FORD FLTM BA 113-08-2013 SPOT WELD TEST CRITERIA FOR BARE AND COATED STEEL SHEET.pdf

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1、Date Action Revisions Rev 02 2013 05 08 Revised See summary of Revisions for Updates D. Ruhno, NA 2009 02 03 Revised Pages 1 and 2 T. Coon, FNA 2005 11 28 Activated D. Ruhno Copyright 2013, Ford Global Technologies, LLC Page 1 of 13 FORD LABORATORY TEST METHOD BA 113-08 SPOT WELD TEST CRITERIA FOR B

2、ARE AND COATED STEEL SHEET Application This procedure defines the test setup for material qualification of bare and coated (zinc, zinc/iron, zinc/alloy, and aluminized) steel sheet products that are included in the chart below. Additionally, this procedure may be used as the foundation for developin

3、g production spot weld processes for high strength steel grades. Types of Steel Common Global Grade Name Ford Global Material Specification Mild (Low Carbon) Steels CR1, CR2, CR3, CR4, CR5, HR0, HR1, HR2, HR3 WSS-M1A365-A11/A15 WSS-M1A365-A20/A23 Dent Resistant Steels CR180, CR210 WSS-M1A367-A11/A12

4、 Bake Hardened Steels CR180B2, CR210B2, CR240B2 WSS-M1A367-A21/A23 High Strength Low Alloy Steels CR240LA, CR270LA, CR300LA, CR340LA, CR380LA, CR420LA, HR270LA, HR300LA, HR340LA, HR380LA, HR420LA, HR500LA, HR550LA WSS-M1A367-A35/A36 WSS-M1A367-A45/A46 Dual Phase Steels1) CRDP600, CRDP800, CRDP1000 W

5、SS-M1A368-A13/A14/A15 Ferrite Bainite Steels1) HRFB600 WSS-M1A368-A42 Martensitic Steels1) CRMS900, CRMS1100, CRMS1300, CRMS1500, HRMS1200, HRMS1400 WSS-M1A368-A81/A84 WSS-M1A368-A91/A92 Press Hardened Aluminized Boron Steels1) N/A WSS-M1A357-A12) WSS-M1A358-A12) 1) Advanced High Strength Steels are

6、 included within a limited applicability. Requests for source approvals of these grades should be checked against the “Okay-to-Use List” for their expected application. Non-conforming grades/applications need to be reviewed by the Sheet Metal Tech Club. 2) WSS-M99P39-A1/A2/A3/A4 performance specific

7、ation must be called out with these Boron steels. Materials covered by the application of this test method are tested in accordance with AWS D8.9M:2012 “Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steel Materials“. The table below defines which sections of th

8、e procedure are followed for each type of material being tested. Material Weld Tests Thickness Tensile Strength Coating Lessthan1.25mm Greaterthanor equal to1.25mm Lessthanor equal to480 MPa UltimateTensileStrengthGreaterthan480 MPaUltimateTensileStrengthBare (Uncoated) Coated (Zn or Zn-Fe) Electrod

9、e EnduranceTest (Sec. 10 10.10.3) WeldQualityTest (AWS D8.9M:2012Sec. 11 11.8.5) WeldLobe(Sec. 10 10.4.4 or 11-11.4.4 for two additional weld times+25%typically only used to explore the performance of new steels, not for material qualification or program stack-up prove-out) FORD LABORATORY TEST METH

10、OD BA 113-08 Copyright 2013, Ford Global Technologies, LLC Page 3 of 13 Forms/Data Sheets Qualification reports must contain Ford versions of the following forms / data sheets where appropriate. The forms are reproduced in this procedure for convenience. Note: These are to the 2012 release of AWS D8

11、.9. Ford Version AWS Original Name FB-1 B1 Welding Data Sheets FB-2 B2 Tip Imprint Data Sheet FB-3 B3 Test Material Data Sheet FB-4 B4 Endurance Test Report FB-5 B5 Weld Property Report FX-1 N/A Ford Weld Lobe Data Sheet Summary of Revisions 2013 05 08 Application - Added statement making this FLTM

