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ENGINEERINGSTANDARDSTestMethodsMaterialsGM9621PWeldingProcessControlProcedure1Scope1.1Purpose.Thisstandarddefinesweldin-spectionandweldingequipmentprocesscontrolrequirementsforproducersofGMweldedormechanicalclinchedproduct.1.2Application.Therequirementsofthisstan-dardareapplicabletoweldingandjoiningproc-essesutilizedbyaGeneralMotorsfabricatingand/orassemblyplanttojoinautomotivepartsandassemblies.2ReferencesNote:Onlythelatestapprovedstandardsareapplicableunlessotherwisespecified.2.1ExternalStandards/Specifications.ANSI-Z49.1ISO104472.2GMStandards/Specifications.GMN100722.3AdditionalReferences.WS-4,GMWeldVerificationProcedures.3Procedure3.1DesignationofResponsibility3.1.1ProductEngineering.Theproductengi-neeringfunctionisresponsiblefordefiningthestructuralrequirementsofthevehicle.Theserequirementsincludethejoiningmethod,quan-tity,location,andproducttolerances.Productacceptancecriteriaistobeconsistentwithpub-lishedGMEngineeringStandards.3.1.2ManufacturingEngineering.Themanu-facturingengineeringfunctionisresponsibleforevaluatingtheproductdesignformanufactura-bility.Manufacturingengineeringdefinestheprocess,typeoftooling,andoperationalse-quencestomanufacturetheproductinconfor-mitytothereleaseddesign.3.1.3PlantResponsibility.Theplantsmustadheretotheproductspecificationsapprovedbyproductengineeringandtheprocessre-quirementsdefinedbymanufacturingengineer-ing.Productengineeringmustapproveanyvariancefromproductspecifications.Variancefromprocessrequirementsmustbeinagree-mentwithwrittenprocedures.3.2ProcessEvaluation.3.2.1WeldToolVerificationandQualifica-tion.Theprocuringmanufacturingengineeringfunctionmustverifythatnewasbuilttoolingagreeswiththetooldesignand/orToolandEquipmentStatementofRequirements.TheapplicablesectionofWS-4,GMWeldVerifica-tionProceduresistobeutilizedtoperformtheverificationandqualificationactivities.Anyweldtoolingrevisionsnecessitatedbythisproceduremustbecompletedandtooldesigndocumentsupdated.Recordsoftheverificationandqualifi-cationactivityaretobemaintained.3.2.2WeldToolRe-Qualification.Eachweldtoolmustbere-qualifiedwheneverachangeoccursintheproductorprocessthatwaspartoftheoriginalverificationandqualificationactivity.Itisrecommendedthatthere-qualificationactiv-ityutilizethesameprocessdescribedinWS-4.Recordsofthere-qualificationactivityaretobemaintained.3.2.3EquipmentProcessMonitoring.Equip-mentprocessmonitoringconsistsofmeasuringtheprocessparametersestablishedduringtoolqualificationaswellasvisualevaluationoftheequipmentfunctionaloperation.Equipmentprocessmonitoringrequirementsforvariousweldingandjoiningprocessesarecontainedintheappendicesofthisstandard.3.2.4EquipmentMaintenance.Eachlocationshallhavedocumentedplansforthemainte-nanceofequipment.Theequipmentmainte-nancescheduleshouldbeconsistentwiththetoolorequipmentmanufacturersrecommenda-tions.3.3ProductMonitoringandInspection.Prod-uctmonitoringandinspectionconsistofevaluat-ingtheweldedproductwiththereleaseddesign©Copyright2003GeneralMotorsCorporationAllRightsReservedAugust2003OriginatingDepartment:NorthAmericanEngineeringStandardsPage1of7GM9621PGMENGINEERINGSTANDARDSandtheapplicableGMEngineeringStandardstoidentify,contain,andrepairnonconformingweldpatterns.Methodologiesforphysicaltest-ingofresistanceweldsarecontainedinISO10447,Welding–Peelandchiseltestingofresistancespot,projectionorseamwelds.Theproductmonitoringandinspectionplanforallweldsmustbedescribedinwrittenproceduresorstandardizedwork.Note:Peeltestingisthepreferredmethodofinspectionforaluminumspotwelds.Chiseltest-ingisnotanacceptablemethodofinspectionforaluminumspotwelds.3.3.1In-ProcessInspectionandTest(Resis-tanceSpotWelds).Adeformationorultrasonicnondestructivecheckofallspotwelds(forallstylesandallcells)isrecommendedtooccur4timespershiftatevenlyspacedintervals.Theminimumfrequencyisonecheckperweldgunandmetalstack-up,sampledfourtimespershift.©Copyright2003GeneralMotorsCorporationAllRightsReservedConcurrentwiththedeformationchecks,visuallyinspectforsealerpresenceifspecifiedandvisu-allyinspectallweldsforconformancetotheapplicableproductdrawingandGMEngineeringStandard.3.3.2In-ProcessInspectionandOtherTests.Weldsandjoiningtechniquesotherthanthosementionedin3.3.1shouldbeverifiedforcon-formancetothevisualacceptancecriteriaoftheapplicablestandardaminimumof4timespershift.3.3.2WeldDestructTest–AssemblyPlants.AttheStartofSystemFillthefrequencyoffullbodydestructisoneofeachnewbodystylepermonthuntilprocesscapabilityisdemonstratedanddocumented.Processcapabilityconsistsofcompletingthreeconsecutivedestructteststhatmeetrequirements.Thefrequencycanthenbereducedtoaquarterlydestructtestofeachbodystyle.3.3.4WeldDestructTest–FabricatingPlants.AtStartofProductionthefrequencyofdestructtestsistobeoneofeachassemblypermonthuntilprocesscapabilityisdemonstratedanddocumented.Processcapabilityconsistsofcompletingthreeconsecutivedestructteststhatmeetrequirements.Thefrequencycanthenbereducedtoaquarterlydestructtestofeachas-sembly.3.4WeldImageAnalysis.Inspection,measur-ingandtestequipmenttoperformtheimageanalysisofweldcrosss