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1、ENGINEERINGSTANDARDS Test Methods Materials GM9621P Welding Process Control Procedure 1 Scope 1.1 Purpose. This standard defines weld in-spection and welding equipment process control requirements for producers of GM welded or mechanical clinched product. 1.2 Application. The requirements of this st
2、an-dard are applicable to welding and joining proc-esses utilized by a General Motors fabricating and/or assembly plant to join automotive parts and assemblies. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ANS
3、I-Z49.1 ISO 10447 2.2 GM Standards/Specifications. GMN10072 2.3 Additional References. WS-4, GM Weld Verification Procedures.3 Procedure 3.1 Designation of Responsibility 3.1.1 Product Engineering. The product engi-neering function is responsible for defining the structural requirements of the vehic
4、le. These requirements include the joining method, quan-tity, location,and product tolerances.Product acceptance criteria is to be consistent with pub-lished GM Engineering Standards. 3.1.2 Manufacturing Engineering. The manu-facturing engineering function is responsible for evaluating the product d
5、esign for manufactura-bility. Manufacturing engineering defines the process, type of tooling, and operational se-quences to manufacture the product in confor-mity to the released design. 3.1.3 Plant Responsibility. The plants must adhere to the product specifications approved by product engineering
6、and the process re-quirements defined by manufacturing engineer-ing. Product engineering must approve any variance from product specifications. Variance from process requirements must be in agree-ment with written procedures. 3.2 Process Evaluation. 3.2.1 Weld Tool Verification and Qualifica-tion. T
7、he procuring manufacturing engineering function must verify that new as built tooling agrees with the tool design and/or Tool and Equipment Statement of Requirements. The applicable section of WS-4, GM Weld Verifica-tion Procedures is to be utilized to perform the verification and qualification acti
8、vities. Any weld tooling revisions necessitated by this procedure must be completed and tool design documents updated. Records of the verification and qualifi-cation activity are to be maintained. 3.2.2 Weld Tool Re-Qualification. Each weld tool must be re-qualified whenever a change occurs in the p
9、roduct or process that was part of the original verification and qualification activity. It is recommended that the re-qualification activ-ity utilize the same process described in WS-4. Records of the re-qualification activity are to be maintained. 3.2.3 Equipment Process Monitoring. Equip-ment pro
10、cess monitoring consists of measuring the process parameters established during tool qualification as well as visual evaluation of the equipment functional operation. Equipment process monitoring requirements for various welding and joining processes are contained in the appendices of this standard.
11、 3.2.4 Equipment Maintenance. Each location shall have documented plans for the mainte-nance of equipment. The equipment mainte-nance schedule should be consistent with the tool or equipment manufacturers recommenda-tions. 3.3 Product Monitoring and Inspection. Prod-uct monitoring and inspection con
12、sist of evaluat-ing the welded product with the released design ? Copyright 2003 General Motors Corporation All Rights Reserved August 2003 Originating Department: North American Engineering Standards Page 1 of 7名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 1 页，共 7
13、页 - - - - - - - - - GM9621P GM ENGINEERING STANDARDSand the applicable GM Engineering Standards to identify, contain, and repair nonconforming weld patterns. Methodologies for physical test-ing of resistance welds are contained in ISO 10447, Welding Peel and chisel testing of resistance spot, projec
14、tion or seam welds. The product monitoring and inspection plan for all welds must be described in written procedures or standardized work. Note: Peel testing is the preferred method of inspection for aluminum spot welds. Chisel test-ing is not an acceptable method of inspection for aluminum spot wel
15、ds. 3.3.1 In-Process Inspection and Test (Resis-tance Spot Welds). A deformation or ultrasonic nondestructive check of all spot welds (for all styles and all cells) is recommended to occur 4 times per shift at evenly spaced intervals.The minimum frequency is one check per weld gun and metal stack-up
