measured with a 0.025 mm feeler gage before
painting. The length affected by overlap shall total no more than 12 mm in 300 mm of continuous weld; 6
mm in any weld having a specified length of 150 mm or less.
7.11 Porosity
7.11.1 For multi-pass welds, in-process porosity exceeding the limits of Paragraph 7.11.2 shall be
completely removed before welding over existing passes.
7.11.2 In all other cases, welds shall not exhibit surface porosity exceeding 2.5 mm in any dimension
and shall not have more than one spot of surface porosity in any 100 mm of weld length.
7.12 The separation between faying surfaces of lap joints shall be 1.5 mm when either part is 5
mm thick and shall be 3 mm when either part is > 5 mm thick. When the separation between faying
surfaces of lap joints is > 3 mm a qualified and approved WPS is required. The qualification test
assembly shall represent worst-case production conditions.
7.13 Weld Length and Spacing Tolerance
7.13.1 All weld lengths and numbers of welds are to conform to the dimensions and requirements
specified on the engineering drawing. Intermittent Welds must have weld segments (anchor welds) at
each end of the joint unless otherwise specified on the drawing. Allowable tolerance is as follows:
Weld Length (mm) Tolerance (mm)

25 +12 / -0
> 25 < 100 +25 / -0
100 +25 / -6

7.13.2 Weld spacing (distance between segments) must be equal to or less than (and may not exceed)
the distance specified on the engineering drawing.
7.14 Excessive weld spatter must be removed. Excessive weld spatter is defined as more than 10
particles per 1000 cm ( ten particles per ft). All remaining particles must be firmly attached and the
surface shall meet coated surface preparation criteria. All weld spatters must be removed from mounting
surfaces. These surfaces are specified on the engineering drawing.
7.15 Sharp edges are prohibited and must be removed.
7.16 Whiskers (unfused wire ends), stub ends, lengths of wire hanging on the weldment and weld
metal runoff are prohibited and must be removed.
8. INSPECTION AND TESTING
Qualified personnel (AWS Certified Welding Inspector or equivalent) shall use appropriate inspection and
quality control methods to ensure compliance with the requirements of this specification. Welds must be
cleaned prior to final weld inspection. Nondestructive evaluation methods may be necessary to verify
conformance with requirements. Ultrasonic Testing (UT) is acceptable when performed by qualified UT
operators and using qualified procedures that demonstrate the ability to detect defects under worst case
conditions and within the acceptance criteria of this specification.
CNH MAT4125S Arc Welds, Sample Evaluation Requirements provides the minimum requirements for
metallurgical evaluation of arc welds and must be used when specified. When specified and the
weldment is being relocated from one manufacturing source to another, a part sample from the new
source shall be evaluated in accordance with MAT4125S.
9. REPAIR OF WELD DEFECTS
All repair areas shall be inspected. Repair welding shall be performed to establish conformance with the
requirements of the component drawing and this specification. All repair areas shall be re-inspected to
the original requirements upon completion of the repair. General requirements for repair welding are as
follows:
9.1 WELD CRATERS
Add additional weld metal to craters that are less than 85% of the full cross-section of the weld size.
9.2 ARC STRIKES OUTSIDE THE WELD JOINT, INCOMPLETE FUSION, CRACKS, POROSITY
AND THREE DIMENSIONAL DEFECTS
These defects shall be removed by a suitable means of excavation, such as Air Carbon Arc Gouging,
Plasma Arc Gouging, or by grinding (depending on the length and depth of the defect) and repair weld
added.
Crack removal shall be verified using Liquid Penetrant Testing or Magnetic Particle Testing before re-
welding.

