The purpose of this specification is to provide the minimum acceptance criteria for arc welding of various types of automotive parts made of aluminum alloys.
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This specification defines quality characteristics and metrics pertinent to laser beam welding used in automotive body applications, exclusive of butt joint configurations. Laser beam welds may be applied as intermittent (stitch) or continuous and either linear or shaped. The evaluation methods and inspection criteria specified herein can be used to evaluate the effectiveness of particular welding equipment and procedures used to weld a particular base material combination. The criteria and metrics are the same for all welds regardless of the service load. The quality standards established by this specification do not constitute a lower bound of suitability for service; welds that do not meet the weld quality criteria of this specification may be satisfactory for certain applications. The acceptance criteria of this standard are not intended for applications outside this scope (such as post-crash weld quality assessment); attempts to do so may lead to an erroneous result.
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This document contains several standardized test methods designed to evaluate the resistance spot welding behavior of coated and uncoated sheet steels in a laboratory environment. The test methods allow for uniform testing of automotive sheet steels to determine the following:
(1) The effect of the interaction between a sheet steel’s coating (metallic, nonmetallic, or both) and the welding electrodes on electrode deterioration and weld size/quality behavior over an extended number of welds
(2) Current levels and current range
(3) Mechanical properties of welds at different weld sizes and hold times
(4) Metallurgical and hardness properties of welds
(5) The effects of sheet lubricants, conductive paints, or other surface treatment on current break-through
(6) The robustness of a grade of steel to variations in key welding process variables
The test methods are intended for application in a laboratory environment to characterize certain aspects of the welding behavior of sheet steel products under controlled experimental conditions. They are not intended to simulate production welding practices or to predict welding performance of a given grade of steel in production operations. The test methods and parameters are designed to be used for sheet steels ranging in thickness from 0.5 mm to 4.0 mm. The tests may be used for sheet steel materials of all yield strengths typically used in automotive applications. In the endurance test, a minimum of two tests per material is recommended to obtain an accurate assessment. The endurance test was developed for low strength (tensile strength less than or equal to 300 MPa) coated steels of lighter gauges. This test is normally used for coated steels with tensile strength less than or equal to 500 MPa and gauges less than 1.2 mm. The weld property tests are designed primarily for gauges of 1.2 mm and heavier.
The specific type and number of tests required shall be at the discretion of the specifying party. While the test methods were developed to compare the welding behavior of different steel grades, they can be judiciously applied to evaluate other aspects of welding behavior. Not all of the above mentioned tests are required to establish the resistance spot welding behavior of a given grade of steel. The current level/current range testing and weld property testing together generally provide a good indication of the resistance spot welding behavior, whereas the DoE testing is intended to examine the robustness of a given grade of high strength steel to variations in key process variables.
The specific tests required to establish the resistance spot welding behavior of a given grade of steel should be agreed upon by the steel supplier (or test laboratory) and the automotive company (or buyer of the steel).
A commentary is provided in Annex E on alternative test methods and is intended to serve as a guide should the users of this document desire to utilize alternative test methods for the weld characterization of sheet steels. Because the weldability evaluation procedures in alternative methods deviate from the procedure described in this document, the use of the alternative test methods may add to the complexity and cost of the material evaluation. The type of evaluations required, and any deviations required to perform them, should be agreed upon between the party for whom the testing is to be performed and the testing laboratory.
Resistance spot welding behavior is dependent upon a wide variety of interacting material and weld process factors. To obtain repeatable and reproducible performance data, it is imperative that all experimental variables and the way a test is conducted be closely controlled. Therefore, the instructions for the various sampling and testing procedures in this manual are stated in mandatory language and should be followed as closely as possible. Deviations from the prescribed procedures or test methods, permissible with the consent of the party for whom the testing is performed, have to be noted and reported.
For the purpose of determining appropriate welding parameters and tests required, steel grades have been classified into four groups based on their minimum tensile strength. These groups are listed in Table 1. Also provided in Table 1 are examples of typical steel grades that fall into each of these four groups.
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This specification describes weld geometry and workmanship criteria essential to ensure the quality of automotive and light truck weldments. This specification covers the arc and hybrid arc welding of coated and uncoated steels.