12、applicable to production spot weld process development - Specification Table: (Removed) “Category” column and added “Common Global Grade Name” - Grades: (Added) CRDP1000 & HRFB600, (Removed) reference to TRIP steel (unapproved) - Renamed “Boron Steel” as “Press Hardened Aluminized Boron Steel” - Foo

13、t notes: Updated to reflect above changes to the grades and added reference to “Ok-to-Use List” - Weld Table: Thickness transition changed from 1.05 mm to 1.25 mm - Weld Table: Tensile strength transition changed from 500 MPa to 480 MPa - Weld Table: Endurance Test required (“X”) for coated material

14、 1.25 mm with tensile 480 MPa - Weld Table: Minimum requirements added for Endurance and Weld Lobe tests Testing Procedure - 6.2.4: (Added) Use Ford VOSS weld schedules. Modification to these schedules requires Ford Joining Engineering approval. - 6.2.8: (Added) Changes made to welding speed require

15、ment for material 1.85mm - 6.7.1: (Added) Clarification on method used to calculate minimum weld size - 6.7.2: (Added) Required stabilization weld sizes for various gauge ranges - 9.3.3-9.3.8.3: (Added) Modified procedure for electrode stabilization - 10.4.1 & 10.7.1: (Added) Tests with B20 (20mm) e

16、lectrodes can utilize a 200A increment vs. 100A - 10.5.6: (Added) Definition of Endurance Limit and recording practice - 11.4.1: (Added) Tests with B20 (20mm) electrodes can utilize a 200A current increments - 11.5.1: (Added) New weld sizes for re-stabilization procedure - 11.6: (Removed) Option to

17、perform weld test on only low hold time samples if no hold time sensitivity - Modified criteria for performing dye penetrant testing Forms/Data Sheets - FB-1: Changed “Failure Mode” to “Fracture Mode” - FB-2: Added Label titles to table - FB-3: Added required elements to the coating and substrate ch

18、emistry tables - FX-1: Added units to the data sheet Global - All references to “AWS D8.9M:2009” changed to “AWS D8.9M:2012” Copyright 2013, Ford Global Technologies, LLC Page 4 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_ Laboratory Name:Address:Test Code: Test Type: Test Opera

19、tor: Test Date:Steel /Type: Sheet Thickness: Coating Type: Coating Weight/Thickness:Top BottomCoil/Heat/ID No: Electrode Type: Electrode-Face Dia.: Electrode-Face Thick:Welding Machine: Welding Control: Welding Mach. Tap: Cooling Tube-OD Dia.:Water WaterCurrent Analyzer: Force Gauge: Flow: l/min Tem

20、p: C Welding Rate:Squeeze Time: Weld Time(s): Hold Time(s): Off Time (Repeat Welding):Weld Force: Force Pressure Setting: Welding Mode: Panel Type:Comments:WELDING DATA SHEET (FB-1)Copyright 2013, Ford Global Technologies, LLC Page 5 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_

21、Sample Welding Current Data Weld Button Data Peelor Expul.or Min. Max. Mean SampleWeld Current Current no Expul. Dia. Dia. Dia. Type Remarks No. Setting (kA) (E or N) (mm) (mm) (mm) (C, R, L)WELDING DATA SHEET (FB-1 cont.)FractureMode(D8.1M)Copyright 2013, Ford Global Technologies, LLC Page 6 of 13

22、FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_ Laboratory NameAddressTest Code Test Type Test DateTest OperatorCommentsLabel Top Bottom CompositeElectrode Set #1 StartElectrode Set #1 EndElectrode Set #2 StartElectrode Set #2 EndElectrode Set #3 StartElectrode Set #3 EndTIP IMPRINT DATA

23、 SHEET (FB-2)Copyright 2013, Ford Global Technologies, LLC Page 7 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_ Laboratory Name: _ Address: _Coil No. or ID:_ Reporter Name:_ Report Date: _Steel Grade:_ Coating Type:_ Nominal Coating Wt.:_g/m2/_g/m2Brand Name Type Brand Name TypeS

