NAVISTAR MPAPS FT-9553-2014 Assembly and Testing Procedures for Projection Weld Nuts or Studs.pdf

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1、This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 1 of 6 NAVISTAR, INC. Material, Parts, and Process Specifications

2、(MPAPS) NUMBER: MPAPS FT-9553 Former Designation: TMS-9553 TITLE: Assembly and Testing Procedures for Projection Weld Nuts or Studs CURRENT REV No.: 1404 DATE: April 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-9553 Feb. 2011 PRINTED COPIES OF THIS

3、 DOCUMENT 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 a

4、nd to determine the applicability of regulatory limits prior to use. Change Notice: Changed to new MPAPS format; editorial changes. 1.0 APPLICATION This specification is applicable to all NAVISTAR projection weld nuts and weld studs whose Engineering drawings, part assembly drawings, or installation

5、 drawings reference this specification. This specification is also applicable to NAVISTAR Engineering Standard Parts whose General Specifications (GS) reference this specification. 2.0 SCOPE This specification covers assembly and testing procedures for projection weld nuts and studs. A quality plan

6、and KCC values are included. Minimum values for the break-away torque and push-out force are shown in Table 1 for each projection weld nut size. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requireme

7、nts of the MPAPS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following specifications, standards, and regulations are referenced in this specification: Quality System Standard ISO 9001 or TS-16949 NAVISTAR Eng.

8、Design Standard A-16 NAVISTAR Manufacturing Standard MS-D-13 NAVISTAR MPAPS A-6, Part I NAVISTAR Eng. Standard Parts, Section E CFR Title 29, Part 1910 MPAPS B-50 4.0 REQUIREMENTS 4.1 Projection Weld Process The projection weld is a resistance weld. The weld nut/stud and base metal are pressed toget

9、her by the electrodes. The flow of electrical current/fusion between the weld nut/stud and base metal is localized. Fusion occurs at points predetermined by the contact of three or more projections on the weld nut/stud with the subjacent base metal. The weld process should be controlled such that th

10、e fusion zone or fusion area at each projection shall not be less than 70 % of the base area of the projection. 4.2 Assembly Procedure When the clamp force is applied to the upper and lower electrodes, the weld current is turned on and projections on the weld nut are fused to the workpiece. The prod

11、uction installation tooling and weld assembly process is validated by the performance of (destructive) validation tests in which the weld nut is twisted off or pushed out of the workpiece. The production assembly procedure is tested and NUMBER: MPAPS FT-9553 TITLE: Assembly and Testing Procedures fo

12、r Weld Nuts and Studs REVISION: APRIL 2014 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 2 of 6 verified by the

13、performance of (non-destructive) torsional and push-out tests in which a minimum torque value and push-out force are applied to verify that the weld nut has been properly installed on the workpiece. 4.3 Test Procedure Each weld nut size and material thickness combination shall be tested to establish

14、 and validate the installation tooling and assembly process for that nut size and material thickness combination. Sufficient testing shall be performed to fully define and establish control limits for those process parameters affecting the performance/strength of the nut joint. Periodic validation (

15、destructive) testing during each production run shall be performed as required to demonstrate that the assembly and weld process are both in-control and capable of meeting the minimum push-out force and twist-off torque values described in Table 1 for that size nut. Periodic in-process verification

16、(non-destructive) testing during each production shift (8-hours) shall be performed as required to verify performance to minimum push-out and torque values as described in Table 2 for each size weld nut and material thickness combination. 4.3.1 Validation Testing These are destructive tests performe

17、d to failure of the nut joint. The tests may be performed on production parts/panels or on test coupons of the same material and thickness as the production parts and with weld nuts installed using the production tooling. Note: For validation testing, damage pertains to loosening of the nut; distort

18、ion of the part or test panel is allowable. Frequency of testing will be determined by the manufacturing plant quality control department and will be included in the Quality Control Plan for each part. 4.3.1.1 Push-Out Validation Test After assembly of the nut in the part or test coupon, the part or

19、 coupon is clamped in a test fixture as shown in Figure 1. A load is applied in the direction indicated and the load is increased to failure. The peak value of the load must meet or exceed the value shown in Table 1 for that nut size and material thickness combination. 4.3.1.2 Torque-Out or Twist-Of

20、f Validation Test After assembly of the nut in the part or test coupon, the part or coupon is clamped in a test fixture as shown in Figure 2. A torque is applied in the direction indicated and the torque increased to failure. The peak value of the torque must meet or exceed the value shown in Table

21、1 for that nut size and material thickness combination. 4.3.2 In-Process Testing These are non-destructive tests performed to verify satisfactory performance of the nut joint and to assure that the assembly process is in control. The tests are performed on the nuts after assembly in the production p

22、arts/panels. Frequency of testing will be determined by the manufacturing plant quality control department and will be a part of the Quality Control Plan for each part. 4.3.2.1 Push-Out or Pull-Out In-Process Test After assembly of the nut in the production part, the part is held or clamped in a tes

