NAVISTAR MPAPS P-9516-2016 Quality Requirements for Resistance Spot Welds.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. 2016 by Navistar, Inc. NOVEMBER 2016 Page 1 of 19 NAVISTAR, INC. Material, Parts, and Process Specificati

2、ons (MPAPS) NUMBER: MPAPS P-9516 Former designation: TMS-9516 TITLE: Quality Requirements for Resistance Spot Welds CURRENT REV. No.: 1611 DATE: Nov. 2016 WRITTEN/EDITED BY: J. Goldschmidt APPROVED BY: R. Goluch SUPERSEDES: 1410 Oct. 2014 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT

3、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 determine the applicability of re

4、gulatory limits prior to use. 1.0 APPLICATION This specification covers the quality requirements for resistance spot welds used in fabricating truck bodies and other truck components made from bare or coated low carbon steel (Grade 1 or Grade 1GALV per MPAPS A-6), high-strength steel grades (Grade 6

5、 or Grade 6GALV per MPAPS A-6), stainless steel per MPAPS A-37, and aluminum alloys per MPAPS C-10. The specification is applicable to spot welded assemblies produced in NAVISTAR plants and/or produced by suppliers in supplier facilities and then shipped to NAVISTAR plants. 2.0 SCOPE This specificat

6、ion 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 criteria, and repair options for each class of spot weld are detailed in this specificati

7、on. 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 Weld Description Obsolete Weld Class Obsolete Symbol Compliance Critical Any weld con

8、tributing to structural integrity in such manner that compliance to FMVSS or to roof strength requirements could be compromised by a substandard weld. Class A or or Compliance Welds Durability Critical Any weld contributing to structural integrity in such manner that cab durability requirements coul

9、d be compromised by a substandard weld. - Commercial or Normal Spot welds subjected to moderate or low levels of stress, requiring only a commercial or normal level of quality. Class B None Commercial Welds Manufacturing M Any weld used only to hold two or more parts in place to aid in the manufactu

10、ring process and is not required to meet the requirements in this spec. - None NUMBER: MPAPS P-9516 TITLE: Quality Requirements for Resistance Spot Welds REVISION: 1611 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical St

11、andards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. NOVEMBER 2016 Page 2 of 19 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specifica

12、tion. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. 3.1 Definitions Welding terms used in this specification are defined below. 3.1.1 Minimum

13、Weld Diameter The smallest diameter measured on a fused nugget or pulled button. 3.1.2 Average Weld 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

14、evidence of metal coalescence, is complete, is not excessively distorted (see Section 3.1.5) and 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 (for

15、steel). 3.1.3.1 Compliance Critical 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 3 of Table 1. 3.1.3.2 Commercial/Normal Welds: Commercial/normal welds will have an average diameter

16、equal to or greater than the applicable value shown in Column 3 of Table 1. 3.1.4 Undersize Weld A tested 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

17、a satisfactory weld but greater than or equal to the value in Column 4, Table 1 (for steel). 3.1.4.1 Compliance Critical 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.

18、1.4.2 Commercial/Normal Welds: Commercial/normal welds with an average diameter equal to or greater than the applicable value shown in Column 4 of Table 1. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS C-10 NAVISTAR Supplier Packing and Shipping Std. D-13 AWS A3.0M/A3.0 CFR Title 29, P

19、art 1910 AWS C1.1M/C1.1 NAVISTAR MPAPS B-50 AWS C1.4M/C1.4 NAVISTAR TDS-SD-7.18 AWS D8.1M NAVISTAR MPAPS A-6, Parts I spot welding of other stainless steel grades should be verified. *Material Thickness value is the thinnest piece of those being welded *Centerline to centerline *Minimum contacting o

20、verlap (L). TABLE 4 WELD BUTTON DIAMETER REQUIREMENTS FOR ALUMINUM ALLOYS Column 1 Column 2 Column 3 Material Thickness * SET-UP WELD BUTTON DIAMETER MINIMUM WELD BUTTON DIAMETER mm in mm in mm in 0.65 0.025 3.8 0.15 3.0 0.12 0.81 0.032 4.3 0.17 3.56 0.14 1.02 0.040 4.8 0.19 4.06 0.16 1.27 0.050 5.3

21、 0.21 4.57 0.18 1.60 0.063 6.1 0.24 5.08 0.20 1.80 0.071 6.6 0.26 5.33 0.21 2.03 0.080 6.8 0.27 5.72 0.22 2.29 0.090 7.2 0.28 6.10 0.24 2.54 0.100 7.6 0.30 6.35 0.25 3.18 0.125 8.6 0.34 7.11 0.28 . * Material Thickness value is the thinnest piece of those being welded NUMBER: MPAPS P-9516 TITLE: Qua

22、lity Requirements for Resistance Spot Welds REVISION: 1611 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. 2016 by Navistar, Inc. NOVEMBER 2016 Page 16 o