16、, sampled four times per shift. ? Copyright 2003 General Motors Corporation All Rights Reserved Concurrent with the deformation checks, visually inspect for sealer presence if specified and visu-ally inspect all welds for conformance to the applicable product drawing and GM Engineering Standard. 3.3
17、.2 In-Process Inspection and Other Tests. Welds and joining techniques other than those mentioned in 3.3.1 should be verified for con-formance to the visual acceptance criteria of the applicable standard a minimum of 4 times per shift. 3.3.2 Weld Destruct Test Assembly Plants. At the Start of System
18、 Fill the frequency of full body destruct is one of each new body style per month until process capability is demonstrated and documented. Process capability consists of completing three consecutive destruct tests that meet requirements. The frequency can then be reduced to a quarterly destruct test
19、 of each body style. 3.3.4 Weld Destruct Test Fabricating Plants. At Start of Production the frequency of destruct tests is to be one of each assembly per month until process capability is demonstrated and documented. Process capability consists of completing three consecutive destruct tests that me
20、et requirements. The frequency can then be reduced to a quarterly destruct test of each as-sembly. 3.4 Weld Image Analysis. Inspection, measur-ing and test equipment to perform the image analysis of weld cross sections must be capable of evaluating the specified measurable criteria to an accuracy of
21、 0.01 millimeters. The use of the Native American Technologies Weld Measuring System (NAMeS)? is recommended. Weld cross sections are to be viewed at 15X or less magnification. 3.4.1 Weld Cross Section. The number of re-quired weld cross section samples is to be de-termined by the specified length o
22、f the weld bead in accord with the following table. Table 1: Weld Beads vs Cross Sections Specified Weld Bead Length (mm) Number of Cross Sections Location of Cross Sections 30 or less 1 Midpoint of weld 31 100 2 Equally spaced from each other and from the ends of the welds 100+ 3 Equally spaced fro
23、m each other and from the ends of the welds 4 Nondestructive Evaluation (NDE) 4.1 Ultrasonic evaluation of resistance spot welds can be utilized in place of the required deformation or destruct tests provided the per-sonnel and process have been qualified in ac-cord with GMN10072, Personnel and Proc
24、ess Qualification for Ultrasonic Testing of Resistance Spot Welds.5 Safety Welding, cutting and allied processes can be performed safely with minimal health risk, pro-vided proper procedures are followed and nec-essary precautions are taken. An informative reference that provides guidance for person
25、nel in the safe set-up and use of welding and cutting equipment is the ANSI Z49.1, Safety in Welding, Cutting, and Allied Processesdocument. 6 Release and Revisions 6.1 Release. This procedure originated in May1990 and approved by the Weld Committee in May 1990. It was first published in September 1
26、990. 6.2 Revisions. Rev Date Description (Organization)A NOV 1990Editorial B MAY 2003Total rewrite to address welding and joining (GMNA Weld Council)Page 2 of 7 August 2003名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 2 页，共 7 页 - - - - - - - - - GM ENGINEERING STAND
27、ARDSGM9621PAppendix AResistance Welding Processes Table A1: Spot Weld Equipment Equipment Monitoring Activity Every Cap Change Each Shift Weekly Monthly Verify electrodes are the ones specified. X Verify electrode alignment. X Verify water cooling. X Check for any water and/or air leaks. X Verify ti
28、p dresser operation. X Check cables/shunts for wear, cuts and/or loose con-nections. X Verify that the weld schedules, fault settings and step-per settings agree with the Weld Tool Data Sheets documented values. X Verify gun force is within specified limits. X Verify secondary current capability. X
29、Verify gun action including lubrication and flash shields. X ? Copyright 2003 General Motors Corporation All Rights Reserved Page 3 of 7 August 2003名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 3 页，共 7 页 - - - - - - - - - GM9621P GM ENGINEERING STANDARDSTable A2: Pr
30、ojection Welding Equipment Equipment Monitoring Activity Every Cap Change Each Shift Weekly Monthly Verify electrodes are the ones specified.X Check electrodes for excessive wear, proper alignment, and parallelism. X Verify water cooling.X Check for any water and/or air leaks.X Check cables/shunts f
