Spot Weld Joints

The English translation is believed to be accurate. In case of discrepancies the German version shall govern.

Strength Testing of Steel Materials

PV 6702

Konzernnorm Descriptors: spot welding, resistance spot welding, welding, strength test, wedge test, chisel test, metallography Contents
Page

1 2 3 3.1 3.2 3.3 4 4.1 4.2 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 6 6.1 6.2 6.3 7 7.1 7.2 8

Scope .................................................................................................................................. 2 Requirements...................................................................................................................... 2 Process-specific parameters ............................................................................................... 2 Nugget diameter.................................................................................................................. 2 Spot diameter...................................................................................................................... 3 Particular features of three-sheet joints .............................................................................. 4 Finding ................................................................................................................................ 5 External findings.................................................................................................................. 5 Internal finding..................................................................................................................... 5 Test method ........................................................................................................................ 5 Non-destructive testing ....................................................................................................... 5 Visual test............................................................................................................................ 5 Wedge test .......................................................................................................................... 6 Ultrasonic test ..................................................................................................................... 6 Adaptive process visualization ............................................................................................ 6 Destructive testing............................................................................................................... 7 Chisel test ........................................................................................................................... 7 Peel test .............................................................................................................................. 7 Shearing test ....................................................................................................................... 7 Cross tension test ............................................................................................................... 8 Metallographic testing ......................................................................................................... 9 Evaluation of the destructive test results........................................................................... 10 Metallographic testing ....................................................................................................... 10 Chisel test (and peel test) ................................................................................................. 11 Shearing test ..................................................................................................................... 12 Overall assessment........................................................................................................... 13 Chisel test (or peel test) .................................................................................................... 13 Metallographic testing (nugget diameter, among others) .................................................. 13 Referenced standards....................................................................................................... 14

Changes The following changes have been made as compared to Test Specification PV 6702, 2004-07: Section 5.2.5, Table 1: Nos. 1 and 4 corrected Section 6.2: dpS replaced with dpF Previous issues 1975-04; 1998-06; 2000-02; 2001-05; 2003-03; 2003-06; 2004-07
Form FE 41 - 01.03

Page
Fachverantwortung/Responsibility K-QS-32 Dr. Witt Tel. 73623 Dr. Eisenberg Normung/Standards (EZTD, 1733) Fischer Tel: +49-5361-9-27995 Sobanski

VOLKSWAGEN AG

Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group. Parties to a contract can only obtain this standard via the responsible procurement department.

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Klass.-Nr. 04 81 5

September 2004

Page 2 PV 6702: 2004-09

Scope

This Test Specification describes the testing and evaluation of resistance spot welded joints on steel materials. Generally valid limit values are listed in order to ensure uniform quality of production. Specimen dimensions that are already part of DIN EN ISO 14273 are not stated. 2 Requirements

Dimensional and geometric requirements according to Volkswagen standard VW 011 05, Parts 1, 2 and 4. Definition of pores and cracks according to DIN EN ISO 6520-2. Number and position of weld spots according to drawing. Checking of individual spots according to Section 5. 3 Process-specific parameters

When sheets are joined by means of resistance spot welding, a punctiform joint is created in the joining plane between the sheets. This joint is called a weld spot. Testing of resistance spot welded joints generally requires a destructive test. During the course of testing, the nugget diameter is determined by means of a transverse microsection and/or the spot diameter is determined using a destructive test, such as a chisel test. The diameter depends on the thickness of the sheets to be joined. 3.1 Nugget diameter

The nugget diameter dL is the diameter of the melted weld nugget, measured on the transverse microsection in the respective joining plane. The transverse microsection is used to determine: the nugget diameter and position of the weld nugget with respect to the joining plane, the nugget geometry (nugget height, penetration depth, etc.) and imperfections in the area of the weld nugget (pores, cracks, segregations, etc.). The following applies to the nugget diameter dL: dL = 3.5 t1 t1 = thickness of the thinner sheet It is critical for the strength of a welded structure and must be indicated in the drawing. When welding black-and-white joints, it is important to note that in general the weld nugget is displaced in the white direction. NOTE: White = austenitic steels; black = all other steels. Legend: 1 2 dEi t1,2 tEi Joining plane Adhesion zone Indentation diameter i Sheet-metal thicknesses Indentation depth i

