Group Standard

PV 6702
Issue 2010-03

Class. No.: Descriptors:

04815 spot welding, resistance spot welding, welding, strength testing, chisel test, metallography, weld spot, ultrasonic test, peel test, lap-shear test, cross-tension test, spot diameter, nugget diameter, wedge test

Spot-Welded Joints on Steel Materials Testing of Body Assemblies

Previous issues PV 6702: 1975-05, 1986-06, 2000-02, 2001-05, 2003-03, 2003-06, 2004-07, 2004-09 Changes The following changes have been made as compared to PV 6702: 2004-09: PV (test specification) reorganized, technical responsibility changed Tables 1, 2, and 3 added Contents 1 2 3 3.1 3.2 3.3 4 4.1 4.1.1 4.1.2 4.1.3 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 Scope ......................................................................................................................... 2 Basis for the test specification .................................................................................... 2 Characteristics to be tested ........................................................................................ 2 External assessment .................................................................................................. 2 Internal assessment ................................................................................................... 4 Strength tests ............................................................................................................. 7 Test method ............................................................................................................... 8 External assessment .................................................................................................. 8 Visual inspection ........................................................................................................ 8 Wedge test ................................................................................................................. 8 Optical systems .......................................................................................................... 9 Internal assessment ................................................................................................... 9 Chisel test .................................................................................................................. 9 Peel test ..................................................................................................................... 9 Metallography ............................................................................................................. 9 Ultrasonic test .......................................................................................................... 10 Process monitoring .................................................................................................. 10 Page 1 of 13
Page

Check standard for current issue prior to usage. This electronically generated standard is authentic and valid without signature. The English translation is believed to be accurate. In case of discrepancies the German version shall govern. Numerical notation acc. to ISO practice.

Technical responsibility PKT/F PKT/F Matthias Graul Dr. Torsten Jckel Tel.: +49 5361 9 39891

Standards Department EKDV/4 Uwe Fischer Tel.: +49 5361 9 27995 EKDV Manfred Terlinden

Confidential. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group. Parties to a contract can only obtain this standard via the B2B supplier platform www.vwgroupsupply.com.

Volkswagen Aktiengesellschaft

VWNORM-2008-12l

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4.3 4.3.1 4.3.2 5 6 6.1 6.2 7 8 1

Strength .................................................................................................................... 10 Lap-shear test .......................................................................................................... 10 Cross-tension test .................................................................................................... 11 Rework ..................................................................................................................... 11 Assessment of the usability ...................................................................................... 12 Chisel test (or peel test) ........................................................................................... 12 Metallographic testing .............................................................................................. 12 Referenced documents ............................................................................................ 12 Bibliography ............................................................................................................. 13 Scope

This Test Specification describes the testing and evaluation of resistance spot-welded joints on steel materials. Generally valid limits are listed here in order to ensure uniform quality of production. Specimen di mensions that are already specified in DIN EN ISO 14273 are not stated. The PV applies to sample tests, acceptance tests, and series production monitoring tests and pro vides information for specifying rework measures. It is used to evaluate the quality of joints used to join sheet steels in motor vehicle body construction with a sheet thickness of 0,5 mm to 4,0 mm and a maximum total sheet thickness of 8 mm. 2 Basis for the test specification

This Test Specification is based on Volkswagen Standards VW 01105-1 and VW 01105-4 and the applicable material and design restrictions contained therein. The released component drawing serves as the basis for evaluation of the weld spots. The require ments defined below must be met for all spot-welded joints. Deviating specifications in drawings take precedence. The Planning Department, the Quality Assurance Department, and the operator will jointly agree on and specify the test frequency, depending on process assurance. 3 Characteristics to be tested

In the following, a distinction is made between external and internal assessment. 3.1 External assessment

For the external assessment, the following can be checked visually, according to Table 1: Evaluation group B applies, unless stated otherwise in the drawing.

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Table 1 Limit values for irregularities on resistance-welded spots, external character istics
No . Ref. no. ISO 6520 -2 Designation Note, sketch External characteristics Surface crack 01 16001 16002 outside of and within the elec trode indenta tion Cracks that are visible without tools and without having to destroy the component Not permissible Not permissible Permissible in the edge area and outside the in the edge area electrode inden tation D Limit values for quality level C B

Weld spot that has melted 02 522 through the material on one side

Blind hole at the weld spot caused by material splashing out Permissible if all other requirements are fulfilled

03

526

Irregularities of the electrode Dimples, material adhesions, in indentation, ex dentation diameter, indentation cept protru sions depth, asymmetries, scorch marks

