ACCEPTANCE CRITERIA

- ISO 5817

BY
A.GANESH
CMS/AWTI
 WHAT IS ISO 5817?

 International standard for - Quality levels for

imperfections of fusion welded joints in steel, Nickel,
Titanium and their alloys.

 Applicable for thickness > 0.5mm.

 Covers Fully penetrated butt joints and all fillet joints.

 WHY ISO 5817?
Acceptance criteria for
 Welder Qualification to ISO 9606-1 certification

 WPS & PQR to various ISO standards

 Also used as a reference for drafting of application codes

or application standards.

ISO 3834 EN 15085

ISO 5817
 CONVENTIONAL DRAWINGS

 Conventional drawings speak about part dimensions

 Base metal specifications

 Welding process, weld dimensions

 Acceptance criteria for few joints, like bogie frames

and anchor links.
 Throat thickness in case of fillet welds.
HOWEVER ……..

 No mention is made regarding proper acceptance

criteria for most of the welded joints .

SO ….?
 Inspection is unable to control the quality of welded
joints.
 Even in cases where acceptance criteria is mentioned,
is liberal and incomplete.
 Most of the weld joints are meeting strength
requirements, but lacks in appearance and aesthetics.
POOR WELDING PROFILES
 General misconceptions prevailing among welders are…

a. Depositing more weld gives more strength.

b. Employing high current will give strong joint.

c. Depositing weld runs on previously deposited runs

containing imperfections will disappears the
imperfections.

 Recent development in ICF drawing is that ISO

5817 Quality level B is incorporated in FIAT
BOGIE welding drawings. .
AN OVERVIEW OF ISO 5817/2007
DIFFERENCE BETWEEN AN IMPERFECTION
& DEFECT?

 Imperfection is deviation from ideality

 Defect is an imperfection above acceptance level

resulting in impaired use in service condition.
TYPES OF IMPERFECTIONS

 Systematic imperfection:
Imperfections that are repeatedly
distributed in the weld over the weld length to be
examined, the size of a single imperfection being
within the specified limits

 Short imperfection:
When the length of imperfections is less
than 25% of the length of weld, it is called short
imperfection.
CLASSIFICATION OF IMPERFECTIONS

 Linear imperfection:
When the length of imperfection is more than
3 x width of imperfection.

 Rounded imperfection:
Length of imperfection is less than 3 x width
of imperfection
QUALITY LEVELS OF ISO 5817
 Quality level B – Stringent

 Quality Level C – Moderate

 Quality level D – Lenient

 Choice of quality level for specific component is

defined by the design parameters taking into
account stress concentration and criticality of the
component
SURFACE IMPERFECTIONS

GROUP 1
 CRACKS
Refere
No nce to IMPERFECTION THICK D C B
ISO
6520-1

1.1 100 CRACK ≥ 0.5 Not Not Not

permitted permitted permitted

1.2 104 CRATER CRACK ≥ 0.5 Not Not Not

permitted permitted permitted
 SURFACE PORE
No ISO:6520-1 IMPERFEC REMARKS “t“ D C B
TION (mm)
1.3 2017 SURFACE Maximum 0.5 to 3 d ≤ 0.3s for
PORE dimension of butt Not Not
single Pore d ≤ 0.3a for permitted permitted
-butt welds fillet
-fillet welds
Maximum >3 d ≤ 0.3s, d ≤ 0.2s Not
dimension of max 3mm max 2mm permitted
single Pore for butt for butt
-butt welds d ≤ 0.3a, max d ≤ 0.2a
-fillet welds 3 mm for fillet max 2mm
for fillet
 END CRATER & LACK OF FUSION

No ISO IMPERFECTION “t“

D C B
6520-1 (mm)
1.4 2025 ENDCRATER PIPE 0.5 to 3 h ≤ 0.2t Not Not
permitted permitted
>3 h ≤ 0.2t, h ≤ 0.1t, Not
max 2mm max 1mm permitted
1.5 401 LACK OF FUSION ≥ 0.5 Not Not Not
(INCOMPLETE permitted permitted permitted
FUSION )

