1、 SURFACE VEHICLE RECOMMENDED PRACTICE STRSW (Squeeze Type Resistance Spot Welding) Equipment Acceptance Criteria for the Collision Repair Industry SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of
2、 this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or
3、cancelled. SAE invites your written comments and suggestions. Copyright 2004 SAE International All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
4、without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: 724-776-4970 (outside USA) Fax: 724-776-0790 Email: custsvcsae.org SAE WEB ADDRESS: http:/www.sae.org Issued 2004-10 J2667 ISSUED OCT2004 1. Scope This SAE Recommended Practice prov
5、ides a minimum standard for evaluating squeeze-type resistance spot welding (STRSW) equipment and minimum weld performance criteria for two-sided automotive collision repair welding. This document contains several standardized test methods that are designed for evaluating equipment performance in a
6、laboratory environment. 1.1 Purpose This SAE Recommended Practice provides manufacturers of STRSW equipment with minimum performance criteria for collision damage repairs. Collision repair centers and related businesses will also benefit by having a guideline for selecting STRSW equipment that meets
7、 this minimum performance criteria. 1.2 Background The use of STRSW in the automotive collision repair market has continued to grow. STRSW is being used in the collision repair process to help closely duplicate the appearance and function of the original production welds. The proper performance of S
8、TRSW is especially critical during a collision, as the welds play an important role in the structural integrity and energy management of the vehicle. 2. References 2.1 Applicable Publications The following publications form a part of this specification to the extent specified herein. SAE J2667 Issue
9、d OCT2004 - 2 - 2.1.1 AMERICAN WELDING SOCIETY (AWS) PUBLICATIONS Available from American Welding Society, PO Box 351040, Miami, FL 33135 AWS D8.7-88Recommended Practices for Automotive Weld QualityResistance Spot Welding. AWS D8.9-97Recommended Practices for Test Methods for Evaluating the Resistan
10、ce Spot Welding Behavior of Automotive Sheet Steels AWS PARWThe Professionals Advisor on Resistance Welding, American Welding Society AWS A3.0Standard Terms and Definitions 2.1.2 RESISTANCE WELDER MANUFACTURERS ASSOCIATION PUBLICATION Available from Resistance Welder Manufacturers Association (RWMA)
11、, 1900 Arch Street, Philadelphia, PA 19103-1498. Resistance Welder Manufacturers AssociationResistance Welding ManualDecember, 1989 3. Definitions For additional welding terms, see AWS A3.0, Standard Welding Terms and Definitions. 3.1 Button or Weld Button That part of a weld, including all or part
12、of the nugget, that tears out in the destructive testing of spot-, seam- or projection-welded specimens. 3.2 Coupon A single, small piece of test material, with specified dimensions, that is used to make up test samples. 3.3 Faying Surface The mating surface of a member that is in contact with or in
13、 close proximity to another member to which it is to be joined. 3.4 Fracture Mode The appearance of the weld button after peel testing. 3.5 Indentation In a spot, seam, or projection weld, the depression on the exterior surface of the work pieces. 3.6 Nugget or Weld Nugget The weld metal joining the
14、 work pieces in spot-, seam- or projection-welding. SAE J2667 Issued OCT2004 - 3 - 3.7 Peel Test A destructive test for determining a spot welds fracture mode and button size. The test involves mechanically separating the lap joint by peeling. 3.8 Resistance Spot Welding (RSW) A resistance welding p
15、rocess that produces a weld at the faying surfaces of a joint by the heat obtained from resistance to the flow of welding current through the work pieces from electrodes that serve to concentrate the welding current and pressure at the weld area. 3.9 Weld Current The effective (RMS) welding current
16、of a spot weld that is measured at the secondary side of the welding transformer by an integrating current meter (ammeter). 4. Standard Units of Measurements 4.1 Stated Values All units in this document are hard metric. Metric was purposely selected for ease of use, because metric is the standard un
17、it of the United States, because automotive companies have converted to metric, and so that the document may be internationally usable. If necessary, conversions of units of measurement shall be performed according to ANSI/AWS A1.1 Metric Practice Guide for the Welding Industry. It is highly recomme
18、nded that all measurements be made with metric instruments in the application of these test methods. If this is not possible and non-metric instruments are used, it shall be noted on all data and report sheets that non-metric instruments were used and that the values recorded or reported are convers
19、ions from non-metric measurements. 5. Applicable Sheet Steel for Equipment Testing 5.1 Material Applications This Recommended Practice is applicable to resistance spot welding applications of all automotive components fabricated from un-coated (bare) and galvanized (hot-dip, zinc-coated), galvanneal
20、ed (zinc-iron alloy-coated), or electrogalvanized (zinc- or zinc-iron alloy-coated) steel. 5.2 Coating Limitations The surface of the material at the time of welding should be free of all contaminants such as rust, dirt, paint, sealers, adhesives oils, etc. that would adversely affect weld quality.