See specification of surface quality classes OG1 to OG4 acc. to VW 01105-1

04

5262

Protrusions

Material protrusions in the form of beads or burrs next to the electrode indentation Permissible if there are no sharp edges and if the re quirements regarding the surface quality class (OG), corrosion protection, appearance, and function are fulfilled

05

602

Weld spatter

Permissible if the requirements regarding the surface Spatter adhering tightly to the work quality class (OG), corrosion protection, appearance, piece surface and function are fulfilled According to VW 01105-1 (e eneb) or drawing Deviations are permissible as long as the function of the component is not impaired The electrode mark must be visible all around on all sheets. Deviations must be agreed upon between the Quality Assurance, Design Engineering, and Testing Departments. Exception: vE 2,5 mm in the door entry area with hot-worked sheets.

06

Spot position

07

Edge distance vE Nominal value: v 1,25 dLmin

ISO 6520-2, referenced in column 2, is available as German standard under DIN EN ISO 6520-2 in NOLIS.

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3.2

Internal assessment

The internal assessment of a resistance-welded joint is usually done through a destructive test. The characteristics are evaluated according to Table 2. Evaluation group B applies, unless stated other wise in the drawing. Table 2 Limit values for irregularities on resistance-welded spots, internal characteris tics
No . Ref. no. ISO 6520 -2 Designation Note, sketch Internal characteristics Crack in nugget center D Limit values for quality level C B

10

1100

Permissible

11

1200

Crack in edge area of the nugget Crack in the nugget in the extension of the joining plane Crack in the heat-affected zone (HAZ), on the joining plane

Permissible

Permissible up to l 0,2 tmin

Not permissible

12

1300

Permissible up to l 0,5 tmin

Not permissible

13

14001

Permissible up to l 0,2 t

Not permissible

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Ref. no. No ISO 6520 . -2

Limit values for quality level Designation Note, sketch Crack position: center Permissible D C B Permissible, cracks extending all the way through the part not permissible Crack position: transition area Permissible up Permissible Crack in the heat-affected zone, on the electrode side to l 0,5 t Permissible up to l 0,25 t

14

14002

Crack position: edge area Permissible up to l 0,5 t Crack position: outside of edge area in the HAZ Permissible up to l 0,2 t

Permissible up to l 0,2 t, but max. 150 m

Evaluation analogous to "Cracks in base material" (1500)

15

1500

Cracks in base material

Permissible up to l 0,2 t

Not permissible

16

20111

Pore, worm hole in nugget center

Permissible

17

20112

Pore, worm hole in edge area of nugget

Permissible

Not permissible if open towards the edge of the nugget in the joining plane

18

2012

Porosity

Permissible

15%

8%

19

2013

Localized porosity

Permissible

Not permissible if open towards the edge of the nugget in the joining plane

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Ref. no. No ISO 6520 . -2

Limit values for quality level Designation Note, sketch Metallic or oxidic inclusions D C B

20

303 304

Inclusions

Permissible as long as the function of the component is not impaired

Partially missing crystalline connec tion 21 400 Lack of fusion Permissible Permissible if dL min is complied with in the rest of the cross-section, i.e. (dL - h) dL min

22

401

No crystalline connection, or "sticker"

Permissible if No formation of weld nugget in join function is not ing plane impaired Desired dimension not met

Not permissible

23

5213

Nugget too small

Permissible

Not permissible

Asymmetric shape and position of nugget

24

5215

Asymmetric nugget

Permissible if all other requirements are fulfilled

0,1 mm tL < Nugget penetration Desired dimension not met depth too small, Desired dimen sion: tL 0,20 mm 0,2 mm permissible if all tL < 0,2 mm other character only permissible istics are OK if other destruc tL < 0,1 mm per tive tests yield missible if other OK results destructive tests yield OK results

25

5216

Permissible if function is not impaired

26

525

Excessive gap, gap width ts

Increased gap width between the welded workpieces Permissible if all other requirements are fulfilled

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Ref. no. No ISO 6520 . -2

Limit values for quality level Designation Note, sketch Applies to 2-sheet joints only *) tr 0,50 t tr 0,75 t tr 0,85 t D C B

Contraction of 27 wall thickness in edge area of nugget

Material pressed out into the joining 28 612 Pressed-out material plane, including spatter Permissible if all other requirements are fulfilled

*) Multi-sheet joints may exhibit higher contractions. ISO 6520-2, referenced in column 2, is available as German standard DIN EN ISO 6520-2 in NOLIS.