MICRO LACK OF Only ≥ 0.5 Permitted Permitted Not

FUSION detectable by permitted
micro
examination
 INCOMPLETE ROOT PENETRATION
No ISO IMPERFECTION “t“ D C B
6520-1 (mm)

1.6 4021 INCOMPLETE Only for ≥ 0.5 Short Not Not

ROOT single side imperfections : permitted permitted
PENETRATION butt welds h≤0.2 t max
2mm
 UNDERCUT
No ISO IMPERFECTION REMARKS “t“ D C B
6520-1 (mm)
1.7 5011 CONTINUOUS Smooth 0.5 TO 3 Short Short Not
UNDERCUT transition is imperfection imperfection permitted
required , this is h ≤ 0.2t h ≤ 0.I t
not regarded as
systematic
imperfection
5012 INTERMITTENT >3 h≤0.2t, But h≤0.1t, But h≤0.05t,
UNDERCUT max 1 mm max 0.5mm max0.5mm
 SHRINKAGE GROOVE

No ISO:6520-1 IMPERFECTION REMARKS “t“ D C B

(mm)

1.8 5013 SHRINKAGE smooth 0.5 to Short Short Not

GROOVE transition is 3 imperfection imperfection permitted
h ≤ 0.2mm h≤0.I t
required
+0.1t

>3 Short Short Short

imperfection imperfection imperfection
h≤0.2t but h≤0.I t but h ≤ 0.05t but
max 2 mm max 1 mm max 0.5 mm
 EXCESS WELD
No ISO IMPERFECTI REMARKS “t“
6520-1 ON (mm) D C B

1.9 502 EXCESS Smooth >0.5 h≤1mm+0.25b h≤1mm+0.15b h ≤ 1mm+0.15b

WELD transtion is mm but max 10mm but max 7mm but max 5 mm
METAL (Butt) required
1.10 503 EXCESS ≥0.5 h≤1mm+0.25b h≤mm+0.15b h≤ 1mm+0.15 b
CONVEXITY but max 5 mm but max 4mm ,but max 3 mm
(Fillet)
1.11 504 EXCESS 0.5 - 3 h≤1 mm +0.6b h≤1 mm +0.3b h≤ 1 mm +0.1b
PENETRA-
TION >3 h≤1mm+1.0 b h≤1mm+0.6b , h≤ 1mm+0.2b ,
but max 5mm but max 4mm but max 3mm
EXCESS CONVEXITY EXCESS WELD & EXCESS PENETRATION
 INCORRECT WELD TOE
No ISO 6520-1 IMPERFEC Remarks “t“ D C B
TION (mm)

1.12 503 INCORRECT -BUTT ≥ 0.5 α ≥ 90° α ≥ 110° α ≥ 150°

WELD TOE WELDS
-FILLET ≥ 0.5 α ≥ 90° α ≥ 100° α ≥ 110°
WELDS
 OVERLAP, SAGGING &
INCOMPLETELY FILLED GROOVE
No ISO:6520-1 IMPERFECTION REMARKS “t“ D C B
(mm)
1.13 506 OVERLAP ≥0.5 h≤0.2b Not Not
permitted permitted
1.14 509 SAGGING Smooth 0.5 to 3 Short Short Not
transtion is imperfection imperfection permitted
required h≤0.25t h≤0.I t
511 INCOMPLETELY >3 Short Short Short
FILLED imperfection imperfection imperfection
GROOVE h≤0.25t,but h≤0.I t but h≤0.05 t but
max 2mm max 1 mm max 0.5 mm
 BURN THROUGH &
ASSYMETRIC LEG LENGTH
No ISO 6520-1 IMPERFECTION REMARKS “t“ D C B
(mm)
1.15 510 BURN THROUGH ---- ≥ 0.5 Not Not Not
permitted permitted permitted
1.16 512 EXCESSIVE In case ≥ 0.5 h≤2mm+0.2a h≤2 mm h≤1 .5mm
ASYMMETRY OF where +0.15a +0.15a
FILET WELD asymmetric
( EXCESSIVE weld has not
UNEQUAL LEG been
LENGHT) prescribed
 ROOT CONCAVITY&
ROOT POROSITY