31、or wear, cuts and/or loose connec-tions. X Check feeder mechanism for debris and proper operation (if applicable). X Verify error proofing device operation (if applicable). X Verify that the weld schedules and fault settings agree with the Weld Tool Data Sheets documented values. X Verify gun force
32、is within specified limits. X Verify secondary current capability. X Verify gun action including lubrication and flash shields. X ? Copyright 2003 General Motors Corporation All Rights Reserved Page 4 of 7 August 2003名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 4 页
33、，共 7 页 - - - - - - - - - GM ENGINEERING STANDARDS GM9621PTable A3: Gas Metal Arc Welding Equipment Equipment Monitoring Activity During Con-tact Tip Change Each Shift Weekly Monthly Verify shielding gas flow. X Verify wire feed system operation. X Verify torch and mounting bracket are tight and in p
34、osi-tion. X Check torch, nozzle and contact tip for damage. X Verify operation of anti-spatter system. X Verify torch cleaning system operation. X Check for alternate shorting paths. X Check gas diffuser for dirt or damage. X Verify tip to work distance and torch position. X Check conduits and contr
35、ol cables for damage. X Check gas and anti-spatter hoses for cuts, holes and leaks. X Check weld wire delivery system and feed drive roll tensioner setting. X Check electrical return circuit (coppers and cables) for damage and for completeness. X Verify weld voltage, fault settings, weld current and
36、 gas flow rates are within limits posted on the Weld Tool Data Sheet. X Check water cooling to torch (if applicable). X ? Copyright 2003 General Motors Corporation All Rights Reserved August 2003 Page 5 of 7名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 5 页，共 7 页 - -
37、 - - - - - - - GM9621P GM ENGINEERING STANDARDSTable A4: Drawn Arc Welding Equipment Equipment Monitoring Activity Each Shift Daily During Collet Change Monthly Check collet for broken or burned away tines, and check that collet nut is tight. X Check the position or stick out of the probe/flash shie
38、ld. X Check piston for stick out. X Verify drop time (at the welder control) does not exceed setup value by more than 5 milliseconds. X Check feeders and feed tubes for debris, excessive wear, and correct operation. X Check work lead circuit (welder control/feeder to work piece). Ensure cables are i
39、ntact, connections are tight, and contact blocks function properly. X Check mount and slide unit for excessive play make sure tubes and cables do not inhibit movement. X Check stick-out from collet, check lift distance and opera-tion. X Verify that arc voltage, current and time are within the proces
40、s tolerances specified on the Weld Tool Data Sheet. X Check feed tubes for wear and proper alignment. X Check for abrasion between the inner and outer collet X Check the power feed cable for wear and exposed cop-per. X Check weld head/gun front end for tight rings, flanges, and nuts. X ? Copyright 2
41、003 General Motors Corporation All Rights Reserved Page 6 of 7 August 2003名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 6 页，共 7 页 - - - - - - - - - GM ENGINEERING STANDARDS GM9621PTable A5: Mechanical Clinch Equipment Equipment Monitoring Activity Weekly Monthly Che
42、ck punch for damage and punch tip for excessive wear. X Check stripper springs for wear, compressed, or broken. X Check condition of die, look for damage, excessive wear of die blades. X Check for excessive wear on the anvil. X Check general condition of clinch unit seals, hoses, and fittings. X Ver
43、ify operating air or hydraulic pressure is within limits documented on the Tool Information Sheet. X Check proper punch and die alignment. X Check correct punch is installed. X Check for wear of punch holder, is punch loose in holder. X Check condition of stripper assembly. X Check that correct die
44、is installed. X Check condition of slides for excessive wear or loose. X Check condition of stop blocks, loose or worn. X Verify travel of clinch unit for proper shut height. X Verify operation of proximity switches on dumps and slides. X ? Copyright 2003 General Motors Corporation All Rights Reserved August 2003 Page 7 of 7名师资料总结 - - -精品资料欢迎下载 - - - - - - - - - - - - - - - - - - 名师精心整理 - - - - - - - 第 7 页，共 7 页 - - - - - - - - -