3.3

Strength tests Cross-tension strength Lap-shear tension strength

The following characteristics can be used to evaluate the strength of a spot-welded joint:

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Test method

Table 3 indicates the suitable non-destructive and destructive test methods for testing individual quality characteristics of spot-welded joints. Table 3 Matrix for selection of a test for a particular characteristic Ultrasonic testing Visual inspection X X X X X X X X X X X X X X X X X X External assessment Visual inspection X X Inline optical (thermography) Inline adaptive Metallography

Electrode indentation Fractured surface Fracture type Spot diameter Nugget diameter Pores Internal cracks Tensile forces Existence, position Edge distance Protrusions External cracks Spatter 4.1 4.1.1 X X X X X X

For the visible test of the spot-welded joint without auxiliary means, the tester evaluates the joint with the naked eye. Use of a magnifying glass or microscope is not permitted. 4.1.2 Wedge test

The wedge test is an auxiliary method. In this test, a wedge is driven in next to or between the welded spots. This is a supplemental test and is used between the destructive test intervals (e.g., destructive chisel test). It is used exclusively for inspection and monitoring of the welding equipment and provides information on whether or not a joint was formed. It can be used for sheet joints in which the thinnest sheet may have a sheet thickness up to 1,2 mm, and for materials with tensile strengths < 400 N/mm2. NOTE 1 Since the wedge test does not yield any clear information with regard to the testable char acteristics acc. to Table 3, no selectable testable characteristic is shown.

Tensile test

Wedge test

Chisel test

Peel test

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4.1.3

Optical systems

Optical systems are non-destructive systems that use imaging followed by analysis of the image. These systems work in the wavelength range of visible and/or invisible light (thermography). They are suitable only for evaluation of external characteristics and the spot diameter of a spot-welded joint. NOTE 2 These systems can be used if proof is provided that the parameters measured can be related explicitly to a specific quality characteristic. 4.2 Internal assessment

Two spot-weld pullout diameters occur in destructive testing of three sheet joints; the diameters are determined according to the smallest sheet thickness (see VW 01105-4). 4.2.1 Chisel test

The chisel test, e.g., according to DVS 2916-1, is a destructive test. In the chisel test, an appropriately shaped chisel is driven between the welded sheets until the spotwelded joint is destroyed. In this process, the spot weld can pull out or the fracture can occur in the joining plane (interfacial failure). Combinations of both these fracture types (so-called mixed fractures) are also possible (see Table 2). If the testing effort is too high, transverse microsections can be taken as an alternative, and the nugget diameter determined from these. This applies, in particular, to sheet thicknesses > 2,0 mm as well as to high-strength and/or press-quenched and tempered steels. If multiple weld spots are tested in series and are spaced close together, it is recommended to test the weld spots individually. In this case, the weld spots must be separated, e.g., by cutting them out with a saw. During determination of the spot diameter, d1 and d2 are determined for the weld nugget using a caliper gage (2nd measurement offset by 90), and the mean value is determined from the two mea surements. If an exact measurement in two directions is not possible, the measured diameter must be used as dS. 4.2.2 Peel test

The peel test is a destructive test. During the peel test, the spot-welded joint is destroyed using a peel mandrel, e.g., according to DVS 2916-1, to peel back the two sheets. In this process, both the weld and the component can tear. Sheet tears usually take the form of "one-sided" tag-like sheet separations due to the load being exerted on one side. 4.2.3 Metallography

Metallographic testing is a destructive testing method. For this test, the weld spots under test are cut in the center and a microsection is produced. The metal microstructure is made visible using an appropriate caustic agent (e.g., 2% solution of nitric acid in alcohol). The evaluation is performed on the microsection at a magnification of 50:1 (or greater) on the unetched microsection (for cracks) or on the etched microsection (for the microstructure).

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4.2.4

Ultrasonic test

During the ultrasonic test, a probe that functions both as a transmitter and a receiver is used to send a time-limited ultrasonic pulse to the weld structure. Subsequently, the ultrasonic device switches immediately to receive mode and records the arriving echo sequence. The ultrasonic pulse is largely reflected at the steel/air interface, but not if it moves through an intact weld nugget. Information about the material thickness can be inferred from the echos. Indirectly, this information can be used to determine whether or not a weld nugget is present. Likewise, loose weld spots and weak "stickers" can be detected from the ultrasonic echo sequence. 4.2.5 Process monitoring

Various process visualizations can be used as part of process monitoring. NOTE 3 These systems can be used if proof is provided that the parameters measured can be related explicitly to a specific quality characteristic. 4.2.5.1 Adaptive process visualization

Adaptive process visualization is a 100% online monitoring process, in which a correlation can be generated between process parameters and the weld spot geometry. This visualization can be used to ensure the production process. 4.2.5.2 Optical systems