24、urface Lubricants:_ Post-Coating Treatment:_Comments:_Side Trimmed Center Trimmed Test(Top* and Edge X Point Edge Y Mean Std. Dev. MethodBottom) (g/m2) (g/m2) (g/m2) (mm) (mm) Used* Note: Top side is marked sideSampleNumberElement Zn Al Fe Pb Sb Sn Cd Mg Zn Al Fe Pb Sb Sn Cd Mg* Note: Top side is ma

25、rked sideElement C Mn P S Al Si Ca Cr Mo V Ti Nb Cu Ni N BAnalysisEdge XCenterEdge YMeanTEST MATERIAL DATA SHEET (FB-3)Sheet Coating WeightBot. SideY MpaUTS MpaMethodUsed CommentsSample 1 Sample 2Sheet Coating Composition (% weight) (bath chem. not acceptable)Cat. %El n RSheet Substrate Composition

26、(% weight)Mechanical PropertiesTop* SideCopyright 2013, Ford Global Technologies, LLC Page 8 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_ LABORATORY NAME:ADDRESS:TELEPHONE No.:FAX No.:Coil No. or ID: Steel Grade:Top Btm.Coating Type:Brand Name Type Brand Name TypeSurface Lubrica

27、nts:Other Data or Comments:Welding Machine Type:Welding Machine Tap:Air Cylinder Size:Top Elect. Btm Elect.Electrode Type (No.):Cooling Tube-OD Dia.:Weld Force: Welding Mode:Set Squeeze Time: Weld Time: Set Hold Time:Off Time (Repeat Welding): Water Flow: Water Temp.:Mean Coating Wt.:Post-Coating Tr

28、eatment:Dressed Face Dia.:Flow Meter Brand:Air Cylinder Type:Model Number:Face Thick:Flow Meter Model No.:Comments or Variances to Specified Equipment:Comments or Variances to Specified Parameters:Actual Hold Time:Panel Type:Welding Rate:Welding ParametersMachine Capacity:Force Gauge Brand & Model N

29、o.:Equipment InformationCurrent Analyzer Brand & Model No.:Weld Controller Name: Controller Mode:Head Velocity:Material DataMean Thickness:APPROVED BY:TITLE:ENDURANCE TEST REPORT (FB-4)REPORT DATE:REPORTED BY:Copyright 2013, Ford Global Technologies, LLC Page 9 of 13 FORD LABORATORY TEST METHOD BA 1

30、13-08 Job#_ Qualification#_ welds kAwelds kAwelds kAweldskA mm kA mmkA mm kA mmkA kAkA mm kA mmkA mm kA mmkA kAkA mm kA mmkA mm kA mmkA kAkA kAkA kAkA kAkAkAkANote: * = Optional whenever asterisk is shown on this page.At Endurance Limit:After Last Weld:Current Levels, Current Ranges And Weld Button

31、Sizes:Mean Electrode Face Diameters (mm)Mean All I max:- Mean All I min:=Mean All CR:As Machined:Test 1 II max:IOP- Test 3* II min:=Test 3* ICR:- Test 1 II min:=Test 1 ICR:Test 2* II max:- Test 2* II min:=Test 2* ICR:Test 3* II max:Top ElectrodeTest 2 Test 3CompositeTest 1 Test 2 Test 3Btm. Electrod

32、eTest 1 Test 2 Test 3At 8000 Welds*:=Mean FCR:Test 1 FI max:-Test 1 FI min:=Test 1 FCR:Test 2* FI max:-Test 2* FI min:=Test 2* FCR:Test 3* FI max:-Test 3* FI min:After Final Dressing:Test 1At 7000 Welds*:After Stabilization*:After Initial I max*:At 5000 Welds*:At 6000 Welds*:At 1000 Welds*:At 2000 W

33、elds*:At 3000 Welds*:At 4000 Welds*:Mean FI max:-Mean FI min:Mean II max:- Mean II min:=Test 3* FCR:DFI max:DII max:DII min:=Mean ICR:DFI max:DFI max:DII max:DII min:NANAMeanDFI max:DFI max:DFI max:DII max:DII min:Endurance LimitTest 1Test 2*Test 3*ENDURANCE TEST REPORT (FB-4 cont.)Weld Quality Endu