On leak-tight welds, repairs of small areas of porosity and incomplete fusion may be made by using
GTAW with a qualified GTAW Repair WPS and qualified GTAW Repair Welder. Other higher deposition
rate processes (GMAW or FCAW) may also be used.
9.3 UNACCEPTABLE UNDERCUT
Filling in the undercut with weld metal usually repairs this defect. Depending on the geometry and visual
criteria, it may be necessary to grind out some of the weld and re-weld the last pass or passes.
9.4 OVERLAP
Unacceptable overlap must be removed by a suitable means such as grinding or Air Carbon Arc Cutting.
Additional weld metal may be needed after removal of the overlap in order to restore the proper size and
shape of the weld.
9.5 UNDERSIZE AND SHORT WELDS
Undersize and short welds shall have additional weld metal deposited to bring them up to the proper size
and/or length.
9.6 OVERSIZE AND LONG WELDS
Oversize and long welds should only be ground or gouged out when they do not meet other minimum
quality requirements or will cause interference with mating or adjacent parts.
9.7 MISLOCATED HOLES
Weld repair of mislocated holes requires a qualified welder and a qualified procedure, and must be
approved by Product Engineering using a deviation approval request. Large holes will require a filler
plate insert and backgouging to sound metal before welding the second side of the insert. See Figure 8.
Figure 8a: Original Preparation Figure 8b: 1st Side Welded,

2nd Side Backgouged
Weld repair for a small hole will require temporary or permanent backing. Backgouging to sound metal is
required before welding the second side of the hole repair location when temporary backing is approved.
When repairing a small hole and the material thickness is greater than 3 mm, each thru hole must be
chamfered at an angle that is 20 to a depth of 3 mm remaining before repair weld. See Figure 9.
Where material does not cover the backside of the hole, the 1st side weld shall be back gouged to sound
metal and the 2nd side weld deposited. Remove any reinforcement on either side.

FIGURE 9: Weld Repair for Small Holes
9.8 MISLOCATED PARTS
Mislocated parts must be removed and/or replaced using specific instructions or weld repair procedure
provided by the applicable CNH Plant Welding Engineer.
9.9 EXCESS COPPER
Copper requirements are defined in Paragraph 6.15.
10. PROCESS CONTROL
All producers of CNH arc welded components (internal and external) must have a process control system
that demonstrates conformance to this specification.
11. IMPLEMENTATION AND LEGACY ISSUES
All drawings of CNH arc welded components must identify the appropriate weld specifications, standards
and weld category 1 or 2 in addition to displaying complete weld symbols. All drawings, of CNH arc
welded components, released or revised after the issue date of this specification must list ENS0211 in
the Applicable Standards Block or display the following note on the body of the drawing.
Weld Quality shall meet CNH Engineering Specification ENS0211 (86979030).
Upon release this document supercedes the following standards and as a result CNH Product
Engineering must approve the use of any of the superceded standards in lieu of ENS0211.
The superceded standards are:

Case ES-B211 Case Welding Quality Standard Arc Welding
ES 48.11 Zedelgem Standard on Arc Welding
FNHA-4-A-006.00 (86574453) New Holland Welding Quality Standard
Unless otherwise specified by CNH Product Engineering, the following weld types from Case ES-B211
will be required to meet ENS0211 specifications:
CLASS A welds must meet Category 1 weld requirements listed in paragraph 5.4
CLASS B welds must meet Category 2A weld and surface requirements listed in paragraph 5.5
CLASS C welds must meet Category 3 weld and surface requirements listed in paragraph 5.6

APPENDIX 1
DETECTION AND REPAIR OF WELD DEFECTS
This appendix includes a brief description of defects which may be encountered in arc welding along with
suggestions for detection, repair and avoidance.
The following defects are covered:
Cracks
Weld Spatter
Incomplete Fusion
Improper Fillet Weld Size
Concavity Undersize Weld
Convexity Oversize Weld
Undercut
Overlap
Porosity
Unfilled Crater
Missing Weld
Mislocated Weld
Melt-through
Weld Drip (End-Melt)
Arc Strikes
Lack of Penetration
In general, proper control of any welding process will depend heavily on a consistent secondary electrical
circuit (work lead or welding gun, all connections, contact tip, ground lead, clamps, as well as contact
between component parts and tooling or the work table). Poor connections will cause resistance to
increase and use energy meant for the welding arc. This defeats the purpose of developing and using
optimum parameters, and significantly effects weld quality. Rotating fixtures must use a suitable rotary
ground. Grounding through slides and bearings is unacceptable. Welding equipment manufacturer
maintenance guidelines must be followed and fixture/tool contact surfaces must be kept clean, free of
rust and excess debris so electrical current flow is properly maintained.