Optical systems are non-destructive systems that use imaging followed by analysis of the image. These systems are based on application of the radiation laws. They function in the wavelength range of invisible light. One of them is thermography, with many excitation options for detecting flaws and geometry char acteristics. Thus, the systems can generate information on the internal characteristics of the work piece. 4.3 4.3.1 Strength Lap-shear test

The lap-shear test is a destructive test. An individual weld spot is tested in a tensile test machine until the weld spot or the component fails. The tearing force required to do this is measured. If possible, the lap-shear test must be performed for all spot-welded joints. The test must simulate the real stress direction. Auxiliary equipment might be needed for this purpose. If a stress of this type cannot be simulated, an easy-to-reproduce stress according to Figure 1 may be chosen. Specimen dimensions and procedure according to DIN EN ISO 14273. If a quasi-static tensile test is not possible, metallography may be used instead.

Page 11 PV 6702: 2010-03

Figure 1 Lap-shear test before and after stress Legend 1 rs Outer notch after stress Lever which divides the tensile force into a cross-tension portion FC and a shearing ten sion portion FS Cross-tension test

4.3.2

The cross-tension test is a destructive test. Like the lap-shear test, this test is conducted in a tensile test machine, but the load is applied to the weld spot vertically to the sheet plane. The test may be performed according to Figure 2 in exceptional cases. During the cross-tension test, 25% to 40% of the minimum lap-shear tension force Fmin must be achieved, according to the respective deformability (also see VW 01105-1).

Figure 2 Cross-tension 5 Rework

Adding weld spots If a weld spot is faulty, rework is possible by placing at least one new weld spot next to the not OK weld spot, separated by a sufficient distance ( 20 mm or with a higher welding current). This is primarily possible if, for example, sufficient space is available at the flanges and there are no other restrictions against placing a weld spot in another location. If necessary, an area must be identified or excluded for rework in the drawing. For rework options, see PV 6717.

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Assessment of the usability

It must be ensured by means of an overall evaluation that the quality of a spot-welded joint remains constant over the entire manufacturing period. In an overall evaluation, both the nugget diameter dN in the microsection (formation of the weld nugget according to VW 01105-1; no "ring nugget") and the spot diameter dS, among others, must be evaluated using a destructive test such as the chisel test. The minimum requirements with respect to the nugget diameter dN and the spot diameter dS must be fulfilled. This is particularly applicable for setting welding parameters when preparing a machine for handover, when performing first sampling of components, and when implementing parameter changes that are expected to result in a considerable change in the overall evaluation. In addition to this, the lap-shear tension force may also be determined. 6.1 Usable: Spot diameter dSmin OK or Spot diameter up to 15% < dSmin with an occurrence 5%, and the number of loose spots is < 0,5% Chisel test (or peel test)

Proof of usability: Where the portion of not-OK spots is higher, the component-specific usability must be proven. To this end, coordination with the Quality Assurance, Design Engineering, and Testing Departments is re quired. Criteria for usability such as Reliability testing Dynamic and quasi-static tests, and others

may be used. 6.2 Usable: Nugget diameter dN OK or max. 5% of spots up to 15% < dN min, and number of loose spots max. 0,5%. Proof of usability: Where the portion of weld spots that are conditionally OK or not OK is higher, the component-specific usability must be proven. To this end, coordination with the Quality Assurance, Design Engineering, and Testing Departments is required. Criteria for usability such as Reliability testing Dynamic and quasi-static tests, and others Metallographic testing

may be used. 7 Referenced documents

The following documents cited in this standard are necessary for application. In this Section terminological inconsistencies may occur as the original titles are used.

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Standards with the titles given in German are either only available in German or may be procured in other languages from the institution issuing the standard. PV 6717 VW 01105-1 VW 01105-4 DIN EN ISO 14273 DIN EN ISO 6520-2 DVS 2916-1 8 [1] Bibliography DIN EN ISO 5817 Welding Fusion-Welded Joints in Steel, Nickel, Titanium, and Their Alloys (Beam Welding Excluded) Quality Levels for Imperfections Panels (Deep-Drawn Parts) in Steel Body Construction; Evaluation, Re work, Inspection Resistance Spot Welding; Design, Calculation; Uncoated and Coated Steel Sheets Resistance Spot Welding; Three-Sheet Joints Specimen dimensions and procedure for shear testing resistance spot, seam and embossed projection welds Welding and allied processes - Classification of geometric imperfections in metallic materials - Part 2: Welding with pressure Testing of resistance welded joints - Destructive testing, quasi static