Figure 1 Definition of the weld spot geometry

Page 3 PV 6702: 2004-09 3.2 Spot diameter

The spot diameter dP is generally determined in a destructive test, e.g., chisel test. In exceptional cases, peel tests can also be used. The disadvantage is that this type of test can often give rise to lugs on the sheet because the load is applied to one side of the sheet only, thus preventing precise evaluation of the spot diameter. In the case of a fracture in the joining plane (weld nugget), see Figure 2, the spot diameter dP is the mean diameter of the fracture surface in the joining plane of the workpiece parts, excluding the adhesion zone. It must be possible here to clearly interpret the fracture surface as a break in the joining plane (weld nugget) (e.g., with material chips). Legend: 1 Fracture in the joining plane 2 Adhesion zone

dP =

d1 +d2 2

Figure 2 Spot diameter dP; fracture in the joining plane (weld nugget) With a shear fracture at the transition to the sheet, the spot diameter dP is the mean diameter of the base surface of the sheared button, see Figure 3. With a mixed fracture, dP is the mean diameter of the base surface of the sheared button, including the fraction portion in the joining plane. In the case of resistance spot-welding of sheets with thicknesses from approx. 1.75 mm and/or higher-strength sheets (e.g., H 400 LA) or also sheets made from hot-formed and hardened quenched and tempered steels, more cracks can occur in the joining plane (weld nugget). In production, the spot diameter dP is used to set the desired value of the nugget diameter.

Page 4 PV 6702: 2004-09

symmetrical

Legend: dP d 1, d 2 d3 Spot diameter Measuring points for dp not measured

dP
asymmetrical

dP
partial

dP Figure 3 Spot diameter dP; weld with shear fracture at transition to the sheet/mixed fracture

3.3

Particular features of three-sheet joints

Two weld spot shear diameters occur for three sheet joints during destructive testing; the diameters are determined according to the smallest sheet thickness (see VW 011 05-4).

Page 5 PV 6702: 2004-09 4 4.1 Findings External finding position, place and number of the weld spots as well as edge distance, spatter, electrode indentation, electrode penetration depth and surface cracks. 4.2 Internal finding nugget diameter as well as position and shape of the weld nugget with respect to the joining plane; nugget penetration depth, expansion of the heat-affected zone as well as pores, solidification voids and cracks, microcracks (grain boundary openings with zinc inclusions), macrocracks as well as oxide deposits. 5 Test method

For the external finding, the following can be checked visually:

For the internal finding, the following can be checked by means of a microsection test:

This Test Specification presents suitable non-destructive and destructive test methods to test the spot weld joint, giving the minimum requirements for spot and nugget diameters. Other test methods, e.g., non-destructive methods such as ultrasonic tests or destructive methods such as torsional testing with separation of joint (DVS1 2916), that lead to similar or even better quality statements can be used if they have been verified. The minimum requirements are valid for the component and shall be adhered to. The test frequency is specified by the responsible planning department in coordination with Quality Assurance and the manufacturing department in accordance with the requirements for the weld joint. For acceptance tests, it has to be considered that the proper outside appearance of a weld spot cannot be the sole basis for an evaluation of its quality. A number of further characteristics have to be considered, especially requirements according to VW 011 05-12, 2 and 4, as well as test procedures taken from DVS standard 2916. 5.1 5.1.1 Non-destructive testing Visual test

Number and position of weld spots according to drawing. The electrode indentation shall be clean, uniform, and shall not be tilted. See VW 011 05-1 for the electrode penetration depth. Furthermore, it shall be free of spatter, burrs, copper adhesions and deep craters.

1 2

DVS = German Association for Welding Technology The following applies according to VW 011 05-1:

dP

min.

1.15 3.5 t

t = smaller sheet thickness [mm]

Page 6 PV 6702: 2004-09 5.1.2 Wedge test

In the wedge test, a flat chisel is driven in next to or between the weld spots. As a test method, the wedge test has a relatively minimal destructive effect. It is a supplementary test and is used between the intervals of the destructive test (destructive chisel test) until the use of more meaningful test methods (e.g., ultrasonic test). Its sole aim is to check and monitor the welding equipment. Additionally, it can be used to estimate the minimum required spot diameter of a spot weld joint, e.g. in thin sheet processing. If it proves impossible to estimate the spot diameter, the latter shall be determined by means of a chisel test (Section 5.2.1) or a metallographic test (Section 5.2.5). It is no longer possible to estimate the spot diameter for resistance weld spots on sheets > 1.0 mm or on sheets of a higher strength (as of tensile strength values > 400 N/mm). Thus, the wedge test shall no longer be used. 5.1.3 Ultrasonic test

An ultrasonic test can be used as a replacement for and as a supplement to the wedge test, if the manufacturing department provides proof that this test is equally suited to ensuring the quality of the production process. 5.1.4 Adaptive process visualization

Adaptive process visualization is a 100% online test, which involves creating a correlation between process parameters and the weld spot geometry. This visualization can be used to assure the quality of the production process, if the manufacturing department has provided proof that it is at least as suited to doing so as the non-destructive test methods currently used (e.g., ultrasonic test).