WELD DEFECT: CRACKS

METHODS OF DETECTION: Magnetic Particle Testing (MT), Penetrant Testing (PT),
Radiographic Testing (RT), Visual Testing (VT) or
Ultrasonic Testing (UT)
DEFECT AVOIDANCE MEASURES:
Qualified procedures
Trained, tested and qualified welders
Cracks are the most serious types of weld

defects since they are likely to grow under
tensile or cyclic (fatigue) loading. Cracks
must be completely removed by gouging
or grinding prior to further welding or
repair welding.
Crack removal must be confirmed with

dye penetrant or magnetic particle
(ferrous material) inspection. It should be
noted that if the weld is completely ground
out, the original weld joint may appear as
a linear indication. This can occur with
fillet welds on lap, tee, and corner joints;
and with partial penetration groove welds.
The depth of the prepared groove may
have to be measured to confirm the
defect has been completely removed.
REPAIR:
Normally, crack removal sites are repairable with the same qualified welding procedure used for manual
(GMAW) production welding. Repair procedures and welders must be qualified for the position in which
repair welds are to be made.

WELD DEFECT: WELD SPATTER

METHODS OF DETECTION: Visual Testing (VT)
Initial, frequent checks
Weld spatter is often an indication that one or more factors

involved in making a weld is outside the proper control
limits. These factors include shielding gas type and flow
rate, excess air currents at the arc, arc voltage and current
(wire feed speed) as well as operator technique (skill
level). Weld spatter also affects assembly operations,
coating preparation operations and coating performance
(when not removed) as well as customer perception of the
overall quality of the product. When considerable weld
spatter occurs, (that is consistently getting amounts
greater than the allowable limit) with the use of any
process, verify weld quality by either sectioning or
conducting a break test on a representative sample
weldment.
REPAIR:
Scrape or grind the weld spatter from the surface as required to meet allowable limits.

WELD DEFECT: INCOMPLETE FUSION

METHODS OF DETECTION: Magnetic Particle Testing (MT), Penetrant Testing (PT),
Radiographic Testing (RT), Visual Testing (VT) or
Ultrasonic Testing (UT)
Incomplete fusion (also called lack-of-fusion) is a serious problem, second only to cracking in its capacity
to render a weldment unfit for service.
For weldments which are only visually inspected, incomplete fusion may be treated similar to overlap.
There is a visual cue that something is wrong with the weld; usually it is an obvious line of poor or
missing fusion along one edge of a weld bead. This may be accompanied by a high and ropey looking
bead profile; or an irregular bead which shows improper control of torch angle or travel speed.
Fusion problems deeper into the weld may only be found by means of x-rays, ultrasonic testing or by
conducting a break test on a representative sample. These methods, and repairs to defects found by
these methods, are beyond the scope of this document. If such problems are suspected, engineering
evaluation must be sought.
REPAIR:
Grind the affected area to clean, shiny metal. Be sure to remove all non-metallic inclusions such as slag
and flux that may be embedded in the weld. Do not attempt to burn out by welding over defects which
remain in the weld. After grinding out the affected area, complete the repair using an approved welding
procedure.

WELD DEFECT: IMPROPER FILLET WELD SIZE

METHODS OF DETECTION: Visual testing with gage
Initial, frequent checks with a proper gage
REPAIR:
Unequal fillet weld size may be corrected by adding an additional weld pass or passes to build the weld
up to the required size. Prior to adding another pass, the initial weld should be carefully examined to
determine that there is thorough fusion to the base metal and weld metal for the entire weld. Preparation
(gouging, grinding, etc.) to clear lack-of-fusion or other defects must be accomplished prior to adding
additional weld metal.

WELD DEFECT: CONCAVITY UNDERSIZE WELD

Fillet Welds
Groove Welds
REPAIR:
Undersize weld concavity may be corrected by adding an additional weld pass or passes to build the
weld up to the required size. Prior to welding over the affected area, all other defects must be removed.

