Gws-5a (Test Procedures - Resistance Spot Welding of Steel-)

GM Global Manufacturing Engineering
Global Wel ding Standard

Test Procedures
Resistance Spot Welding of Steel
GWS-5A

April 2011

Copyright 2011. General Motors. All rights reserved.
Uncontrolled When Printed
DOCUMENT MANAGEMENT INFORMATION

Authors: Approval:

J ohn Bohr - ME Body GM Global Weld Council
Mark Gugel - ME Body

Sponsoring Group:

GM Manufacturing Center Global Weld Council

Forward Questions and Comments to:

Global Weld Council at weld.council@gm.com
Proposed changes to this standard must be presented to the GM Global Weld Council. To suggest
a change to this standard, reference the Procedure for Weld Standard Changes on the Global
Weld Councils webpage.

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Document Expirati on Date:

This document will expire May 2016. It may be revised, reaffirmed or withdrawn prior to this date.
Contact the organization listed above for the latest version.

Document Revisions:

Date Revision Revision History
August 2007 Initial Release
April 2, 2008 Editorial Figure in Table 2-1 revised for clarity.
April 15, 2008 Editorial Figure in Table 2-1 revised for accuracy. Corrected measurement
from 0.015mm to 0.15mm
April 27, 2011 Revised to allow weld size evaluation of interfacial fractures.
Global Welding Test Procedures (GWS-5A)
Section A: Resistance Spot Welding of Steel
General Motors Global Manufacturing Engineeri ng

April 2011
Copyright 2011. General Motors Company. All rights reserved.
i
TABLE OF CONTENTS

Section Descripti on Page

1. General ........................................................................................................................................ 1
1.1 Scope ................................................................................................................................. 1
1.2 Purpose .............................................................................................................................. 1
1.3 Weld Deviation Process ...................................................................................................... 1
1.4 References ......................................................................................................................... 2
1.4.1 Normative ............................................................................................................. 2
1.4.2 Informative ............................................................................................................ 2
1.5 Definitions, Acronyms and Abbreviations ............................................................................. 2
1.5.1 Definitions ............................................................................................................. 2
1.5.2 Acronyms and Abbreviations ................................................................................. 4
2. Weld Lobe Test ........................................................................................................................... 5
2.1 Equipment Requirements .................................................................................................... 5
2.1.1 Welding Equipment ............................................................................................... 5
2.1.2 Water Flow Rate ................................................................................................... 5
2.1.3 Inspection, Measurement and Test Equipment ...................................................... 5
2.1.4 Tools ..................................................................................................................... 6
2.2 Material Requirements ........................................................................................................ 6
2.3 Selection of Test Parameters .............................................................................................. 6
2.4 Predressing of Electrode Caps ............................................................................................ 6
2.5 Electrode Alignment ............................................................................................................ 6
2.6 Test Procedure ................................................................................................................... 7
2.6.1 Conditioning Welds ............................................................................................... 7
2.6.2 Weld Lobe Generation .......................................................................................... 7
2.6.2.1 Minimum Weld Size Range ....................................................................... 7
2.6.2.2 Expulsion Range ...................................................................................... 8
2.7 Reasons to Reject Steel and/or Metal Stackup for Production Applications ........................ 10
3. Electrode Cap Performance Test ............................................................................................. 12
3.1 Equipment Requirements .................................................................................................. 12
3.1.1 Welding Equipment ............................................................................................. 12
3.1.2 Water Flow Rate ................................................................................................. 12
3.1.3 Inspection, Measurement and Test Equipment .................................................... 12
3.1.4 Tools ................................................................................................................... 12
3.2 Material Requirements ...................................................................................................... 12
3.3 Predressing of Electrode Caps .......................................................................................... 13
3.4 Electrode Alignment .......................................................................................................... 13
3.5 Test Procedure ................................................................................................................. 13
3.5.1 Electrode Cap Performance ................................................................................ 13
3.6 Reasons to Reject Steel and/or Metal Stackup for Production Applications ........................ 14
Annex A: Figures ................................................................................................................................... 1


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1. General

1.1 Scope

This document establishes the procedures to evaluate the resistance spot weldability of sheet
steel based on the following global initiatives:
electrode cap dressing
global weld schedules
global acceptance criteria (i.e. GMW14057)
global welding equipment (i.e. GWS-2D, GWS-2E & GWS-2T)
This document also establishes the procedures to determine electrode cap performance when
welding different grades and types of steels, steel coatings and/or various metal stackups.