Page 7 PV 6702: 2004-09 5.2 Destructive testing

Both the nugget diameter dL and the spot diameter dP can be determined in a destructive test. 5.2.1 Chisel test

The chisel test, e.g., according to DVS 2916, is a destructive test. In the chisel test, an appropriately shaped chisel is driven between the welded sheets until the spot weld joint is destroyed. In this process, the weld spot can shear out or the fracture can occur in the joining plane. Combinations of both these fracture types (mixed fractures) are also possible. If the testing effort is too high, transverse microsections shall 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 or formed and hardened quenched and tempered steels. When testing several closely spaced weld spots in a row, it is recommended that the weld spots be tested individually. In this case, the weld spots shall be separated by means of sawing, for example. Hardening of the material during welding can cause buttons with diameters larger than the weld nugget to form when the weld spots shear at the transition to the sheet during workshop tests. During determination of the spot diameter, button diameters d1 and d2 are determined using a caliper gauge (2nd measurement offset by 90 ) and the mean value is determined from the two measurements. If a precise measurement in two directions is not possible, the smaller diameter is to be used as dP. 5.2.2 Peel test

The peel test belongs to the destructive testing category. During the peel test, the spot weld joint is destroyed using a peel mandrel, e.g., according to DVS 2916, to peel back the two sheets. Both the weld connection and the component can tear. In the case of a tear in the sheet, a one-sided sheet-metal lug is generally formed due to the load being exerted on one side. A precise evaluation of the spot diameter is extremely difficult if not impossible in this case. See Section 6.1 for evaluation. 5.2.3 Shearing test

The shearing test belongs to the destructive testing category. An individual weld spot is tested in a tensile test machine until the weld spot or the component fails. The tear force required to do this is measured. If possible, the shearing test shall be performed for all spot weld joints. The test shall simulate the real stress direction. Auxiliary equipment might be needed for this purpose. If such stress cannot be simulated, a simple reproducible stress according to Figure 4 or Section 5.2.4, Figure 5 can be chosen. Specimen dimensions and procedure according to DIN EN ISO 14273.

Page 8 PV 6702: 2004-09

outer notch

Figure 4 Shear tension For a single-shear joint, the minimum shearing force Fmin. generates a bending moment of Mb = Frs which grows with increasing stress (up to Fmax.) and also produces a portion of cross tensile force FK. rs is used as shown in Figure 4. Minimum shear tension forces Fmin. per weld spot in the free shearing test according to VW 011 05-1. For determining the minimum shear tension forces Fmin. according to VW 011 05-1, the lowest value in each case shall be applicable to sheets of varying thicknesses and strengths. The thinnest sheet of a single-shear joint or the thinnest outside sheet of a two-shear joint applies as the reference dimension for the joint. In the case of two consecutive spots in the direction of force, 1.8 Fmin can be taken as the standard value for the load carrying capacity (VW 011 05-1, Table 2). This applies accordingly to staggered rows of weld spots. 5.2.4 Cross tension test

The cross tension test belongs to the destructive testing category. Like the shear tension 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 can be performed according to Figure 5 in exceptional cases. In the cross tension test, 25 to 40% of the minimum shear tension force Fmin. (see also VW 011 05-1) should be reached as per the respective deformation capability.

Figure 5 Cross tension

Page 9 PV 6702: 2004-09 5.2.5 Metallographic testing

Metallographic testing belongs to the destructive testing category. It can be performed on all load bearing spot weld joints where a quasi-static tensile test is not possible. 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% alcoholic nitric acid). The transverse microsection is evaluated at a magnification of 50 :1 (or greater), on the unetched microsection (for cracks) or on the etched microsection (for the microstructure). On this transverse microsection, both the weld nugget diameter and the imperfections (e.g., pores, aluminum inclusions, oxide deposits, grain boundary openings with zinc inclusions as well as surface cracks or microcracks) can be determined. NOTE: Microcracks can occur in the area of the weld spot (heat-affected zone) in high-strength steel when black-and-white joints (austenitic high-strength stainless steel with zinc-coated steel) are resistance spot welded. These can be identified in the flat microsection (microsection parallel with the sheet surface) by the fact that they run radially with respect to the weld nugget.