No ISO IMPERFECT REMARKS “t“ D C B

6520-1 ION (mm)

1.17 515 ROOT Smooth transItion 0.5 – 3 h≤0.2mm +0.1t Short imperfection Not permitted
CONCAVITY is required h≤0.1 t
Short imperfections Short imperfection Short imperfection
>3
h≤0.2 t ,max 2 mm h≤0.1 t , max 1mm h≤0.05 t max
0.5mm

1.18 516 ROOT Spongy formation >0.5 Locally permitted Not permitted Not permitted
POROSITY at the root of a
weld due to
bubbling of the
weld metal at the
moment of
solidification
(eg lack of gas
backing)
 POOR RESTART
No ISO IMPERFECTION THICK D C B
6520-1

1.19 517 POOR RESTART ≥0.5 Permitted Not permitted Not permitted
The limit depends
on the type of
Imperfection
occurred due to
restart
 THROAT
No ISO:6520-1 IMPERFECTION “t“ D C B
(mm)
1.20 5213 INSUFFICIENT Not applicable 0.5 - 3 Short Short Not permitted
THROAT to processes imperfection imperfection
h≤0.2mm +0.1a h≤0.2mm
THICKNESS with proof of
greater depth of Short Short Not permitted
penetration >3 imperfections imperfections
h≤0.3 mm+0.1a h≤0.3mm
but max 2mm +0.1a, but
max 1 mm
1.21 5214 EXCESSIVE The actual ≥0.5 Permitted h≤1mm +0.2a, h≤1mm +0.15a,
THROAT throat thickness but max 4 mm but max 3 mm

THICKNESS of fillet is too

large

Excessive throat
thickness
 ASTHETICS OF WELD
No ISO:6520-1 IMPERFECTION THICK D C B
(MM)
1.22 601 STRAY ARC ≥ 0.5 Permitted Not Permitted Not
Permitted
1.19 602 SPATTER ≥ 0.5 Acceptance depends on application e.g. material,
corrosion protection
1.24 610 TEMPER ≥ 0.5 Acceptance depends on application e.g. material,
COLOUR corrosion protection
( DIS
COLOURATION )
INTERNAL IMPERFECTION

GROUP 2
 CRACKS
No ISO IMPERFECTION THICK D C B
6520-1

2.1 100 CRACKS All types of cracks ≥0.5 Not Not Not
except Micro permitted permitted permitted
cracks and crater
cracks
2.2 1001 MICROCRACKS A crack usually ≥0.5 Permitted Acceptance depends on
visible under the type of parent metal with
microscope (50x) particular reference to
crack sensitivity
 ROOT POROSITIES

POROSITIES
CLUSTER POROSITY
LINEAR POROSITY
 CAVITIES AND WORM HOLES
No ISO IMPERFECTI “t” D C B
6520- ON mm
1
2.6 2015 ELONGATED -butt ≥0.5 h≤0.4s, but max 4 mm h≤0.3s, but max 3mm h≤0.2s, but max 2 mm
CAVITY , welds l≤ s, but max 75 mm l≤s, but max 50 mm l≤s, but max 25 mm
2016 WORM HOLES

-fillet ≥0.5 h≤0.4a, but max 4 mm h≤0.3a, but max 3mm h≤0.2a, but max 2 mm
welds l≤a, but max 75 mm l≤a, but max 50 mm l≤a, but max 25 mm

2.7 202 SHRINKAGE ≥0.5 Short imperfections Not permitted Not permitted
CAVITY permitted but not
breaking of the surface
Butt welds :h≤0.4s, but
max 4 mm
Fillet welds h≤0.4a but
max 4 mm
2.8 2024 CRATER PIPE 0.5 -3 h or l ≤0.2t Not permitted Not permitted
>3 h or l ≤0.2t but max 2
mm
 INCLUSIONS
No ISO 6520-1 IMPERFECTION “t” D C B
mm