The procedures established in this document are used to determine the practical limits of
production weldability of sheet steel joined by the resistance spot welding process, utilizing weld
lobes in conjunction with data from destructive weld tests and metallurgical examinations.

This document is intended for Steel Manufacturers, Electrode Cap Manufacturers, Material
Engineers, Product Design Release Engineers, Design Follow-up Engineers, Weld Engineers
and other individuals that are responsible for selecting steels, electrode caps, and material
stackups that are processed for production resistance spot welding in vehicle designs for which
GM is responsible.

1.2 Purpose

The purpose of this procedure is to describe the standard weld tests used to determine resistance
spot welding characteristics of sheet steels, stackups, and coatings. The test methods and data
from the completed tests are used to evaluate any or all of the following:
1. New steel grades, or new steel coatings (e.g. pre-primed steels)
2. Effect of steel manufacturing process changes to approved steels
3. Proposed production stackups that do not meet GWS-1A requirements
4. Proposed welding conditions (e.g. use of non-standard electrodes)
5. Establishing and validating production weld schedules
6. To evaluate new and existing suppliers of sheet steel and/or electrodes

1.3 Weld Deviation Process

Any deviations to this test procedure require the advanced written approval of the GM
Manufacturing Engineer - Welding responsible for the project. Any approved deviation shall only
apply to that specific instance, and it shall not be considered a change to this test procedure.


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1.4 References

1.4.1 Normati ve

The following normative references contain provisions that, through reference in this document,
constitute provisions of this standard. The editions indicated were valid at the time of publication.
All normative documents are subject to revision and the most recent editions of the normative
standards indicated below shall apply.

GWS-1A, Weld Design Standards, Section A: Resistance Spot Welding.

GWS-1A Associated Files: Weld Schedules.

GWS-2D, Resistance Welding Equipment, Section D: DC Welder Controls.

GWS-2E, Resistance Welding Equipment, Section E: Electrode Cap Dresser.

GWS-2T, Resistance Welding Equipment, Section T: Transformer-Rectifiers.

GMW14057, Acceptance Criteria and Repair Procedures: Resistance Spot Welds-Steel.

1.4.2 Informati ve

None

1.5 Defi nitions, Acronyms and Abbreviati ons

1.5.1 Definitions

Carbon Imprint: The carbon paper impression left on paper by the electrode face when the
electrodes are closed with no welding current. This is used to verify the alignment of the
electrodes before a test is begun and to measure electrode face diameter. See Figure A - 3 and
Figure A - 9.

Coupon: A steel sheet of predetermined size used to install welds for testing. It is also referred
to as Weld Coupon.

Cycle: Unit of time. For this procedure 60 cycles is equal to 1 second.

Delamination in Base Steel: Refers to discontinuity in sheet steel where the sheet separates by
layers.

Discontinui ty: An interruption of the typical structure of a material, such as a lack of
homogeneity in its mechanical, metallurgical or physical characteristics.

El ectrode Cap: Consumable part of the electrode that is used to apply the weld force and weld
current.

El ectrode Cap Sticking: A term used to describe a condition where the electrode cap appears
to be welded to the surface of the steel sheet. With minimal force the cap can be separated from
the steel without distorting the steel or having the cap release from the shank.


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Expulsion: Molten metal that is extruded from between sheets being welded or from the
interface between the outer sheet metal surface and the electrode(s). See glossary in
GMW14057.

Electrode Imprint: The impression left in the metal surface by the electrode face after welding.

Faying Surface: The surface where welding is initiated.

Fracture:
Full Interfacial Fracture: A type of weld fracture mode that shows evidence of fusion but
shows neither evidence of a through-sheet button pull nor a partial thickness fracture. See
Figure A - 4.

Partial Interfaci al Fracture: A type of weld fracture mode that shows evidence of fusion for
part of the area, and other fracture modes for the remainder of the fused area. See
Figure A - 4.

Partial Thickness Fracture: A type of weld fracture mode that shows removal of parent
metal by the weld from the mating sheet, for all or part of the fused area, but not a full button
pull (characterized by a hole in the parent metal sheet). See Figure A - 4.