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This specification expresses the quality characteristics and metrics pertinent to individual resistance spot welds on automotive aluminum structures. The acceptance criteria are the same for all welds regardless of the service load and intended to be applied in conditions typically encountered during manufacturing. Welds at variance from the stated weld quality criteria in this document can still have mechanical properties that satisfy product and design requirements as per agreement between customer and supplier. Any attempted application of this document or the evaluation criteria used herein to other uses, for example post-crash weld quality assessment, may lead to an erroneous result.
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This specification defines quality characteristics and metrics pertinent to resistance spot welds on steels used in automotive applications. The evaluation methods and inspection criteria specified herein can be used to evaluate the effectiveness of particular welding equipment and procedures used to weld a particular base material combination. The criteria and metrics are the same for all welds regardless of the service load. The quality standards established by this specification do not constitute a lower bound of suitability for service; welds that do not meet the weld quality criteria of this specification may be satisfactory for certain applications. The acceptance criteria of this standard are not intended for applications outside this scope (such as post-crash weld quality assessment): attempts to do so may lead to an erroneous result.
The specific type and number of tests that are required shall be at the discretion of the specifying party. While the test methods were developed to compare the welding behavior of different steel grades, they can be judiciously applied to evaluate other aspects of welding behavior. Not all of the above mentioned tests are required to establish the resistance spot welding behavior of a given grade of steel.
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This standard specifies the requirements for classification of weld-through paint primers only. The paint primers are classified based on the maximum coating thickness for successful welding and the welding procedure used during the classification test. This standard provides a system for paint manufacturers to classify the weldability features of weld-through paint primers. This standard is limited to weld-through paint primers only and does not include galvanized or other types of protective coatings.
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This standard makes sole use of U.S. Customary Units. Approximate mathematical equivalents in the International System of Units (SI) are provided for comparison in parentheses or in appropriate columns in tables and figures.
This guide provides information on proven processes, techniques, and procedures for welding aluminum hulls and related ship structures. The information presented applies chiefly to the welding of aluminum hulls that are over 30 ft (9 m) in length and made of sheet and plate 1/8 in. (3.2 mm) thick and greater. Thin-gage aluminum welding usually requires specific procedures in the area of fixturing, welding sequence, and other techniques for distortion control that are not necessarily applicable to thick plates. Similarly, the choice of welding process or applicable process conditions, or both, also differs according to thickness.
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This code covers underwater welding in both dry and wet environments. Five basic methods for underwater welding are covered in this specification as follows:
(1) Welding in a pressure vessel in which the pressure is reduced to approximately one atmosphere, independent of depth (dry welding at one atmosphere).
(2) Welding at ambient pressure in a large chamber from which water has been displaced in an atmosphere such that the welder/diver does not work in diving equipment (dry welding in a habitat).
(3) Welding at ambient pressure in a simple open-bottomed dry chamber that accommodates, as a minimum, the head and shoulders of the welder/diver in full diving equipment (dry chamber welding).
(4) Welding at ambient pressure in a small, transparent, gas-filled enclosure with the welder/diver outside in the water (dry-spot welding).
(5) Welding at ambient pressure with the welder/diver in the water without any mechanical barrier between the water and the welding arc (wet welding).
This document is intended to define the important variables associated with underwater welding and to describe welding and inspection procedures so that work of a known quality level can be conveniently specified.
Three weld classes (A, B, and O) are specified herein. They encompass the range of quality and properties currently produced by application of the various methods. Each weld class defines a set of criteria for weldment properties that must be established during qualification, and a set of weld soundness requirements that are to be verified during construction. Welds in each class must meet all the criteria specified for that class. This code does not address the selection of the class that meets the service requirements of a particular application. The selection of the class of weld to be provided is to be prescribed by the Customer.
All provisions of this document apply equally to new construction and to modification and repair of existing structures underwater. This document may be used in conjunction with other applicable codes or specifications for design, construction, or repair.
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This guide provides information to users in the marine construction industry as to the best practical methods to weld steel hulls for ships, barges, mobile offshore drilling units, and other marine vessels. This guide provides information on steel plates, shapes, castings, and forgings; their selection; and their weldability. It discusses welding processes and proper design for welding. Hull construction is presented in terms of preparation of materials, erection and fitting, and control of distortion. Qualification of procedures and personnel are outlined, and inspection methods are discussed. A common shipyard problem, stray current protection, is discussed as is the health and safety of the work force. Supplementary nonmandatory appendices are provided for informational purposes.
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