welding process control procedure

1、1. 范围1.1 目的本标准详细说明了SGM焊接产品生产者的焊接检查和焊接设备工艺控制要求.1.2 应用本标准涉及的要求适用于上海通用汽车制作或装配工厂所采用的焊接及连接工艺.2. 参考GM9621P3. 流程3.1 过程评估3.1.1 设备过程监控设备过程监控包括工艺参数的测量以及设备功能性运转的目视评估。有关各种焊接工艺的设备过程监控要求。3.1.2 设备维护每个区域都要有设备维护的书面计划。设备维护的进度表应该和制造商的建议一致。3.2 产品控制和检查产品控制和检查包含对焊接产品的评估，参照适用的SGM工程标准来识别、包含和返修不一致的焊接模式。所有焊接的产品控制和检查计划必须有书面流程

2、或在标准化操作中描述。 注意：对于铝点焊，Peel测试是首选方法，Chisel测试是不可接受的方法。1. Scope1.1 PurposeThis standard defines weld inspection and welding equipment process control requirements for producers of SGM welded or mechanical clinched product. 1.2 ApplicationThe requirements of this standard are applicable to welding and joi

3、ning processes utilized by a Shanghai General Motors fabricating and/or assembly plant to join automotive parts and assemblies.2ReferencesGM9621P3. Procedure3.1 Process Evaluation.3.1.1 Equipment Process MonitoringEquipment process monitoring consists of measuring the process parameters established

4、during tool qualification as well as visual evaluation of the equipment functional operation.3.1.2 Equipment MaintenanceEach location shall have documented plans for the maintenance of equipment. The equipment maintenance schedule should be consistent with the tool or equipment manufacturers recomme

5、ndations3.2 Product Monitoring and Inspection.Product monitoring and inspection consist of evaluating the welded product with the released design and the applicable SGM Engineering Standards to identify, contain, and repair nonconforming weld patterns. Methodologies for physical testing of resistanc

6、e 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 method of inspection for aluminu

7、m spot welds. Chisel testing is not an acceptable method of inspection for aluminum spot welds.3.2.1 过程中检查和测试（电阻点焊）在每班的均匀间隔中，对所有点焊（所有类型和所有单元）推荐执行4次形变或超声波的非破坏性检查。至少对每把焊枪和每种板材匹配检查一次，每班如此执行四次。执行形变检查的同时，目视检查指定位置的胶水，并根据适用的产品图纸和SGM工程标准来目视检查所有焊接的一致性。3.2.2 过程中检查和其他测试除了3.2.1以外的焊接和连接方法必须通过目视化标准加以检验，每班至少4次。3.2

8、.3 焊接破坏性检查 总成工厂在系统填充的开始阶段，每种车型的整车破坏性检查频率至少为每月一次，持续到工艺能力得到论证并书面成文。工艺能力由连续三次破坏性检查达到要求来衡量。之后，每种车型的破坏性检查频率可以减少为每季度一次。3.2.4 焊接破坏性检查 制造工厂生产开始阶段，每个总成零件的破坏性检查频率至少为每月一次，持续到工艺能力得到论证并书面成文。工艺能力由连续三次破坏性检查达到要求来衡量。之后，每种零件总成的破坏性检查频率可以减少为每季度一次。3.3 焊接图像分析用来对焊接截面进行图像分析的检查、测量、试验等设备必须满足精度0.01毫米的测量标准。焊接截面使用15X或以下放大倍率来观察。

9、3.3.1 焊接截面焊接截面采样所需的数目取决于指定的焊接长度，参见下表：3.2.1 In-Process Inspection and Test (Resistance 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

10、per weld gun and metal stack-up, sampled four times per shift.Concurrent with the deformation checks, visually inspect for sealer presence if specified and visually inspect all welds for conformance to the applicable product drawing and SGM Engineering Standard.3.2.2 In-Process Inspection and Other

11、TestsWelds and joining techniques other than those mentioned in 3.3.1 should be verified for conformance to the visual acceptance criteria of the applicable standard a minimum of 4 times per shift. 3.2.3 Weld Destruct Test Assembly PlantsAt the Start of System Fill the frequency of full body destruc