WELD DEFECT: CONVEXITY OVERSIZE WELD

Fillet Welds
Groove Welds
REPAIR:
Oversize weld convexity should be removed by grinding. The objection to excessive convexity is not the
height of the center of the weld bead, but the stress concentration resulting from the normally sharper
than usual angle at the toes of the weld. For this reason, simply grinding off the excessive crown height
of the weld may not be sufficient. The toes of the weld should be blended in with the base metal and
care must be exercised so as not to gouge the base metal.

WELD DEFECT: UNDERCUT

When undercut is observed, first check the specification requirements. ENS0211 has various limitations
on undercut, depending on whether the weld in question is Category 1, 2 or 3.
REPAIR:
If the observed undercut exceeds the specified limit, repair as follows:
Adding another weld pass may repair a severe undercut. This technique would be appropriate for multi-
pass welds, where the additional pass would blend smoothly with the other passes.
A shallow undercut on a single pass weld may require the removal by grinding of a significant portion of
the original weld so that the repair weld will blend smoothly with the base metal and the remaining weld
metal.

WELD DEFECT: OVERLAP

METHODS OF DETECTION: Visual testing with feeler gage
Initial, frequent checks with a feeler gage
Overlap may be present in various forms. It may start as an excessive convexity; proceed to a rolled
bead or rollover condition; and end up as a cold lap or lack-of-fusion defect. In many cases there will
be an undercut on one edge of the weld bead and an overlap on the other. This usually happens when
the torch angle or torch position is out of proper alignment and the primary welding parameters need
further adjustment.
With overlap, it is difficult to determine how far along

the weld fusion line an apparent lack-of-fusion
condition extends. ENS0211 prohibits overlap on
Category 1 and Category 2 (Class A) welds; and
limits it to 0.8 mm beyond the fusion line of other
welds in any cross section. If the rolled edge is high
enough, and fusion can be seen underneath the
edge within 0.8 mm, the weld is acceptable provided
it is not a Category 1 or Category 2 (Class A) weld.
In questionable situations, additional evaluation is
necessary to confirm the condition is within
specification allowances. If in doubt, the condition
must be corrected by grinding and, if necessary,
weld repair.
REPAIR:
Note that the weld profile requirements must also be met. Care must be exercised not to grind into the
unaffected base metal adjacent to the weld. Only weld metal should be ground away. If necessary, weld
metal may be ground out in an amount sufficient to prepare the affected area for another weld pass.
Do not attempt to correct an overlap condition just by re-fusing the overlap back into the weld with
GTAW. This technique may produce a weld that looks acceptable, but may simply cover up a serious
lack-of-fusion problem. If GTAW is used; first, qualify a suitable procedure, grind the affected area back
to sound metal; then add filler metal as required to achieve the specified weld size.

WELD DEFECT: POROSITY

When porosity is encountered, first check the

requirements of the quality specification. ENS0211 has
various limitations on porosity, depending on whether the
weld in question is Category 1, 2 or 3.
If the observed porosity exceeds the specified limit,

remove and replace the affected portion of the weld.
REPAIR:
A small, isolated porous area may be removed with a die

grinder. Larger areas of porosity may be ground out with
an air powered depressed-center wheel grinder. In instances of extreme porosity extending for a
considerable distance (300 mm or more), Air Carbon Arc Cutting followed by grinding may be the
quickest way to remove the affected weld. Air Carbon Arc Cutting may also be required to remove
porosity in corners and other areas inaccessible to a grinding wheel. In some cases, a small indication of
porosity on the surface of a weld may give way to extensive Swiss cheese porosity underneath.
After the weld porosity is removed, visually inspect the prepared groove. All evidence of porosity shall be
removed. The prepared groove shall be ground to clean, shiny metal. The ends of the prepared groove
shall taper smoothly up to unaffected weld metal or base metal. Paint shall be removed from all areas
within 12 mm of the affected weld area.
Replace the defective weld using an approved welding procedure.

