通用汽车工程标准 GM9621P 焊接工艺控制流程

1、 Welding Process Control Procedure1 Scope1.1 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 stan-dard are applicable to welding and joining proc-ess

2、es utilized by a General Motors fabricating and/or assembly plant to join automotive parts and assemblies.2 ReferencesNote: Only the latest approved standards are applicable unless otherwise specified.2.1 External Standards/Specifications.ANSI-Z49.1 ISO104472.2 GM Standards/Specifications.GMN100722.

3、3 Additional References.WS-4, GM Weld Verification Procedures. 3 Procedure3.1 Designation of Responsibility3.1.1 Product Engineering. The product engi-neering function is responsible for defining the structural requirements of the vehicle. These requirements include the joining method, quan-tity, lo

4、cation,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 design for manufactura-bility. Manufacturing engineering defines t

5、he 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 and the process re-quirements defined by manufacturing engineer-i

6、ng. 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. The procuring manufacturing engineering function must verify that ne

7、w 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 activities. Any weld tooling revisions necessitated by this procedure m

8、ust 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 product or process that was part of the original verification and qua

9、lification 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 process monitoring consists of measuring the process parameters establis

10、hed 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.3.2.4 Equipment Maintenance. Each location shall have documented plan

11、s 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 consist of evaluat-ing the welded product with the released design© C

12、opyright 2003 General Motors Corporation All Rights ReservedAugust 2003 Originating Department: North American Engineering Standards Page 1 of 7GM9621PGM ENGINEERING STANDARDSand the applicable GM Engineering Standards to identify, contain, and repair nonconforming weld patterns. Methodologies for p

13、hysical test-ing of resistance welds are contained in ISO 10447, Welding Peel and chisel testing of resistance spot, projection 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 met

14、hod of inspection for aluminum spot welds. Chisel test-ing is not an acceptable method of inspection for aluminum spot welds.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 t

15、o occur 4 times per shift at evenly spaced intervals.The minimum frequency is one check per weld gun and metal stack-up, sampled four times per shift.© Copyright 2003 General Motors Corporation All Rights ReservedConcurrent with the deformation checks, visually inspect for sealer presence if sp

16、ecified and visu-ally inspect all welds for conformance to the applicable product drawing and GM Engineering Standard.3.3.2 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

17、 the applicable standard a minimum of 4 times per shift.3.3.2 Weld Destruct Test Assembly Plants. At the Start of System 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

18、 three consecutive destruct tests that meet requirements. The frequency can then be reduced to a quarterly destruct test 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 capabi

19、lity 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 of each as-sembly.3.4 Weld Image Analysis. Inspection, measur-ing and test equipment to perform the i

20、mage analysis of weld cross sections must be capable of evaluating the specified measurable criteria toan accuracy of 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 Wel

21、d Cross Section. The number of re-quired weld cross section samples is to be de-termined by the specified length of the weld bead in accord with the following table. Table 1: Weld Beads vs Cross SectionsSpecified Weld Bead Length(mm Number of Cross SectionsLocation of CrossSections 30 or less 1 Midp

22、oint of weld 31 1002Equally spaced from each other and from the ends of the welds 100+ 3Equally spaced from each other and from the ends of the welds4 Nondestructive Evaluation (NDE4.1 Ultrasonic evaluation of resistance spot welds can be utilized in place of the required deformation or destruct tes

23、ts provided the per-sonnel and process have been qualified in ac-cord with GMN10072, Personnel and ProcessQualification for Ultrasonic Testing of Resistance Spot Welds.5 SafetyWelding, cutting and allied processes can be performed safely with minimal health risk, pro-vided proper procedures are foll

24、owed and nec-essary precautions are taken. An informative reference that provides guidance for personnel in the safe set-up and use of welding and cutting equipment is the ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes document.6 Release and Revisions6.1 Release. This procedure origina

25、ted in May1990 and approved by the Weld Committee in May 1990. It was first published in September 1990.6.2 Revisions.Description (Organization1990EditorialB MAY 2003welding and joining (GMNA Weld CouncilPage 2 of 7 August 2003GM ENGINEERING STANDARDSGM9621PAppendix AResistance Welding ProcessesTabl

26、e A1: Spot Weld EquipmentEquipment Monitoring Activity Every Cap Change Each ShiftVerify electrodes are the ones specified.Verify electrode alignment.Verify water cooling.Check for any water and/or air leaks.Verify tip dresser operation.Check cables/shunts for wear, cuts and/or loose con-nections.Ve

27、rify that the weld schedules, fault settings and step-per settings agree with the Weld Tool Data Sheetsdocumented values.Verify gun force is within specified limits.Verify secondary current capability.Verify gun action including lubrication and flash shields.© Copyright 2003 General Motors Corp

28、oration All Rights ReservedPage 3 of 7 August 2003GM9621P GM ENGINEERING STANDARDS Table A2: Projection Welding EquipmentEquipment Monitoring Activity Every Cap Change Each ShiftVerify electrodes are the ones specified.Check electrodes for excessive wear, proper alignment,and parallelism.Verify wate

29、r cooling.Check for any water and/or air leaks.XCheck cables/shunts for wear, cuts and/or loose connec-tions.Check feeder mechanism for debris and proper operation(if applicable.Verify error proofing device operation (if applicable.Verify that the weld schedules and fault settings agree withthe Weld

30、 Tool Data Sheets documented values.Verify gun force is within specified limits.Verify secondary current capability.Verify gun action including lubrication and flash shields.© Copyright 2003 General Motors Corporation All Rights ReservedPage 4 of 7 August 2003GM ENGINEERING STANDARDS GM9621P Ta

31、ble A3: Gas Metal Arc Welding EquipmentEquipment Monitoring Activity During Con-tact Tip Change Each ShiftVerify shielding gas flow.Verify wire feed system operation.Verify torch and mounting bracket are tight and in posi-tion.Check torch, nozzle and contact tip for damage.Verify operation of anti-s

32、patter system.Verify torch cleaning system operation.Check for alternate shorting paths.Check gas diffuser for dirt or damage.Verify tip to work distance and torch position.Check conduits and control cables for damage.Check gas and anti-spatter hoses for cuts, holes andleaks.Check weld wire delivery

33、 system and feed drive rolltensioner setting.Check electrical return circuit (coppers and cables fordamage and for completeness.Verify weld voltage, fault settings, weld current and gasflow rates are within limits posted on the Weld ToolData Sheet.Check water cooling to torch (if applicable.© C

34、opyright 2003 General Motors Corporation All Rights ReservedAugust 2003 Page 5 of 7GM9621P GM ENGINEERING STANDARDS Table A4: Drawn Arc Welding Equipment Each Shift X X X X X X Daily During Collet Change Monthly Equipment Monitoring Activity Check collet for broken or burned away tines, and check th

35、at collet nut is tight. Check the position or stick out of the probe/flash shield. Check piston for stick out. Verify drop time (at the welder control does not exceed setup value by more than 5 milliseconds. Check feeders and feed tubes for debris, excessive wear, and correct operation. Check work l

36、ead circuit (welder control/feeder to work piece. Ensure cables are intact, connections are tight, and contact blocks function properly. Check mount and slide unit for excessive play make sure tubes and cables do not inhibit movement. Check stick-out from collet, check lift distance and operation. Verify that arc voltage, current and time are within the process tolerances specified on the Weld Tool Data Sheet. Check feed tubes for wear and proper alignment. Check for abrasion between the inner and outer collet Check the power feed cable for wear and exposed co