12、t 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 of each body style.3.2.4 Weld Destruct

13、Test Fabricating PlantsAt 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 meet requirements. The frequency can then be

14、reduced to a quarterly destruct test of each assembly.3.3 Weld Image AnalysisInspection, measuring 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 0.01 millimeters. The use of the Native America

15、n Technologies Weld Measuring System (NAMeS) is recommended. Weld cross sections are to be viewed at 15X or less magnification.3.3.1 Weld Cross SectionThe number of required weld cross section samples is to be determined by the specified length of the weld bead in accord with the following table.Tab

16、le 1: Weld Beads vs Cross SectionsSpecified 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 from each other and from the ends of the welds 4 非破坏性评估4.1

17、在人员和工艺具有资格的情况下，可以在需要形变检查或破坏性检查的电阻点焊区域采用超声波评估。5 安全如果遵循适当的流程，并采取必要的防范措施，焊接、切割、连接等工艺可以安全的操作。6 发布和修订6.1 发布。本流程创建于2004年7月，7 附件A. B. 焊接质量控制流程C. 焊接质量问题跟踪单D. 焊接质量检查计划E. 焊接非破坏性检查规定F. 焊接破坏性检查规定G. 焊接质量问题返修作业规定H. 焊接参数更改规定Table 1: Weld Beads vs Cross SectionsSpecified Weld Bead Length (mm) Number of Cross Sectio

18、ns 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 from each other and from the ends of the welds 4 Nondestructive Evaluation (NDE)4.1 Ultrasonic evaluation of resistance spot welds can be utilized

19、in place of the required deformation or destruct tests provided the personnel and process have been qualified in accord with GMN10072, Personnel and Process Qualification for Ultrasonic Testing of Resistance Spot Welds.5 SafetyWelding, cutting and allied processes can be performed safely with minima

20、l health risk, provided proper procedures are followed and necessary 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

21、 and Revisions6.1 Release. This procedure originated in July 2004 and approved by the Weld Committee in July 2004. It was first published in July 2004.6.2 Revisions.7 AppendixA. B. Weld Quality Control ProcedureC. Weld Quality Issue Follow SheetD. Weld Quality Control PlanE. Weld Pry CheckF. Weld De

22、structive CheckG. Weld Repair WorkH. Weld Schedule ModificationAppendix A （返回）（返回）Appendix C （返回） 日期：焊接质量问题跟踪单车型：工段：工位号：焊枪号：焊点号：实施者：问题描述：原因：措施：质量跟踪建议：焊接参数改动：是；否；Sch No.焊接参数改动前改动后备 注 预压时间 (CY) 焊接脉冲数(IMP) 脉冲中焊接时间(CY) 焊接电流(KA) 冷却时间 (CY) 维持时间 (CY) 压力 (LBS) STEPPER记录者：跟踪记录：车辆识别号：第一辆第五辆第十辆第二十辆第四十辆电极帽更换次数第

23、一次第二次第三次第四次焊接质量关闭日期：生产工段长：焊接工程师：注：1. 如果调整飞溅、毛刺等，跟踪周期选择电极帽更换次数 2. 对于分拼等工位可以不填写车辆识别号 3. 跟踪阶段如有问题需及时通知焊接工程师 4. 跟踪阶段此单须放置于问题工位，由生产班组长保管 5. 完成跟踪后须将此单交由焊接工程师保留Appendix D （返回） 焊接质量检查计划一、 概述为满足白车身焊接检查需要，特制定本计划指导书。本指导书规定了车身车间焊接检查的时间和频率。二、 适用范围本标准适用于车身车间焊接质量控制。三、 职责由各生产工段负责车身焊接质量控制。四、 内容1破坏性检查 在试生产阶段，TRYOUT、N

24、S和S的各批次做一次破坏性检查。如果在S阶段，连续3次焊接合格率在97%以上，则可改为两个批次(仅指在S阶段)做一次破坏性检查。在正式生产阶段，开始按每周一次破坏性检查进行；如连续3次保持焊接破坏性检查合格率在97%以上，则焊接破坏性检查可改为每个月一次(如在S阶段最后3次的焊接合格率连续在97%以上，则可跳过该阶段，直接进入每月一次的检查频率)；之后， 如连续3次保持焊接破坏性检查合格率在99%以上，则焊接破坏性检查可改为每三月一次。 对二种以上产品共线生产可适当降低检查频次, 但不得低于每产品每六个月一次的焊接破坏性检查要求。另外进行分总成破坏性检查若检查合格率未达到97%以上，则要进行问