Microcracks

Pores and solidification cracks

Oxide deposits

h = d Pore+ bR

Surface cracks bR = width of a crack l = length of a crack projected vertically to the joining plane

ll

Aluminum inclusions Figure 6 Weld nugget geometries and imperfections

Page 10 PV 6702: 2004-09

Evaluation of the destructive test results

Grade 1 = OK Grade 3 = can still be used; check the process Grade 6 = rework (if permitted) or scrap 6.1 Metallographic testing Table 1 No. Designation OK Grade 1 1 Indentation depth tE Limit values/specifications Conditionally OK Grade 3 Not OK Grade 6

depending on the required surface quality (OG), see also VW 011 05-1 OG1: tE OG2: tE OG3: tE 0.10 t 0.15 t 0.20 t dL = dLmin. Ring nugget not permitted 0.2 dL < dpore < 0.25 dL and chisel or shearing test OK -OG1: tE > 0.10 t OG2: tE > 0.15 t OG3: tE > 0.20 t dL < dLmin. Ring nugget dpore 0.25 dL

Nugget diameter dL dLmin. see VW 011 05-1

dL > dLmin. Ring nugget not permitted dpore 0.2 dL

Pore diameter dpore within the weld nugget

Solidification crack (size) within the weld nugget h = dpore + bR Aluminum inclusion Oxide deposit

0.2 dL

0.2 dL < h < 0.25 dL

0.25 dL

5 6

Permitted in the area of the adhesion zone Permissible: Course in the weld nugget center in the area of the adhesion zone at the edge of the nugget and vertically to the joining plane l < 150 m (measured vertically to the joining plane) l < 500 m 500 m l 800 m l 150 m1)

7a

Surface cracks in the edge area of the electrode indentation Surface cracks in the center of the electrode indentation (center: 0.2 dL)

7b

l > 800 m1)

Page 11 PV 6702: 2004-09 8 Microcracks (see DIN EN ISO 5817 for definition) Not permissible: 1) -

Microcracks that run parallel to the joining plane and project into the weld nugget; - Microcracks that run at the edge of the weld nugget and vertically to the joining plane. 1) Deviations are permitted but must be verified in tests. The new limit value shall be stipulated in a work instruction. 6.2 Chisel test (and peel test)

The Quality Assurance department of the manufacturing department is responsible for testing. If the evaluation yields grades 3 and 6, quality improvement measures must be taken. The designations have the following meanings: dpA dpM dpF dpAR spot diameter for a shear fracture at transition to the sheet spot diameter for a mixed fracture spot diameter for a fracture in the joining plane spot diameter for a shear fracture at transition to the sheet with a ring nugget The weld spot shears out of the component and the minimum spot diameter dpmin.1) dpmin. or is achieved: dpA The weld spot shears out and breaks as a mixed fracture2) and the minimum spot diameter dpmin.1) is achieved: dpM dpmin.. Proof of the weld quality shall be provided by a supplemental determination of the shear tension strength or by means of a transverse microsection. The weld spot fractures in the joining plane or in the weld nugget2) (separation in the joining plane with a material fracture) and the minimum spot diameter dpmin.1) dpmin.. is achieved: dpF Proof of the weld quality shall be provided by a supplemental determination of the shear tension strength or by means of a transverse microsection. The weld spot shears out of the component and the minimum spot diameter dpmin.1) is not achieved: dpA dpmin. or The weld spot shears out of the component as a mixed fracture and the minimum spot diameter dpmin.1) is not achieved: dpM dpmin. or The weld spot shears out of the component and the minimum spot diameter dpmin.1) is not achieved2) (separation in the joining plane with low fracture surface share (adhesion welding)): dpF dpmin. or 3) The weld spot shears out with a ring nugget : dpAR dpmin..