WELD DEFECT: UNFILLED CRATER

Initial, frequent checks with a suitable gage
ENS0211 requires weld craters be filled to at least 85% of

the full cross section of the weld. Table 1 provides
minimum crater fill dimensions for various weld sizes.
Actual size may be determined with an adjustable weld
gauge, similar to that shown here.
Weld craters should be carefully examined for evidence of

cracking. If crater cracks are found, they must be
completely removed by grinding or gouging prior to re-
welding.
REPAIR:
When it becomes necessary to build up a weld crater, care must be exercised to assure complete fusion.
GTAW is often preferred for very small Category 2 (Class A) weld areas, as it allows independent control
of welding heat and filler metal, and must be used with a qualified procedure. If GMAW is used, the weld
must be sufficiently large so as to achieve complete fusion.

WELD DEFECT: MISSING WELD

Initial, frequent checks against the drawing
Visual work instructions
Weld joint check list
REPAIR:
Remove paint as required from the affected area. Weld in accordance with an approved welding
procedure. Difficulty may arise if the weld is in a different position (vertical or overhead) than would be
encountered in production. Accessibility may be poor if additional parts have been installed near the
weld joint. Special techniques may be required, such as SMAW (stick electrode) or GMAW with an
extended contact tip and nozzle. If the operating conditions are significantly different from the normal
production conditions, the repair procedure and welder must be qualified for the position in which repair
welds are to be made.

WELD DEFECT: MISLOCATED WELD

Initial, frequent checks against the drawing
Visual work instructions
Weld joint location print
REPAIR:
A mislocated weld may be treated much the same as a missing weld. The required weld must be made
in the specified location.
Under certain circumstances, a DFS (Deviation From Specification) may be requested from Product
Engineering to allow the mislocated weld to remain where it is. If this is not possible the weld must be
removed. One reason for removal might be because of interference with subsequent assembly. It
should be noted that partial removal of a weld could lead to cracking of the remaining portion of the weld
under loading. Sometimes welds are specifically prohibited in certain high stress areas. Welds
inadvertently placed in such areas must be approved by Product Engineering.

WELD DEFECT: MELT-THROUGH

Melt-through may be defined as any undesirable or uncontrolled penetration of the weld through the joint.
Melt through may cause interference with moving parts in certain key areas or have a negative affect on
component life.
REPAIR:
If accessible, melt-through may be removed by grinding flush with surrounding base material. If undercut
occurs on the back face of the weld, repair as required for undercut listed elsewhere in this document.
In instances where repair is not practical, and interference with assembly is not a problem, a DFS
(Deviation From Specification) must be requested from Product Engineering.

WELD DEFECT: WELD DRIP (END-MELT)

In welding operations, weld drip (end-melt) is

often caused by the welding gun or torch
moving past the end of the joint with the weld
power still ON and/or the use of parameters
not suited for the application.
REPAIR:
Weld drip (end-melt) must be removed by chipping or gouging the excess metal to the extent possible;
then grinding the end of the weld flush with surrounding material. In certain instances, grinding or Air
Carbon Arc Cutting may be required to remove other defects caused by this condition, and repair welding
of the end may be necessary.

WELD DEFECT: ARC STRIKES

Arc strikes may be either a cosmetic or a

performance related defect, depending on their
location and the type of material upon which
they occur.
Examples of cosmetic defects would be arc

strikes on readily weldable steels in non-key
areas of a structure.
Arc strikes are considered a significant issue if

found on steels with higher hardenability
(carbon equivalent or CE above 0.40), high
strength steels or where it would degrade the
operation of moving components. Examples
include structures made from QT (quench &
temper) steel, ductile iron, spring steel, or
hydraulic cylinder rods.
REPAIR:
Arc strikes in cosmetic areas may be blended smooth with surrounding material by sanding or buffing. If
depressions in the base material remain, it may be necessary to fill the depressions by welding, and
subsequently grinding and sanding the affected area flush with the surrounding material. Note: repair
operations on finished production units must be carefully controlled; and all areas or items adjacent to
the repair that could be damaged must be properly shielded or removed.