25、题分析和解决，并增加破坏性检查，直到合格率达到要求。2非破坏性检查 在试生产阶段，每个产品都必须进行一次非破坏性检查。 在正式生产阶段，每种车型每班须进行不少于四次非破坏性检查(在每班的均匀间隔时段内)。如每班生产时间超过或达到10小时，则每班必须增加检查一次(即不少于五次检查)。各工段可根据实际情况增加检查次数，确保焊接质量受控于车身车间内部。Appendix E （返回）焊接非破坏性检查规定一. 检查频率具体见焊接质量检查计划。二. 检查范围检查岗位中“焊接非破坏性检查单”所包含的所有焊点。三. 检查依据GM4488M, GM6122M, GM6435M, GMN7027四. 操作步骤1

26、电阻点焊 （详见GM4488M） 1.1 将被检查的部件放至检查岗位。 1.2 目视检查：检查焊接和工件是否异常。 A. 清点焊点个数。B. 检查焊点位置。C. 检查是否存在不可接受的焊点。 1.3 凿检： 将专用凿子(见附图一)在离焊点3-10mm处插入至一定深度(与被检查焊点内端齐平)，上下扳动凿子以检查焊点是否松动。注意事项见附图二。 1.4 拔出凿子，用0.5-1镑锤子还原零件。 1.5 对于无法凿检的焊点，可以应用超声波检测的方法。 在“焊接非破坏性检查单”上做好记录。如发现异常焊点，在相应的焊点号上做好异常状态记录，并执行焊接质量控制流程。2 弧焊 （详见GM6122M）3. 电阻

27、凸焊螺母、螺柱 （详见GM6435M） 3.1 对于板片凸点焊，用钢丝钳或其它自制工具夹住板片向垂直于板片的方向左右扳动，板片发生变形而凸焊点未脱落，则认为凸焊点合格。检查结束后将零件恢复原状。3.2 对于螺母凸焊，用0.5-1磅榔头从侧面猛击被检查螺母。如凸焊处未出现脱落， 则认为凸焊合格。检查结束后，将零件恢复原状。（改用扭力扳手）4. 提弧焊螺母、螺柱 (详见GMN7027) 3.1 对于螺柱凸焊，用焊接组规定的扭力扳手套住螺柱，左右扳动34次后，检查螺柱根部，无裂纹的为合格。(具体标准见附表一)附表一螺柱焊检验工具扭力对应表序号螺柱型号检具型号扭力值(kg)1T5x14.6WM1000

28、53.212T5x25WM100053.217M6x20WM100063.92813L/F M6 STUDWM100135.289T 5x9(PIN STUD)WM10005A3.21附图一：附图二：凿子顶端与焊点内端齐平不正确正确3-10mm不正确，太远不正确，太近Appendix F （返回）焊接破坏性检查规定一 检查频率具体见焊接质量检查计划。二. 检查范围 破坏性检查零件上所包括的所有点焊，凸焊，混合气体保护焊，螺柱焊焊接质量。三. 检查依据GM4488M, GM6122M, GM6435M, GMN7027四. 操作步骤 按各工段的标准操作单进行如下操作1 目视检查A. 清点焊点个数。B.检查焊点位置。C.检查是否存在不可接受的焊点。2 破坏性检查焊点的焊接强度利用液压张力钳或气动凿子将所有焊点全部撕开。如在一件母材上留下撕洞，在 另一件母材上附有焊核，且焊核尺寸符合标准要求，则此焊点合格，否则为不合格。可借助游标卡尺或直尺对焊核尺寸进行测量。3 在焊接破坏性检查单上做好记录，并通知焊接工程师，焊接工程师在采取改进措 施后，应填写好焊接质量问题跟踪单放于发生问题的工位。生产现场负责做好跟踪和记录。4 检查完毕后，清理工作场地，填写报