ESBM5A-1N261-AA

EngineeringSpecificationFRAME2OF37REV.LET.PARTNO.ESBM5A-1N261-AAPDMay923947a2eNovember28,2008EBIWE12173768000ResistanceSpotWeldingESBM5A-1N261-AAOUTLINEFRAMEI.GENERAL…………………………………………………………..…………………4I.1ScopeofEngineeringSpecification,GeneralStatement………………………..4I.2ProcessDescription……………………………………………….……………..5I.3DesignGuidelines……………………………………………………………….…5I.3.1GoverningMetalThicknessI.3.2GaugeRatioLimitationsI.3.3WeldDiameterI.3.3.1DefinitionsI.3.3.2MinimumWeldDiameterI.3.3.3SpecialCasesI.3.4ElectrodeUsageandFlangeDimensionsI.3.5WeldPitchI.3.6FlatnessI.4ApplicableMaterials……………………………………………………...………13I.4.1BaseSheetMetalSpecificationI.4.2StandardBaseSheetMetalCoatingsI.5WeldIdentificationSymbols………………………….…………………………14I.6WeldClassification……………………………………………...........................14I.7WeldGroups……………………………………………………………….………14I.8WeldQualityLevels,AcceptanceCriteria,andReactionRequirements……....15I.8.1WeldQualityLevelsI.8.2AcceptanceCriteriaI.8.3ReactionRequirementsII.SUMMARYOFPRODUCTIONVALIDATIONANDIN-PROCESSTESTS...17III.TESTPROCEDURESANDREQUIREMENTS…………………………………..22III.1ApplicabilityofTestProceduresforPV-andIP-TestPhases………..…………22III.2WeldParameterMonitoring…………………………………………….………..23III.2.1IntroductionIII.2.2WeldingCurrentoverTime[A]III.2.3ElectrodeForce[N]EngineeringSpecificationFRAME3OF37REV.LET.PARTNO.ESBM5A-1N261-AAPDMay923947a2eNovember28,2008EBIWE12173768000ResistanceSpotWeldingESBM5A-1N261-AAIII.3InspectionoftheVisiblePartoftheWeld.………………………..………….….23III.3.1IntroductionIII.3.2SpotWeldCountIII.3.3SpotWeldPositionIII.3.4DistancefromEdgesIII.3.5SurfaceCharacteristicsIII.3.5.1ClassesofWeldFinishIII.3.5.2SurfaceIndentationandExpulsionIII.3.6BurnThroughIII.3.7SurfaceCracksIII.3.8SurfacePorosityIII.4InspectionofSectionCuts…………………………………………………...…....27III.4.1IntroductionIII.4.2NuggetDiameterIII.4.3WeldPenetrationIII.4.4PorosityIII.4.5CracksIII.4.6InclusionsIII.4.7HardnessLimitsIII.5Destructive,Non-Destructive,andFunctionalTesting………….….…….……...29III.5.1IntroductionIII.5.2StaticTensileTestIII.5.3PeelTestIII.5.4ImpactTestIII.5.5ChiselTest(Destructive)III.5.6DestructiveTestUsingaMachineIII.5.7UltrasonicTestIII.5.8ChiselTest(Non-Destructive)III.5.9Durability/FatigueTestIII.6PermissibleRepairMethods………………………………………………………34III.6.1ResistanceSpotWeldingIII.6.2PlugWeldingIII.6.3FusionFilletWeldingIII.6.4RivetingIII.6.5GasMetalArcBrazingIV.REVALIDATIONREQUIREMENTS…………………………….………………36V.INSTRUCTIONSANDNOTES………………………………………….………...36VI.COMPILATIONOFREFERENCEDOCUMENTS……………..….……..…….37EngineeringSpecificationFRAME4OF37REV.LET.PARTNO.ESBM5A-1N261-AAPDMay923947a2eNovember28,2008EBIWE12173768000ResistanceSpotWeldingESBM5A-1N261-AAI.GENERALI.1ScopeofEngineeringSpecification,GeneralStatementThisEngineeringSpecificationisissuedtodefinedesignfactorsandperformancerequirementsapplicabletotheresistancespotweldingofcoated,uncoated,andlaminatedsheetsteel•uptoathicknessof3.0mmforindividualsheets,•uptoamaximumof6.0mmintotaljointthickness,and•comprisinguptothreethicknessesofsteelofthesameordifferentgaugeusedinthefabricationofassemblies.ItharmonizestherequirementsgloballyforFordMotorCompanyandisapplicabletonewprograms.Thedesignfactorsandperformancerequirementsapplytobothautomaticandmanualweldingapplications.Wheremanualapplicationsmayhaveanimpactondesignorperformance,therelevantBodyandManufacturingEngineeringdepartmentsmayagreeondeviations.Resistancespotweldsofsheetsteelexceeding3.0mmforindividualsheetsand/orexceeding6.0mmintotaljointthicknessrequireacase-by-caseexemptionfromtherelevantBodyandManufacturingEngineeringdepartments.Exemptionswillonlybegrantedonthebasisofaneedsassessment.Resistancespotweldscomprisingfourthicknessesofsteelarepermissibleasnon-structuralweldsonly,e.g.asmanufacturingtackwelds.ThisEngineeringSpecificationalsoappliestospotweldsonsteelcombinationswhichincludeweldsealers,paintprimers,and/oradhesives.PerformancerequirementsofsealersandadhesivesthemselvesarecoveredinseparateEngineeringSpecifications.ThisEngineeringSpecificationisasupplementtothereleaseddrawingpart.Allrequirementshereinmustbemetinadditiontoallotherrequirementsofthepartdrawing.Eachsectionspecifiestheminimummeasuresnecessaryfordocumentingcompliancetothisspecification.ThisEngineeringSpecificationisintendedtoevaluatespecificcharacteristicsasasupplementtonormalmaterialinspections,dimensionalchecking,andinprocesscontrolsandshouldinnowayadverselyinfluenceotherinspectionoperations.Preparationandsubmissionofanacceptablecontrolplanaretheresponsibilityofthemanufacturingsource.ThemanufacturingsourcewillretaintheoriginalcontrolplanandanylaterrevisionsperQS-9000andprovideacopytothedesignresponsibleProductEngineeringactivity.EngineeringSpecificationFRAME5OF37REV.LET.PARTNO.ESBM5A-1N261-AAPDMay923947a2eNovember28,2008EBIWE12173768000ResistanceSpotWeldingESBM5A-1N261-AAI.2ProcessDescriptionResistanceweldingisaprocessinwhichmetalsarejoinedbytheheatgeneratedbytheresistanceoftheworktothepassageofelectriccurrent.Thisprocessinvolvesacoordinatedapplicationofcurrentandmechanicalpres