WELD DEFECT: LACK OF PENETRATION

METHODS OF DETECTION: Ultrasonic Testing (UT) and Destructive Testing
Initial, frequent evaluation samples
Lack of penetration can generally only be determined with destructive testing.
Proper joint penetration involves penetration of weld metal into the prepared area of the weld joint, such
as a vee-groove or a bevel-groove. For fillet welds, proper joint penetration requires welding to the point
of intersection of the two parts being joined together, but not necessarily beyond this point unless
specifically called out on the drawing. At the same time, proper fusion requires melting of the base metal
on either side of the joint.
REPAIR:
In order to repair a lack of penetration condition, the entire weld must be removed. The prepared weld
joint should extend to the specified depth of penetration of the weld, regardless of the initial joint
preparation. The width of the prepared groove must be sufficiently wide so as to allow accessibility to the
root of the weld, and also must be wide enough in comparison to the depth so as to prevent centerline
cracking of the repair weld. Generally the width of a single pass should be approximately 1 times as
wide as it is deep to prevent centerline cracking. Air Carbon Arc Cutting followed by grinding is the best
method to remove a weld rejected for lack of penetration.


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Engineering Specifications ENS0211

CNH Arc Welding Quality

ECO REV CHANGES BY DATE

ISSUED BY ECO NO. NAME

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 2 OF 37 86979030

CNH Arc Welding Quality

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 3 OF 37 86979030

AWSAmerican Welding Society

4.1 RELATED STANDARDS

AWS A3.0 (latest) - Standard Welding Terms and Definitions

4.2 REPLACED STANDARDS

Case ES-B211 Case Welding Quality Standard Arc Welding

5. CLASSIFICATION OF WELDS AND ADJACENT SURFACES

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 4 OF 37 86979030

5.1 CATEGORY 1 - PRIMARY FUNCTION WELDS

All hydraulic cylinder and fluid system welds

failure would present a safety related concern

5.2 CATEGORY 2 - COSMETIC WELDS AND ADJACENT SURFACES

Class A - Appearance Surfaces

Class B - Service Visible Surfaces

5.2.1 Class A - Appearance Surfaces

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 5 OF 37 86979030

5.2.2 Class B - Service Visible Surfaces

Surfaces located under the product or behind bolted access panels.

Any surface not classified as A or B.

5.4 WELD REQUIREMENTS - CATEGORY 1 WELDS

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 6 OF 37 86979030

FIGURE 1: Example of Incomplete Fusion

FIGURE 2: Example of Lack of Penetration

FIGURE 3: Example, Weld Stops and Starts

FIGURE 4: Example of Backside Weld Shrinkage

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 7 OF 37 86979030

5.5 WELD AND SURFACE REQUIREMENTS CATEGORY 2 WELDS

Category 2A (Class A, Appearance Surface)

Weld spatter is not permitted.

Category 2B (Class B, Service Visible Surface)

5.6 WELD AND SURFACE REQUIREMENTS CATEGORY 3 WELDS

6. WORKMANSHIP REQUIREMENTS FOR ALL ARC WELDING PROCESSES

6.1 The surface(s) to be welded shall be free of:

6.2 Laminations in the steel are not allowed.

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 8 OF 37 86979030

6.10 Do not weld on plated material without special ventilation or instructions.

6.11 Weld Drip (End-Melt) must be avoided.

6.12 Avoid arc strikes outside of the weld joint.

CE = %C + %Mn/6 + (Cu+Ni)/15 + (Cr+Mo+V)/5

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 9 OF 37 86979030

7. FINISHED WELD QUALITY REQUIREMENTS

7.1 Cracks are not permitted.

TABLE 2: Maximum Weld Undercut Limits, Based on Material Thickness

Material Thickness (t) Maximum Undercut

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 10 OF 37 86979030

TABLE 3: Planar-type Discontinuity Limits, Based on Weld Throat Size

NAME REV. PAGE CNH NUMBER

CNH ARC WELDING QUALITY B 11 OF 37 86979030