1、NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER: TMS-9516 TITLE: Quality Requirements For Resistance Spot Welds In Steel CURRENT REV. No.: 0806 DATE: June 2008 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: Rev D June 2003 PRINTED COPIES OF THIS DOCU
2、MENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to
3、 determine the applicability of regulatory limits prior to use. Change Notice: Defined steel grades covered by this spec; added requirements for stainless steel; add Section 6.4.2 for FMVSS 221 bus body design; added Sections 7, 8, and 9; replaced “International Truck and Engine Corporation” with “N
4、avistar, Inc.” per corporate directive; editorial changes. Reference: File: 40-11 Keywords: Welding, spot welds, sheet metal welding, resistance welds. 1.0 APPLICATIONThis specification covers the quality requirements for resistance spot welds used in fabricating truck bodies and other truck compone
5、nts made from bare or coated low carbon steel (Grade 1 or Grade 1GALV per CEMS A-6), high-strength steel grades (Grade 6 or Grade 6GALV per CEMS A-6), and stainless steel per CEMS A-37. The specification is applicable to spot welded assemblies produced in NAVISTAR plants and/or produced by suppliers
6、 in supplier facilities and then shipped to NAVISTAR plants. 2.0 SCOPE This specification establishes three resistance spot weld classifications and defines the quality requirements for each class. Specific requirements for spot weld nugget/button size, weld spacing, overlap, test and inspection cri
7、teria, and repair options for each class of spot weld are detailed in this specification. Engineering will determine the required weld classification and designate the appropriate class by using the weld symbol for that class on the engineering drawing. (see Figure 1) Weld Classification Weld Symbol
8、 Weld Description Obsolete Weld Class Obsolete Symbol Class A Compliance Critical Any weld contributing to structural integrity in such manner that compliance to FMVSS or to roof strength requirements could be compromised by a substandard weld. Compliance Welds or or Durability Critical Any weld con
9、tributing to structural integrity in such manner that cab durability requirements could be compromised by a substandard weld. - Class B Commercial or Normal Spot welds subjected to moderate or low levels of stress, requiring only a commercial or normal level of quality. Commercial Welds None 2.1 Res
10、tricted Chemical SubstancesEffective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the CEMS B-50 specification. This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporat
11、e Technical Standards. Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. JUNE 2008 Page 1 of 17 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-2NUMBER
12、: TITLE: Quality Requirements For Resistance REVISION: TMS-9516 Spot Welds In Steel 0806 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of
13、 all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. Quality System Standard ISO 9001 or TS-16949 NAVISTAR CEMS A-6, Pt.I NAVISTAR Manufacturing Standard MS-D-13 NAVISTAR CEMS A-6, Pt.II CFR Title 29, Part 1910 NAVISTAR
14、CEMS A-37 ANSI/AWS C1.1M/C1.1 NAVISTAR TDS-SD-7.18 ANSI/AWS C1.4M/C1.4 ANSI/AWS D8.7 NAVISTAR CEMS B-50 FMVSS 221 3.1 Definitions Welding terms used in this specification are defined below. 3.1.1 Minimum Weld Diameter The smallest diameter measured on a fused nugget or pulled button. 3.1.2 Average W
15、eld Diameter The arithmetic average of the smallest and largest diameters measured on a fused nugget or pulled button. 3.1.3 Satisfactory Weld A tested spot weld which is properly located, shows positive evidence of metal coalescence, is complete, is not excessively distorted (see Section 3.1.5) and
16、 with the fused nugget or pulled button having either a minimum diameter (see 3.1.3.1) or an average diameter (see 3.1.3.2) equal to or greater than the applicable value shown in Column 3 of Table 1. . 3.1.3.1 Compliance Critical and Durability Critical Welds: Compliance and Durability critical weld
17、s will have a minimum diameter greater than or equal to the applicable value shown in Column 3 of Table 1. 3.1.3.2 Commercial/Normal Welds: Commercial/normal welds will have an average diameter equal to or greater than the applicable value shown in Column 3 of Table 1. 3.1.4 Undersize Weld A tested