34、rance Limits To:Copyright 2013, Ford Global Technologies, LLC Page 10 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_ LABORATORY NAME:ADDRESS:TELEPHONE No.:FAX No.:Coil No. or ID: Steel Grade:Top Btm.Coating Type:Brand Name Type Brand Name TypeSurface Lubricants:Other Data or Comme

35、nts:Welding Machine Type:Welding Machine Tap:Air Cylinder Size:Top Elect. Btm Elect.Electrode Type (No.):Cooling Tube-OD Dia.:Weld Force: Welding Mode:Set Squeeze Time: Weld Time: Set Hold Time:Off Time (Repeat Welding): Water Flow: Water Temp.:Mean Coating Wt.:Post-Coating Treatment:Dressed Face Di

36、a.:Flow Meter Brand:Air Cylinder Type:Model Number:Face Thick:Flow Meter Model No.:Comments or Variances to Specified Equipment:Comments or Variances to Specified Parameters:Actual Hold Time:Panel Type:Welding Rate:Welding ParametersMachine Capacity:Force Gauge Brand & Model No.:Equipment Informatio

37、nCurrent Analyzer Brand & Model No.:Weld Controller Name: Controller Mode:Head Velocity:Material DataMean Thickness:APPROVED BY:TITLE:WELD PROPERTY REPORT (FB-5)REPORT DATE:REPORTED BY:Copyright 2013, Ford Global Technologies, LLC Page 11 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualificati

38、on#_ kA mm kAkA mm kAkA kAkA mm kAkA mm kAkA kAShort cyLong cyShort cyLong cyShort cyc.:Long cyc.:Short cyc.:Long cyc.:WELD PROPERTY REPORT (FB-5 cont.)Comments:Comments:SHEAR TENSION DATADI max:DI min:Test 2* I max:-Test 2* I min:DI* max:DI* min: Mean All* I min:=Test 2* CR:Mean All* I max:DI* max:

39、DI* max:Test 3* I max:- Test 3* I min:Current Levels, Current Ranges And Weld Button Sizes:Test 1 I max:- Test 1 I min:=Test 1 CR:HOLD- TIME SENSITIVITY DATA=Test 3* ICR:Mean IFDWS Current (kA) Mean Button Diameters (mm) Mean Fused Diameters (mm)Mean All* CR:HOLD TIMESetup Samples:Number of PIF + FI

40、F vs. Total WeldsPIF+FIF Welds Total WeldsHOLD TIMESetup Samples: NASee Attached TableSee Attached TableMicrohardnessMean IFDWS Current (kA) Mean Button Diameters (mm) Mean Fused Diameters (mm)Number of PIF + FIF vs. Total WeldsPIF+FIF Welds Total Welds Mean Shear Tension Strength (kN)Setup Samples:

41、HOLD TIMESetup Samples:HOLD TIMECopyright 2013, Ford Global Technologies, LLC Page 12 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_ Short cyc.:Long cyc.:Short cyc.:Long cyc.:HOLD TIMESetup Samples:Setup Samples:HOLD TIMEMean Cross Tension Strength (kN)Number of PIF + FIF vs. Tota

42、l WeldsPIF+FIF Welds Total WeldsWELD PROPERTY REPORT (FB-5 cont.)CROSS TENSION DATAComments:Mean IFDWS Current (kA) Mean Button Diameters (mm) Mean Fused Diameters (mm)Copyright 2013, Ford Global Technologies, LLC Page 13 of 13 FORD LABORATORY TEST METHOD BA 113-08 Job#_ Qualification#_ Test 1 Weld

43、Time: cycles Test 1 DMAX: mmTest 1 IMAX : kA Test 1 DMIN: mmTest 1 IMIN : kATest 1 CR: kATest 2 Weld Time: cycles Test 2 DMAX: mmTest 2 IMAX : kA Test 2 DMIN: mmTest 2 IMIN : kATest 2 CR: kATest 3 Weld Time: cycles Test 3 DMAX: mmTest 3 IMAX : kA Test 3 DMIN: mmTest 3 IMIN : kATest 3 CR: kAWeld range for Base TimeWeld Range for Base Time +25%Weld Range for Base Time +50%WELD LOBE DATA SHEET (FX-1)Chart of Weld Lobe KA Cycles