2.9 300 SOLID INCLUSIONS -butt ≥0.5 h≤0.4s,but max 4 mm h≤0.3s,but max 3mm h≤0.2s,max 2 mm
301 SLAG INCLSUIONS welds l≤s, but max 75 mm l≤s, but max 50 mm l≤s, max 25 mm
302 FLUX INCLUSIONS
303 OXIDE INCLUSIONS

-fillet ≥0.5 h≤0.4a,but max 4mm h≤0.3a,but max 3mm h≤0.2a, max 2 mm
welds l≤a, but max 75 mm l≤a, but ma x 50 mm l≤a, but max 25
mm

2.10 304 METALLIC -butt ≥0.5 h≤0.4s,but max 4mm h≤0.3s, but max 3mm h≤0.2s, max 2 mm
INCLUSIONS welds
OTHER THAN
COPPER -fillet ≥0.5 h≤0.4a, but max 4mm h≤0.3a, but max 3mm h≤0.2a, max 2 mm
welds

2.11 3042 COPPER ≥0.5 Not permitted Not permitted Not permitted
INCLUSIONS
 FUSION AND PENETRATION

No ISO 6520-1 IMPERFECTION THICK D C B

2.12 401 Lack of fusion ≥0.5 Short imperfection Not permitted Not permitted
(incomplete fusion ) permitted
4011 Lack of side wall fusion Butt welds h≤0.4s, but
max 4 mm
Fillet welds h≤0.4a,
4012 Lack of inter run fusion
but max 4 mm

4013 Lack of root fusion

 LACK OF PENETRATION
NO ISO IMPERFECTION THICK D C B
6520-1

2.13 402 LACK OF ≥0.5 h≤0.2a, but max 2mm Not permitted Not permitted
PENETRATION (Fillet weld)
≥0.5 Short Imperfection Short Not permitted
(T joint partial butt joint: h≤0.2s or l , Imperfection
penetration) but max 2 mm butt joint:
T joint : h≤0.2 a but h≤0.1s or l , but
(Butt joint partial max 2 mm max 1.5 mm
penetration) Fillet joint :
h≤0.1 a but
max 1.5mm
≥0.5 Short imperfection : Not permitted Not permitted
(Butt joint full h≤0.2t, but max 2 mm
penetration)
GEOMETRICAL DEFECTS

GROUP 3
 GEOMETRICAL DEFECTS
NO ISO IMPERFECTION THICK D C B
6520-1
3.1 507 LINEAR The limits relate to deviations from the correct position .
MISALIGNMENT unless other wise specified , ,the correct position is that the
centre lines coincide .(see clause no 1)refers to smaller
thickness
5071 LINEAR 0.5 to 3 h<0.2 mm+0.25t h<0.2 mm +0.15t h<0.2 mm +0.1t
MISALIGNMENT
BETWEEN PLATES Plates and >3 h≤0.25 t h≤0.15 t but max h≤0.1t but max
longitudinal but max 5 mm 4 mm 3 mm
welds
5072 TRANSVERSELY ≥0.5 h≤0.5t h≤0.5 t h≤0.5 t
CIRCULAR PLATES Circumfern but max 4 mm but max 3 mm but max 2mm
AT CYLINDRICAL -tial weld
HOLLOW
SECTIONS
 INCORRECT ROOT GAP
NO ISO IMPERFECTION THICK D C B
6520-1

3.2 617 Incorrect root gap Gap between the 0.5 to 3 h≤0.5mm+01 a h≤0.3 mm+01 a h≤0.2mm+0.1a
for fillet welds parts to be joint .
gaps Exceeding the
appropriate limits
may , in certain
cases be
compensated for by
a corresponding
increase in throat
thickness
>3 h≤1 mm+0.3 a h≤0.5 mm+0.2 a h≤0.5mm+0.1a
but max 4 mm but max 3 mm but max2 mm
MULTIPLE IMPERFECTIONS
MULTIPLE IMPERFECTIONS