Weld OK (Grade 1)

Weld conditionally OK (Grade 3)

Weld not OK (Grade 6)

1) 2)

3)

The following applies according to VW 011 05-1: dpmin. 1.15 x t with t = smaller sheet thickness in mm NOTE: When sheets with thicknesses greater than approx. 1.75 mm or sheets of higher strengths (e.g., H 4220 LA or hot-formed and hardened quenched and tempered steels) are resistance spot welded, more fractures in the joining plane or mixed fractures can occur. Furthermore, fractures in the joining plane/weld nugget must be reckoned with at the lower end of the parameter setting range. In the case of fractures in the joining plane/weld nugget, the fracture surface must be clearly identifiable as a material fracture. Furthermore, a check must be run as to whether changing the welding parameters would mean that shear-out of the weld spot can be achieved in order to thus increase the process assurance. Often, the ring nugget has come away from the opposite sheet on one side and is only then recognizable as a ring weld. The connection in the core is missing so the result of the transverse-microsection examination is not OK.

Page 12 PV 6702: 2004-09 6.3 Shearing test Weld OK (Grade 1) The minimum shear tension force Fmin. is achieved and The weld spot shears out of the component and the minimum spot diameter dpmin.1) is achieved; dp dpmin. or The weld spot shears out of the component2) and the minimum spot diameter dpmin. is achieved; dp dpmin. and The fracture surface is free of visually perceptible pores (share < 10%). The minimum shear tension force Fmin. is not achieved or The minimum spot diameter dpmin.1) is not achieved: dp < dpmin.

Weld not OK (Grade 6):

1) 2)

The following applies according to VW 011 05-1: dpmin. 1.15 x t with t = smaller sheet thickness in mm NOTE: When sheets with thicknesses greater than approx. 1.75 mm or sheets of higher strengths (e.g., H 4220 LA or hot-formed and hardened quenched and tempered steels) are resistance spot welded, more fractures in the joining plane or mixed fractures can occur. Furthermore, fractures in the joining plane/weld nugget must be reckoned with at the lower end of the parameter setting range. In the case of fractures in the joining plane/weld nugget, the fracture surface must be clearly identifiable as a material fracture. Furthermore, a check must be run as to whether changing the welding parameters would mean that shear-out of the weld spot can be achieved in order to thus increase the process assurance.

Page 13 PV 6702: 2004-09 7 Overall evaluation

It must be ensured by means of an overall evaluation that the quality of a spot weld joint remains constant over the entire manufacturing period. In an overall evaluation, both the nugget diameter dL in the microsection (formation of the weld nugget according to VW 011 05-1; no ring nugget) and the spot diameter dP, among others, are to be evaluated using a destructive test such as the chisel test. The minimum requirements with respect to the nugget diameter dL and the spot diameter dP must also be fulfilled. This is especially important when setting welding parameters when preparing a machine for delivery, 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 shearing force can be determined. The appropriate test procedures are listed in this Test Specification. 7.1 Usable: Spot diameter dPmin. OK or spot diameter up to 15% < dPmin. with a frequency of the number of loose spots is < 0.5% Proof of usability: Where the portion of spots that are not OK is higher, the component-specific usability must be proven. To this end, coordination with Quality Assurance, Design Engineering and Prototype Shop is required. Criteria for usability such as trials dynamic and quasi-static tests can be utilized. 7.2 Usable: Nugget diameter dL OK or max. 5% of spots up to 15% < dL min and number of loose spots is max. 0.5% Proof of usability: Where the portion of weld spots that are conditionally OK or not OK is higher, the componentspecific usability must be proven. To this end, coordination with Quality Assurance, Design Engineering and Prototype Shop is required. Criteria for usability such as trials, dynamic and quasi-static tests can be utilized. Metallographic testing (nugget diameter, etc.) 5% and Chisel test (or peel test)

Page 14 PV 6702: 2004-09 8 Referenced standards4) Resistance Spot Welding; Design, Calculation, Process Assurance; Uncoated and Coated Sheet Steels Resistance Spot Welding; Aluminum Materials Resistance Spot Welding; Three-Sheet Joints Welding and Allied Processes Classification of Geometric Imperfections in Metallic Materials Part 2: Welding with Pressure Specimen Dimensions and Procedure for Shear Testing Resistance Spot, Seam and Embossed Projection Welds Testing of Weld Spots

VW 011 05-1 VW 011 05-2 VW 011 05-4 DIN EN ISO 6520-2 DIN EN ISO 14273 DVS 2916 Other standards DIN EN ISO 5817

Welding Fusion-Welded Joints in Steel, Nickel, Titanium and Their Alloys (Beam Welding Excluded) Quality Levels for Imperfections

4) In this section, terminological inconsistencies may occur as the original titles are used.