Weld Fracture Mode: The type of weld characteristic achieved during destructive testing.

Global Weld Expert Team: A group of individuals designated by the Global Weld Council.
Usually this includes the authors of a given standard or specification and Subject Matter Experts
(SME) from the other GM regions.

Grain: The direction the steel sheet is rolled during the steel processing sequence.

Parent Materi al: Refers to the area around the weld that has not been affected by the weld
current and is not part of the weld button.

Shunt Weld: See Figure A - 5. The first weld(s) on the coupon that will create a parallel path for
part of the weld current used in the subsequent welds.

Stackup: A descriptive method used to identify the position and number of sheets to be welded.

Test Weld: See Figure A - 5. Usually the second weld on the coupon that will be used for peel
testing and evaluation.

Wel d Button: That part of a weld, including all or part of the nugget, which tears out in the
destructive testing of a weld.

Weld Button Size: The weld button size of a symmetrical (round) button is the diameter of the
button. The weld button size of an asymmetrical (oval or oblong) button is calculated by adding
the measurement of the major axis to the measurement of the minor axis and dividing by 2. Refer
to GMW14057. The measurements are to be taken at the faying surface.

Weld Schedule: The parameters specified or set to make a weld.

Weld Size: Refers to either the weld button size or the weld nugget size. With certain steels or
types of loading, a weld button may not always result from a peel or tensile test. In these cases
examination of the fusion zone must be used to determine weld size.


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Weldabili ty: The robustness of a steel to be welded to itself, other steels and in various stackups
(under imposed limits) determined by its:
welding lobe
welded mechanical properties (that perform satisfactorily for the intended service)
electrode cap performance.
The imposed limits are representative of production conditions (i.e. high volume, low cost, global
processing and global weld schedules).

1.5.2 Acronyms and Abbreviations

DT: Determining Thickness

FSC: Faying Surface Condition

HSLA: High Strength Low Alloy steel

I
MAX
: The value of welding current determined during testing that will produce weld expulsion

I
MAX-200
: Welding current value determined by subtracting 200A from I
MAX

l/
MIN
: liters per minute

kA: 1000 Amperes

kN: 1000 Newtons

MPa: 1,000,000 Pascals

ms: milliseconds

NDE: Non Destructive Evaluation

NOK: not okay (not acceptable)

OK: okay (acceptable)

TRIP: Transformation Induced Plasticity

TWIP: Twinning Induced Plasticity


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2. Weld Lobe Test

A weld lobe is a means of graphically expressing the numerous weld current and weld time
combinations that produce acceptable welds under a specified set of conditions. Weld current
values are plotted on the horizontal axis as shown in Figure A - 6.

The left boundary of the lobe displays weld current and weld time combinations that produce
welds of the minimum acceptable weld size. Points to the left of this boundary produce undersize
welds. The right boundary of the lobe displays weld current and weld time combinations that
produce the first occurrence of expulsion. Points to the right of this boundary produce welds with
excessive heat energy evidenced by excessive expulsion, electrode indentation and electrode
sticking or any combination of these occurrences.

The weld current and weld time combinations in the area between the two boundaries (i.e. Weld
Lobe) produce welds with acceptable weld size per the requirements of GMW14057. The
distance between these two boundaries at a given weld time is referred to as the Weld Current
Range. A wide Weld Current Range indicates that the metal stackup would be tolerant to
variables in the manufacturing process [e.g., tip wear, voltage fluctuations, metal contamination
(rust or foreign material)], and other normal changes in the weld equipment. This section defines
the test procedure used to determine the weld lobe.

2.1 Equipment Requirements

2.1.1 Welding Equipment

The following equipment is required to generate the data used to determine a weld lobe.

1. Resistance Spot Welder (e.g. fixture type, robotic or manual) with an air-operated cylinder (or
other specified method used to generate weld force) that is capable of consistently producing
the required weld forces listed in the Associated Files (Global Weld Schedules) of GWS-1A
and capable of being operated at 30 welds/min.
2. Welding Transformer-Rectifier: manufactured to GWS-2T by one of GMs approved suppliers.
3. Welder Control: manufactured to GWS-2D by one of GMs approved suppliers.
4. Electrode Cap Dresser: manufactured to GWS-2E by one of GMs approved suppliers.
5. Electrode Cap: Unless otherwise specified, the standard electrode cap is a GMWZ-16x20,
mounted on an open shank and pre-dressed to a specified diameter as specified in the
Associated File (Global Weld Schedules) of GWS-1A.