18、spot weld which shows positive evidence of metal coalescence and with a fused nugget or pulled button having either minimum diameter (see 3.1.4.1) or average diameter (see 3.1.4.2) smaller than a satisfactory weld but greater than or equal to the value in Column 4, Table 1. 3.1.4.1 Compliance Critic
19、al and Durability Critical Welds: Compliance and Durability critical welds will have a minimum diameter greater than or equal to the applicable value shown in Column 4 of Table 1. 3.1.4.2 Commercial/Normal Welds: Commercial/normal welds with an average diameter equal to or greater than the applicabl
20、e value shown in Column 4 of Table 1. 3.1.5 Substandard Weld A visually inspected or tested spot weld that shows one or more of the conditions listed in this section is a substandard weld. (Refer to ANSI/AWS D8.7) 3.1.5.1 Nugget/Button Diameter Too Small: A tested weld whose fused nugget or button h
21、as either a minimum diameter (for Compliance or Durability Welds) or an average diameter (for Commercial or Normal Welds) that is less than the applicable value shown in Column 4 of Table 1. Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. JUNE 2008 Page 2 of 17 Copyrigh
22、t Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3NUMBER: TITLE: Quality Requirements For Resistance REVISION: TMS-9516 Spot Welds In Steel 0806 This document is restricted and may not be
23、sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. 3.1.5.2 Cold Weld: A tested weld that shows no evidence of metal coalescence. 3.1.5.3 Missing Weld: A weld not present at, or missing from, its specified location. 3.1.5.4 Off-Location Weld: A weld that
24、is displaced from its specified location by a distance greater than 7mm. 3.1.5.5 Incomplete Weld: A weld, such as an edge weld, that does not exhibit base metal around the full circumference of the weld. 3.1.5.6 Distortion: A spot weld is substandard if it is more than 30 out of the normal weld plan
25、e. 3.1.6 Spacing The centerline-to-centerline distance between two adjacent spot welds. 3.1.7 Contacting Overlap The distance that two mating sheet metal parts are in contact in lap joints, including coach or flange type joints. 3.1.8 Edge Welds A spot weld in a lap, coach or flange joint having ins
26、ufficient edge distance to provide adequate heat conduction between the periphery of the weld bead and the edge of the part and/or adequate strength to resist lateral forces of deformation (prevent movement) during welding (See Fig. 3). 3.1.9 End Welds A spot weld that is common to two lines of weld
27、s at their intersection point, or a weld at the extremity of a line of welds as defined on an Engineering drawing. (see Figure 3). 3.1.10 2T Stack-up A welded joint made up of two material thicknesses. 3.1.11 3T Stack-up A welded joint made up of three material thicknesses. 3.1.12 Set-up Weld A weld
28、 which is performed at initial production set-up or after maintenance using the proper electrode size, shape, and configuration for the production process. At the start of a production run, the welding machine, tooling, and setup should be able to produce a pulled button diameter as close as practic
29、al to the set-up values shown in the applicable tables. 3.1.13 Weld Group/Grouping A row, string, pattern or array of spot welds joining one part to another as specified on the product drawing. 4.0 GENERAL REQUIREMENTS4.1 Base Metal 4.1.1 Bare Steel The type of unfinished steel covered by the requir
30、ements of this spec would include: 1) low carbon steel (Grade 1/1C per CEMS A-6, Part I), 2) dent-resistant steel (Grade 6, Types 180-280, per CEMS A-6, Part I) 3) structural steel (SS) (Grade 6, Types 205SS-340SS, per CEMS A-6, Part I) 4) high-strength low-alloy (HSLA) steel per CEMS A-6, Part I 5)
31、 stainless steel per CEMS A-37 Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. JUNE 2008 Page 3 of 17 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo reproduction or networking permitted without license from IHS-,-,
32、-4NUMBER: TITLE: Quality Requirements For Resistance REVISION: TMS-9516 Spot Welds In Steel 0806 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. 4.1.2 Metallic Coated Steel Carbon steel sheet to be spot welde
33、d may also be coated, on one or both sides, with zinc or zinc alloy coating (Grade 1GALV or Grade 6GALV) or aluminum (Grade 1A) per CEMS A-6, Part II. 4.1.3 Primers/Sealers The use of weld-thru primers/sealers is permissible if those suitable and proven weld schedules are used which reflect the limi