23、f 19 TABLE 5 SPACING AND OVERLAP GUIDELINES FOR ALUMINUM ALLOYS Material Thickness * Minimum Spot Weld Spacing* Minimum Contact Overlap* Minimum Edge Distance mm in. mm in. mm in. mm in. 0.41 0.016 12.7 0.50 9.5 0.37 4.8 0.19 0.51 0.020 12.7 0.50 9.5 0.37 4.8 0.19 0.64 0.025 15.9 0.63 11.1 0.44 5.6

24、0.22 0.81 0.032 15.9 0.63 12.7 0.50 6.4 0.25 1.02 0.040 19.0 0.75 12.7 0.50 6.4 0.25 1.27 0.050 19.0 0.75 15.9 0.63 7.9 0.31 1.60 0.063 25.4 1.00 15.9 0.63 7.9 0.31 1.80 0.071 28.6 1.13 19.0 0.75 9.5 0.37 2.03 0.080 28.6 1.13 19.0 0.75 9.5 0.37 2.29 0.090 31.8 1.25 19.0 0.75 9.5 0.37 2.54 0.100 34.9

25、 1.37 22.2 0.87 11.1 0.44 3.18 0.125 38.1 1.25 25.4 1.00 12.7 0.50 *Material Thickness value is the thinnest piece of those being welded *Centerline to centerline *Minimum contacting overlap (L). Measured from weld center to edge of sheet. 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Require

26、ments 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) documentation and approval requirements. Suppliers must mai

27、ntain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 7.2 Approval Parts supplied against contracts or purchase orders citing this specification shall be equivalent in all respects to those samples that were

28、 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 supplier shall notify NAVISTAR Materials Engineerin

29、g 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 Sheets (MSDS), in accordance with CFR Title 29, Part 1910, shall be submitted with the req

30、uest for change. NUMBER: MPAPS P-9516 TITLE: Quality Requirements for Resistance Spot Welds REVISION: 1611 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

31、. 2016 by Navistar, Inc. NOVEMBER 2016 Page 17 of 19 7.3 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 of statistical c

32、ontrol 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. 8.0 SHIPPING, PACKING, IDENTIFICATION, AND PRESERVATION Loading, packing, ident

33、ification, and preservation of parts supplied to this specification shall be in accordance with Navistar Supplier Packing and Shipping Standard D-13. 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Suppliers may purchase controlled c

34、opies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Ave. Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Markit Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ A.0 GENERAL INF

35、ORMATION (Not a Requirement of the Specification) A.1 WELD REPAIR The weld repair procedure used to repair substandard welds must fully restore the joint to the quality level required by the original weld classification specified. A flowchart showing the various weld procedures for steel in general

36、order of preference is shown in Section A.2. A.1.1 Preferred Parts for Weld Repairs using Fasteners Contact the NAVISTAR Fastener Engineering group for guidance in selecting the appropriate fastener (part number) to be used in repair procedures. NUMBER: MPAPS P-9516 TITLE: Quality Requirements for R

37、esistance Spot Welds REVISION: 1611 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. 2016 by Navistar, Inc. NOVEMBER 2016 Page 18 of 19 A.2 WELD REPAIR FL

38、OW CHART S TA R T C - f ra m e sp o t w eld er ac ce ss th e jo i n t? P arts p ain ted o r e - co ated ? G re ater t h an 2 T st ac k u p ? M IG sp o t w eld eq u ip . av ail. ? S ea ler o r ad h esiv e p rese n t? T ried r iv et rep air? 4 .4 . 1 R e - sp o t w eld 4 .4 . 2 M IG sp o t w eld Yes N

39、o No Yes No No Yes 4 .4 . 3 P lu g / p u d d le w eld No Yes A c ce ss t o b o th sid es o f j o in t? Ri v et h ea d o b jection ab le? * S tru ctu ral r iv et o b jection ab le? * No No Yes No Yes Yes 4 .4 . 6 S tru ctu ral r iv et P i n & co l lar lo ck b o lt o b jec -ti o n a b le? * No 4 .4 .

40、4 P in & co ll ar l o ck b o lt Yes No C - f ra m e p ierce r iv et m ac h in e rea ch th e w eld ? F lu sh h ea d o f p ierce rive t o b jec -ti o n a b le? * No No Yes 4 .4 . 5 S elf - p iercin g r iv ets Yes Yes Re m o v e p ain t o r e - co at Yes T ried wel d rep air? No Yes Yes P ai n t re m o

41、 v ab le? No S cra p p arts S cra p p arts S cra p p arts * objectionable = cosmetic appearance of repaired part is adjudged to be unacceptable. NUMBER: MPAPS P-9516 TITLE: Quality Requirements for Resistance Spot Welds REVISION: 1611 This document is restricted and may not be sent outside Navistar,

42、 Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. NOVEMBER 2016 Page 19 of 19 REVISION HISTORY Revision Level Change Approved by Date Approved 1611 Updated section 5.0 to allow pinholes/porosity in durability welds, added more description to the end of table 1, added bulge or expulsion to edge weld, updated fig 3, add manufacturing weld designation to weld descriptions in 2.0 scope, R. Goluch 11/10/2016