2.1.2 Water Flow Rate

The water flow per electrode cap shall be 2 l/min - 4 l/min.

2.1.3 Inspection, Measurement and Test Equipment

The following calibrated equipment shall be used:
1. current analyzer (e.g. Miyachi Model #MM-326B or equivalent)
2. digital read-out force gage capable of reading up to 8.9 kN
3. dial caliper (e.g. Mitutoyo Model #CD-6C or equivalent) to measure weld size
4. flow meter to measure water flow
5. tensile test machine
6. ultrasonic testing equipment (optional)

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2.1.4 Tools

1. end nippers (e.g. Channel Lock #148-14 or equivalent)
2. wire cutters for removing excess parent material from the buttons
3. bench vise
4. hammer
5. chisel

2.2 Material Requi rements

A minimum of three square meters of flat production-intent steel sheet material is required for the
weldability procedure. Steel sheets shall be sheared into coupons with the grain of the steel in
line with the coupon length. Steel coupons shall be sheared to the dimensions shown in
Figure A - 5 and Figure A - 7.

2.3 Sel ecti on of Test Parameters
Use the associated file (Weld Schedules) of GWS-1A to select the weld schedule based on the
DT and FSC of the steel stackup.
Set the squeeze time to ensure welding occurs at 100% of weld force.
Note:
1. Welding one weld gun force higher than specified is allowed in manual operations. However,
this increased weld force may result in higher weld current requirements.
2. When the total metal stackup exceeds 2.5 times the DT, it may be necessary to increase the
weld time as much as two DT intervals. However, this increase in weld time may result in
higher weld current requirements and could increase the weld current as much as 1000A.

2.4 Predressing of El ectrode Caps

The electrode caps shall be predressed to the specified diameter in the associated file (Global
Weld Schedules) of GWS-1A using a GWS-2E electrode cap dresser.

2.5 Electrode Alignment

The upper and lower electrodes shall be aligned as shown in Figure A - 1. Prior to start of
testing, the alignment of the electrode caps must be verified by making carbon imprints using the
following procedure:
1. Set and verify the test weld force.
2. Program the test weld schedule.
3. Switch the welder control to the No Weld mode.
4. Insert paper with cardboard and carbon paper between electrode caps as shown in
Figure A - 2.
5. Initiate the welder control.
6. Inspect carbon imprint made by electrode caps on the paper.

Electrode alignment is considered acceptable when the carbon imprint (See Figure A - 3) from
both the upper and lower caps is:
circular in shape
uniform in color
diameter meets the specified predressed value

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2.6 Test Procedure

2.6.1 Conditioning Welds

After the electrode caps are predressed and aligned, make 50 conditioning spot welds using a
weld current that yields minimum sized welds at the nominal weld time. These conditioning welds
reduce the scatter of test data.

2.6.2 Wel d Lobe Generation

2.6.2.1 Minimum Weld Size Range

1. Set the welder control to the Constant Current mode and the weld and cool times to the next
higher DT interval values shown in the appropriate table for that FSC from Associated Files
(Global Weld Schedules) of GWS-1A or as indicated on the Test Request. Based on the DT,
select a weld current (below the value shown in the Global Weld Schedules) that should
produce an undersized weld as defined by GMW14057.

2. Spot weld one coupon and peel the coupon to measure the weld size. Increase the weld
current (in 100A increments) and spot weld coupons until the measured weld size is equal to
or greater than the minimum required size.

DETERMINING POINT A OF THE WELD LOBE

3. Spot weld one coupon as shown in Figure A - 5 using the weld schedule determined in step
2. Peel the coupon as shown in Figure A - 5 to verify the weld size of Test Weld #2 is greater
than or equal to the minimum required size. Achieving three consecutive coupon samples
with an acceptable weld diameter from Test Weld #2 establishes Point A on the Weld Lobe
shown in Figure A - 6. If an acceptable weld is not met for three consecutive coupons,
continue to increase the weld current using 100A increments until an acceptable weld size on
Test Weld #2 is met on three consecutive coupons.