23、t fixture as shown in Figure 1. A test load is applied as indicated in Table 2 for that size nut and material thickness combination. There shall be no loosening of the nut and no damage to the part after application of the minimum load as indicated in Table 2. 4.3.2.2 Torque-Out or Twist-Off In-Proc

24、ess Test After assembly of the nut in the production part, the part is held or clamped in a test fixture as shown NUMBER: MPAPS FT-9553 TITLE: Assembly and Testing Procedures for Weld Nuts and Studs REVISION: APRIL 2014 This document is restricted and may not be sent outside Navistar, Inc. or reprod

25、uced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 3 of 6 in Figure 2. A test torque is applied as indicated in Table 2 for that size nut and material thickness combination. There shall be no loose

26、ning of the nut and no damage to the part after application of the minimum torque value as indicated in Table 2. Table 1 VALIDATION TEST LOAD and TORQUE VALUES Weld Nut Nominal Size Minimum Push-Out Force, lbs (kN) Minimum Twist-Out Force, ft-lbs (Nm) Material Thickness, mm Material Thickness, mm le

27、ss than 1.4 1.4 or greater less than 1.4 1.4 or greater M6 - 600 (2.67) - 12 (16.3) M8 - 600 (2.67) - 50 (67.8) M10 - 600 (2.67) - 70 (94.9) M12 - 600 (2.67) - 100 (135.6) Table 2 IN-PROCESS TEST LOAD and TORQUE VALUES Weld Nut Nominal Size Minimum Push-Out Force, lbs (kN) Minimum Twist-Out Force, f

28、t-lbs (Nm) Material Thickness, mm Material Thickness, mm less than 1.4 1.4 or greater less than 1.4 1.4 or greater M6 - 300 (1.33) - 6 (8.1) M8 - 300 (1.33) - 25 (33.9) M10 - 300 (1.33) - 35 (47.5) M12 - 300 (1.33) - 50 (67.8) 5.0 QUALITY Parts shall be delivered in a clean dry condition ready for u

29、se without further conditioning or cleaning. 5.1 Weld Quality 5.1.1 Cracking No cracking of the weld nut/stud or of the base metal in or adjacent to the fusion zones is permitted. 5.1.2 Weld-nut Alignment The weld-nut will be properly aligned with the hole in the part such that a standard “Go-No-Go”

30、 thread gage will pass easily through the hole in the part and engage the threads in the nut. NUMBER: MPAPS FT-9553 TITLE: Assembly and Testing Procedures for Weld Nuts and Studs REVISION: APRIL 2014 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permiss

31、ion from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 4 of 6 5.1.3 Weld-nut Thread Distortion Any distortion of the nut threads which changes the prevailing torque characteristics of the weld-nut or that affects the atta

32、inment of the assembly torque specification using the automated assembly tooling is not permissible. 5.1.4 Weld Flash Any weld flash generated during the nut weld process that impedes the easy passage of the thread gage through the hole, or its engagement with the nut threads, or that in any other w

33、ay changes the prevailing torque characteristics of the weld-nut, or that affects the attainment of the assembly torque specification using the automated assembly tooling, is not permissible. Figure 1 Weld Nut Push-Out Test NUMBER: MPAPS FT-9553 TITLE: Assembly and Testing Procedures for Weld Nuts a

34、nd Studs REVISION: APRIL 2014 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 5 of 6 5.2 Quality Control Plan A Qu

35、ality Control Plan for this product will be established by mutual agreement between NAVISTAR and the supplier. Each weld nut/stud (size), part number, and material thickness combination shall be included in the control plan. The following items, where applicable,* will be included in the control pla

36、n as features for management by statistical process control.* 1. Push-Out Force 2. Torsional Test * Additional characteristics for inclusion in the control plan may be specified on the engineering drawing, installation drawing, and/or purchase order. * See Engineering Design Standard A-16. 6.0 SOURC

37、E APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Production Part Approval Process) document

38、ation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 6.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be eq

39、uivalent in all respects to those samples which were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labeling of the product are required, the

40、 supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Sheet(s) (MSDS), in accordance with CF

41、R Title 29, Part 1910 shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or provide statistical evidence of the lot having been produced in a state

42、 of statistical control and with a process capable of providing all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific products. 7.0 SHIPPING AND HANDLING Shipping, packing and identification

43、 shall be in accordance with Manufacturing Std. MS-D-13. NUMBER: MPAPS FT-9553 TITLE: Assembly and Testing Procedures for Weld Nuts and Studs REVISION: APRIL 2014 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standard

44、s. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. APRIL 2014 Page 6 of 6 8.0 DESIGNATION ON DRAWINGS Drawings requiring projection welding of weld nuts and weld studs should specify welding requirements on the engineering drawing using the following weld symbol format:

45、 UG stamp #S74 (or equivalent note) should be added to the body of the drawing to read: “Projection welded assemblies must comply with the requirements of MPAPS FT-9553.” 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may

46、purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Avenue Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/