21、The use of weld-through primers and sealers is acceptable where the limitations and special requirements imposed by the specific primer or sealer are recognized. 5.3 Thickness Requirements Sheet metal used for this Recommended Practice is two layers of 1.27 mm (18 gauge) 60/60 electrogalvanized stee
22、l (ASTM 591). SAE J2667 Issued OCT2004 - 4 - 6. Equipment Minimum Requirements 6.1 The welder must provide a two-sided weld. 6.2 The welder must operate from a minimum of 220 volts, single-phase power. Three-phase power is preferred for cabletype welders. 6.3 The welder must maintain a minimum elect
23、rode tip force of 182 kg (401 pounds) with all available arm sets, as measured with a force gauge. 7. Equipment Performance Requirements 7.1 Visual Inspection All welds must pass the visual inspection (Reference Para. 7) before being subjected to the destructive tests (Reference para. 8). 7.2 Destru
24、ctive Tests After passing the visual inspection, all welds must pass the destructive tests (Reference para. 8). 8. Visual Inspection The test welds must pass this visual inspection before they are subjected to the required destructive tests in Section 8. 8.1 Excessive Indentation The depth of depres
25、sion on sheet surfaces caused by welding electrodes must not exceed 25 percent of the sheet thickness. 8.2 Distortion The base metal must not be distorted to the extent that the face of the weld is more than 30 degrees out of the plane of the metal surface or the sheet is pulled out of line by more
26、than twice its thickness immediately around the weld. 8.3 Missing and Mislocated Welds Welds that are not made at specified locations, or welds that are located outside the tolerance limits are substandard welds. 9. Destructive Testing The test welds must pass these destructive tests to qualify for
27、repairing collision-damaged vehicles. SAE J2667 Issued OCT2004 - 5 - 9.1 Duty Cycle Test The duty cycle test consists of making a series of welds using 6 mm electrode tips on two layers of 1.27 mm (18 gauge) 60/60 electrogalvanized steel (ASTM 591) as shown in Figure 1. The 48 welds must be made con
28、tinuously, in one direction, within a period of 6 minutes, without redressing the electrode tips. The welds made at locations 12, 24, 36, and 48 must pass the peel test in para. 8.2. Show on diagram: peel-test locations 12, 24, 36, and 48; minimum overlap of 30 mm; minimum edge distance of 13 mm to
29、center of welds. FIGURE 1DUTY CYCLE TEST LAYOUT 9.2 Peel Test The peel test is performed by completely peeling apart a welded lap joint. Where feasible, the direction of peel should be in the direction of the joint line or line of welds. The average diameter of each of the resultant buttons must be
30、a minimum of 5mm, measured at the faying surface of the weld button. See Figure 2. NOTEThe 5mm button applies only when welding two layers of 1.27 mm (18 gauge) 60/60 electrogalvanized steel (ASTM 591). Test results will vary when welding other thicknesses or multiple layers of sheet metal. SAE J266
31、7 Issued OCT2004 - 6 - FIGURE 2MEASUREMENT OF A WELD BUTTON RESULTING FROM THE PEEL TEST 9.3 Twist Test The twist test consists of making a weld using 6 mm electrode tips on two layers of 1.27mm (18 gauge) 60/60 electrogalvanized steel (ASTM 591) as shown in the figures below. The weld must create a
32、 weld button that has a diameter equal to or larger than 5 mm. (See Figures 3 through 6.) NOTEThe 5mm button applies only when welding two layers of 1.27 mm (18 gauge) 60/60 electrogalvanized steel (ASTM 591). Test results will vary when welding other thicknesses or multiple layers of sheet metal. S
33、AE J2667 Issued OCT2004 - 7 - FIGURE 3TEST COUPON ASSEMBLY AND WELD LOCATIONS FOR TWIST TEST FIGURE 4SECURE THE WELDED TEST COUPONS IN A VISE AND TWIST TO SEPARATE THE COUPONS SAE J2667 Issued OCT2004 - 8 - FIGURE 5THE TWIST TEST CREATES A TEAROUT HOLE IN ONE COUPON AND A NUGGET ON THE OTHER FIGURE
34、6THE DIAMETER OF THE WELD NUGGET MUST BE EQUAL TO OR LARGER THAN 5 mm SAE J2667 Issued OCT2004 - 9 - 10. Notes 10.1 Key Words Collision repair, collision repair welding, resistance spot welding, squeeze-type resistance spot welding, weld button, peel test, twist test, electrode diameter, duty-cycle
35、test PREPARED BY THE SAE STRSW COMMITTEE OF THE SAE VEHICLE SERVICE DEVELOPMENT DIVISION SAE J2667 Issued OCT2004 Rationale Not applicable. Relationship of SAE Standard to ISO Standard Not applicable. Application This SAE Recommended Practice describes minimum performance criteria for resistance spo
36、t-welding equipment that will be used during the repair of collision-damaged vehicles. Reference Section AWS D8.7-88Recommended Practices for Automotive Weld QualityResistance Spot Welding. AWS D8.9-97Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behavior of Autom
37、otive Sheet Steels AWS PARWThe Professionals Advisor on Resistance Welding, American Welding Society AWS A3.0Standard Terms and Definitions Resistance Welder Manufacturers AssociationResistance Welding ManualDecember, 1989 Developed by the SAE STRSW Committee Sponsored by the SAE Vehicle Service Development Division