Note: If an interfacial fracture occurs (during testing to determine weld size) and the fusion
zone has an acceptable weld size, note the interfacial fracture condition on the test report
and communicate the fracture condition to the Program Lead Weld Engineer.

4. Weld the following additional number of coupons to be used for:
Tensile/Shear 3 coupons (See Figure A - 7).
Cross-Tension 3 coupons (See Figure A - 7).
Hardness traverse and metallurgical examination of Test Weld #2 1 coupon
See Figure A - 8.

DETERMINING POINT B OF THE WELD LOBE

5. Using the weld current from Point A, set the welder control to the Constant Current mode and
the weld and cool times to the DT interval values shown in the appropriate table for that FSC
from Associated Files (Global Weld Schedules) of GWS-1A or as indicated on the Test
Request. Spot weld one coupon and peel test as shown in Figure A - 5. Achieving three
consecutive samples with an acceptable weld size establishes Point B on the Weld Lobe
shown in Figure A - 6. If an acceptable weld size is not met for three consecutive coupons,
continue to increase the current using 100A increments until a weld of an acceptable size on
Test Weld #2 is met for three consecutive coupons.


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6. Repeat Step 4 above for Point B.

DETERMINING POINT C OF THE WELD LOBE

7. Using the weld current from Point B, set the welder control to the Constant Current mode and
the weld and cool times to the next lower DT interval values shown in the appropriate table
for FSC from Associated Files (Global Weld Schedules) of GWS-1A or as indicated on the
Test Request. Spot weld one coupon as shown in Figure A - 5. Achieving three consecutive
samples with an acceptable weld size on Test Weld #2 establishes Point C on the Weld Lobe
shown in Figure A - 6. If an acceptable weld is not achieved for three consecutive coupons,
continue to increase the current using 100A increments until acceptable welds on Test Weld
#2 is met on three consecutive coupons.

8. Repeat Step 4 above for Point C.

2.6.2.2 Expulsion Range

DETERMINING POINT D OF THE WELD LOBE

1. Using the weld current from Point C plus 200A, set the welder control to the Constant Current
mode and the weld and cool times to the next higher DT interval values shown in the
appropriate table for that FSC from Associated Files (Global Weld Schedules) of GWS-1A or
as indicated on the Test Request. If expulsion does not occur on Test Weld #2, increase the
weld current (in 200A increments) until expulsion occurs on Test Weld #2.
2. The first occurrence of expulsion on Test Weld #2 establishes Point D on the Weld Lobe
shown in Figure A - 6.
3. Weld the following additional number of coupons to be used for:
Tensile/Shear 3 coupons See Figure A - 7.
Cross-Tension 3 coupons See Figure A - 7.
Hardness traverse and metallurgical examination of Test Weld #2 make one coupon
(See Figure A - 8)

DETERMINING POINT E OF THE WELD LOBE
4. Using the weld current from Point D plus 200A, set the welder control to the Constant Current
mode and the weld and cool times to the nominal DT interval values shown in the appropriate
table for FSC from Associated Files (Global Weld Schedules) of GWS-1A or as indicated on
the Test Request. If expulsion does not occur on Test Weld #2, increase the weld current (in
200A increments) until expulsion occurs on Test Weld #2.
5. The first occurrence of expulsion on Test Weld #2 establishes Point E on the Weld Lobe
6. Repeat step 3 above for Point E.
DETERMINING POINT G OF THE WELD LOBE
7. Weld one additional coupon at Point G (minus 200A from Point E) to be used for metallurgical
examination of Test Weld #2. This establishes Point G on the Weld Lobe as shown in
Figure A - 6.
DETERMINING POINT F OF THE WELD LOBE

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8. Using the weld current from Point E plus 200A, set the welder control to the Constant Current
mode and the weld and cool times to the next lower DT interval values shown in the
appropriate table for FSC from Associated Files (Global Weld Schedules) of GWS-1A or as
indicated on the Test Request. If expulsion does not occur on Test Weld #2, increase the
weld current (in 200A increments) until expulsion occurs on Test Weld #2.
9. The first occurrence of expulsion on Test Weld #2 establishes Point F on the Weld Lobe
10. Repeat step 3 above for Point F.