34、tations and special requirements necessary for welding these materials. 4.2 Weld Requirements4.2.1 Spot Weld Size for Steel (see Table 3 for stainless steel requirements) 4.2.1.1 Production Set-up Welds: Tested production set-up welds should have a fused nugget or button diameter that is equal to or
35、 greater than the value shown in column 2 of Table 1. The material thickness selected from Table 1 should be based upon the thinnest material in the 2T or 3T stack-up. 4.2.1.2 Production Welds: Tested spot welds will have a fused nugget/button diameter equal to or greater than the values shown in co
36、lumn 3 and/or column 4 of Table 1. The material thickness selected from Table 1 should be based upon the thinnest material in the 2T or 3T stack-up. The welds will be counted as satisfactory, undersize, or substandard (too small, incomplete, cold, off-location or missing) and will meet the requireme
37、nts for the specified weld classification as described in Section 4.2.3 Spot Weld Quality Requirements. 4.2.1.2.1 Edge Welds: Tested spot welds will have a fused nugget/button diameter equal to or greater than the values shown in column 3 and/or column 4 of Table 1. The material thickness selected f
38、rom Table 1 should be based upon the thinnest material in the 2T or 3T stack-up. Welds that meet the size requirement and have parent metal present around the full circumference of the weld are acceptable. The welds will be counted as satisfactory, undersize, or substandard (too small, incomplete, c
39、old, off-location or missing) and will meet the requirements for the specified weld classification as described in Section 4.2.3 (Spot Weld Quality Requirements). 4.2.2 Spot Weld Spacing Weld spacing will be indicated on the Engineering drawing. Tested welds will be counted as substandard (off-locat
40、ion) if they are out of position a distance greater than 7mm from their specified location. 4.2.3 Spot Weld Quality Requirements Quality criteria for the three Weld Classifications described in this specification are defined in this section. If different weld classifications are specified on the sam
41、e drawing, they will be evaluated separately using the criteria for each classification. The primary criterion, spot weld size, is evaluated using static tests as described in Test Methods (See 4.3.1). The use of other accelerated or dynamic testing methods may lead to erroneous results. No deviatio
42、ns to these quality criteria are permitted without the written approval of the Resident Engineer of the Assembly plant. 4.2.3.1 Compliance Critical Welds: No substandard welds are permitted. No two adjacent undersize welds are allowed. No end welds are permitted to be undersized. In addition, spot w
43、elds specified as Compliance Critical will meet requirements indicated in the following table. Suppliers are required to assume all patent liability. 2008 by Navistar, Inc. JUNE 2008 Page 4 of 17 Copyright Navistar International Corporation Provided by IHS under license with INTERNNot for ResaleNo r
44、eproduction or networking permitted without license from IHS-,-,-5NUMBER: TITLE: Quality Requirements For Resistance REVISION: TMS-9516 Spot Welds In Steel 0806 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards.
45、 Compliance Critical Welds Number of Welds (in a grouping) Specified on Drawing Number of UndersizeWelds Allowed Number of SubstandardWelds Allowed 3 or less 0 0 4 to 8 1 0 9 to 16 2 0 17 or more 15% * 0 * Rounded to the nearest whole number 4.2.3.2 Durability Critical Welds: No two adjacent substan
46、dard welds are allowed. No substandard weld is permitted to be adjacent to an undersize weld. No more than two-adjacent undersize welds are allowed. No end welds are permitted to be substandard or undersized. In addition, spot welds specified as Durability Critical will meet requirements indicated i
47、n the table below. Durability Critical Welds Number of Welds (in a grouping) Specified on Drawing Number of UndersizeWelds Allowed Number of SubstandardWelds Allowed 3 or less 1 0 4 to 8 2 1 9 to 16 3 2 17 or more 20% * 5% * * Rounded to the nearest whole number 4.2.3.3 Commercial/Normal Welds: No t
48、wo adjacent substandard welds are allowed. No combination of substandard and undersize welds greater than three-adjacent are permitted. No end welds are permitted to be substandard. The minimum number of satisfactory welds developed on the part, as shown on the Engineering drawing, shall not be less than 60%*. In addition, spot welds specified as Commercial will meet requirements indicated in the table below for Co