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2.7 Reasons to Reject Steel and/or Metal Stackup for Production Appli cations

The Weld Lobe is not solely used to judge the production weldability of a steel and/or metal
stackup. If delamination of the steel is observed during the peel test, the steel is rejected. Any of
the following conditions may result in rejection by the Global Weld Expert Team of a proposed
steel and/or metal stackup:
1. Narrow Weld Current Range:
A 1.0 kA minimum weld lobe current range cannot be met.
2. Inconsistent Weld Size Samples:
Consistent weld size cannot be produced.
3. Weld Lobe Position on Graph:
The weld lobe does not overlap sufficiently with those previously developed for approved
steel sources.
4. Hardness Traverse:
The hardness traverse indicates a brittle weld structure.
5. Metallurgical Cross-Section Examination:
The metallurgical examination reveals any of the following discontinuities.
a. Thinning greater than 30% as described in GMW14057.
b. Penetration less than 10% into each sheet.
c. Any void not wholly contained within the weld nugget. See figure in Table 2-1.
d. Cracks are observed see Table 2-1.


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80%
10% 10%
Surface Crack Outside
the Electrode Imprint
(NOK)
Void
Surface Crack
(<0.15mm) Inside
the Electrode Imprint
(OK)
Electrode
Imprint
Table 2-1: Acceptability of Surface Cracks (By Location)

Steels
Inside Electrode Imprint
Outside Electrode
Imprint
Outer
10%
Inner 80%
Outer
10%
GMW3399M TRIP NOK
OK
depth <0.15mm
NOK NOK
GMW3399M TWIP NOK
OK
depth <0.15mm
NOK NOK
GMW3399M DP
(950MPa and higher)
NOK
OK
depth <0.15mm
NOK NOK
GMW14400M Boron NOK
OK
depth <0.15mm
NOK NOK
GMW3399M MS
(950MPa and higher)
NOK
OK
depth <0.15mm
NOK NOK
All others listed in GWS-1A
Associated File: Global Approved
Steels for Welding
OK OK OK NOK


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3. El ectrode Cap Performance Test

The following items are required to generate the data used to determine electrode cap
performance within the interval of cap dressing. Use the Electrode Cap Test Data Form shown in
Figure A - 11.

3.1 Equipment Requirements

3.1.1 Welding Equipment

The following equipment is required to generate the data used to determine electrode cap
performance.

1. Resistance Spot Welder (e.g. fixture type, robotic or manual) with an air-operated cylinder (or
other specified method used to generate weld force) that is capable of consistently producing
the required weld forces listed in Associated Files (Global Weld Schedules) of GWS-1A or as
indicated on the Test Request and capable of being operated at 30 welds/min.
2. Welding Transformer-Rectifier: manufactured to GWS-2T by one of GMs approved suppliers.
3. Welder Control: manufactured to GWS-2D by one of GMs approved suppliers.
4. Electrode Cap Dresser: manufactured to GWS-2E by one of GMs approved suppliers.
5. Electrode Cap: Unless otherwise specified, the standard electrode cap is a GMWZ-16x20,
mounted on an open shank and pre-dressed to a specified diameter as specified in
Associated Files (Global Weld Schedules) of GWS-1A or as indicated on the Test Request.

3.1.2 Water Flow Rate

The water flow per electrode cap shall be 2 l/min - 4 l/min.

3.1.3 Inspection, Measurement and Test Equipment

The following calibrated equipment shall be used:
1. current analyzer (e.g., Miyachi Model #MM-326B or equivalent)
2. digital read-out force gage capable of reading up to 8.9 kN
3. dial caliper (e.g., Mitutoyo Model #CD-6C or equivalent) to measure weld button size
4. flow meter to measure water flow

3.1.4 Tools

1. end nippers (e.g., Channel Lock #148-14 or equivalent)
2. wire cutters for removing excess parent material from the buttons
3. bench vise

3.2 Material Requi rements

The electrode cap performance procedure is used for several types of evaluations, which have
unique material requirements. See Table 3-1.


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Table 3-1: Material Requi rements

Eval uations Minimum Material Requirements
performance of an electrode cap
material
1 square meter of 0.8mm GMW2M-ST-S
HD70G70GU
specific stackup or welding condition 0.5 square meter of each steel
new steel 1 square meter

3.3 Predressing of El ectrode Caps

The electrode caps shall be dressed to the specified diameter in listed in the Associated Files
(Global Weld Schedules) of GWS-1A or as indicated on the Test Request using a GWS-2E
electrode cap dresser.

3.4 Electrode Alignment

The upper and lower electrodes shall be aligned as shown in Figure A - 1. Prior to start of
testing, the alignment of the electrode caps must be verified by making carbon imprints using the
following procedure:
1. Set and verify the test weld force.
2. Program the test weld schedule.
3. Switch the welder control to the No Weld mode.
4. Insert paper with cardboard and carbon paper between electrode caps as shown in
Figure A - 2.
5. Initiate the welder control.
6. Inspect carbon imprint made by electrode caps on the paper.

Electrode alignment is considered acceptable when the carbon imprint (see Figure A - 3) from
both the upper and lower caps are:
circular in shape
uniform in color

3.5 Test Procedure

3.5.1 El ectrode Cap Performance

1. If Section 2 was performed, use I
Max-200
and skip to Step 5 of this section.
2. If Section 2 was not performed, set the weld force and weld time to the values listed in
the Associated Files (Global Weld Schedules) of GWS-1A or as indicated on the Test
Request. Determine the weld current required to obtain a minimum acceptable weld size as
specified in GMW14057.
3. Determine the weld current (using Constant Current mode) required for obtaining the first
occurrence of expulsion on Test Weld #2 on the coupon as shown in Figure A - 5.
4. Decrease the current by 200A and begin the test.
5. Make imprints of the electrode caps at the start, and every 50-weld interval thereafter. See
Figure A - 9.
Note: A record of electrode imprints must be kept.


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6. Weld at a rate of 30 welds/min on 125mm x 400mm coupons (or other predetermined coupon
size).
Note: Do not make a weld on the footprint of a previous weld as this will accelerate
electrode cap deterioration.
7. After every 48-weld interval, make two welds on a coupon as shown in Figure A - 5. This is
referred to as the 50-weld interval check.
8. Perform a peel test as shown in Figure A - 5 on Test Weld #2 on the coupon and record the
following information on a test data sheet. A typical test data sheet is shown in Figure A - 11.
a. weld number
b. programmed current in kA
c. measured current in kA
d. measure weld size per GMW14057
e. profile (drawing) of each button (e.g. round, oval or crescent)
f. comments (e.g. weld quality, button pulled or no button, excessive expulsion,
sticking, etc.)
9. When the weld size does not meet the minimum requirements at the 50-weld interval check,
record the data and end the test.
10. Continue the test until one of the following conditions occur:
500 acceptable welds are produced
The metal sticks to the electrode cap, requiring a substantial force to free it
(i.e., excessive electrode sticking).
Other conditions exist (as stated in the Special Instructions on the test request).
11. Record the total number of welds at the termination of the test.

Note: The ME Body Weld Engineer should be notified of any modifications or errors that occur
during electrode cap performance testing.

3.6 Reasons to Reject Steel and/or Metal Stackup for Production Appli cations

The Electrode Cap Performance is not solely used to judge the production weldability of a steel
and/or metal stackup. The following conditions may result in rejection by the Global Weld Expert
Team of a proposed steel and/or metal stackup.
Does not achieve 500 acceptable welds
Excessive electrode cap sticking.
Does not meet requirements of Special Instructions.


April 2011
A-1

Annex A: Figures

Figure A - 1: Electrode Ali gnment

Figure A - 2: Testing of Electrode Alignment

C
L
C
L
Acceptable Unacceptable
C
L
C
L

C
L
Folded
Paper
Folded
Carbon Paper
Cardboard
~0.30mm Thick

April 2011
A-2
Figure A - 3: Carbon Imprints Used For Verification of Electrode Cap Alignment

Figure A - 4: Interfaci al Fractures

Acceptable Electrode Alignment
o Imprints are circular
o Imprints are uniform
with uniform deep coloring
Unacceptable El ectrode Alignment
o Imprints are oval
o Imprints are circular
but not uniform in coloring

Lower Cap Upper Cap Lower Cap Upper Cap
P
a
p
e
r

F
o
l
d

L
i
n
e

P
a
p
e
r

F
o
l
d

L
i
n
e

Full Interfacial Fracture
Partial Interfacial Fracture
Partial Button
Partial Thickness Fracture

April 2011
A-3

Figure A - 5: Peel Test Wel d Coupons for Generati ng Weld Lobes
and/or Electrode Cap Performance

Descripti on Symbol Dimension/Tolerance
Test Weld #1 (first weld/shunt weld) #1 N/A
Test Weld #2 #2 N/A
Offset V 6 +3mm
Weld Spacing per GWS-1A X 6 mm
Coupon Length L 150 3mm
Coupon Width W 50 3mm
Typical Peel Test
End Nippers
Bench Vise
Test Weld #1
Test Weld #2
X
#1 #2
V
L
W

April 2011
A-4
Figure A - 6: Weld Lobe

Minimum Acceptable Weld Size on Test Weld #2

First Occurrence of Expulsion on Test Weld #2

Weld Lobe Range
Region of
Excessive
Expulsion
Region of
Undersi zed
Wel d
Wel d Lobe

Weld Current (kA)
W
e
l
d

T
i
m
e

(
m
s
)

A
B
C
D
E
F
Minimum
Maxi mum
Nominal
0
G


April 2011
A-5
Figure A - 7: Tensile/Shear & Cross-Tension Weld Coupon Test

Dimensions (mm)
W (Coupon Width & Overlap) 50 3
L (Coupon Length) 150 3
Weld Location W/2 3 from center of overlap area
L
Tensile/Shear Coupon

W
W
Cross-Tension Coupon

W
L

April 2011
A-6

Figure A - 8: Hardness Traverse

Hardness testing shall be performed as shown in Figure A - 9 (diagonal traverse across the weld from
base metal of top coupon to base metal of bottom coupon) using a suitable instrument for micro-
indentation hardness testing (i.e. Vickers or Knoop).

All hardness testing shall be performed at a temperature of 23 5C. A constant force that is between
0.2kg (1.961 N) and 1kg (9.807 N) shall be used for all indentations. All indentations shall be made at
0.4mm spacing or no less than three times the mean diagonal of any two adjacent indentations.
Note: If the distance between the centers of two adjacent indentations is less than three times the mean
diagonal of either indentation, the spacing has to be increased.

The approach velocity of the indenter shall not exceed 200mm/second. The time from initial application
of force until the test force is reached shall not exceed 10 seconds. The duration of the test force shall be
10 to 15 seconds. The results shall be reported in tabular or graphical form and include the following
headings:

Sample Test Force Tabular Report

TEST FORCE REPORT
Posi tion
Hardness Values
Base Metal Heat-Affected Zone Weld
Nugget
Heat-Affected
Zone
Base Metal


April 2011
A-7
Figure A - 9: El ectrode Imprint History (50 weld intervals)

Figure A - 10: Surface Cracks

200
0
350
400
300
150
250
100
50

April 2011
A-8
Figure A - 11: Typical Electrode Cap Performance Test Data Sheet

Requestor: Date: Test #:
Material: Performed by: Page #: Total Pages:
Stackup: Weld Machine: Welder Control:
Upper Cap #: Dressed Cap Face Dia (mm):
Water Flow (l/min):
Lower Cap #: Dressed Cap Face Dia (mm): Water Flow (l/min):
Weld Schedule
Squeeze Time (ms): Weld Time (ms): Cool Time (ms):
#of Pulses: Hold Time (ms): Weld Force (kN):
Weld #
Programmed
Current

kA
Measured
Current

kA
Measured
Button A
Diameter
mm
Button A
Shape

drawing
Measured
Button B
Diameter
mm
Button B
Shape

drawing
COMMENTS
(e.g., expulsion, cap
sticking, cap imprint)

Weld Size A is between the first and second sheet and Weld Size B is between the second and third sheet.
See example below for metal stackup (G1.5G-B1.7B-G2.0G)
NOTE: A weld button is the result of a peel test.

G1.5G
G2.0G
B1.7B
Weld Size B
Weld Size A
Metal Stackup Ill ustration

Gws-5a (Test Procedures - Resistance Spot Welding of Steel-)

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