WORLDWIDE

ENGINEERING Material Specification GMW16536

STANDARDS

Pumpable Sealer Between Flanges of Welded Structures - Steel

Acceptance Criteria and Repair Procedures

1 Scope
Note: Nothing in this standard supercedes applicable laws and regulations.
Note: In the event of conflict between the English and domestic language, the English language shall take
precedence.
1.1 Purpose. This standard provides the acceptance criteria and repair procedures for weld-through sealer(s)
in automotive products for which GM is responsible for establishing or approving product design.
1.2 Applicability. This standard applies to any application where a weld-through sealer(s) capable of being
pumped at ambient temperatures and intended for use in the body shop is used to seal body joints against
water, dust and air intrusion.
The criteria established in this standard become mandatory when referenced in product release information or
an approved Product Quality Standard (PQS) document. Deviations from any sealer criteria provided in this
standard must be identified in product release information or an approved PQS document.
1.3 Usage. Weld-through sealed structures are considered satisfactory when they provide leak-free seams in
identified water paths, and prohibit water intrusion to meet corrosion requirements for a required period.
Corrosion requirements in structures containing “weld-through” sealer in a vehicle are varied in both type and
magnitude and cannot be addressed by this standard. Therefore, while the sealer quality criteria of this
standard are consistent with service requirements, they have been established specifically for use in process
and product monitoring. Any attempted application of this document to other uses may lead to an erroneous
result or conclusion.
1.4 Clarification. For clarification of this standard or editorial comments, email the GM Weld Council at:
weld.council@gm.com.
Proposed changes to this standard must be presented to the Global Weld Council. To suggest a change to this
standard, reference the “Procedure for Weld Standard Changes” on the Weld Council’s web page.

2 References
Note: Only the latest approved standards are applicable unless otherwise specified.
2.1 External Standards/Specifications.
None
2.2 GM Standards/Specifications.
GMW15563
2.3 Additional References.
 GMS Operating Guidelines and Global Launch Manual, Section B4
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 Procedure for Weld Standard Changes available on Weld Council’s web page.

3 Requirements
3.1 General Acceptance Criteria.
3.1.1 Correct Material. The weld-through sealer applied shall be the material specified in the design release
documentation and/or the Process Data Sheet for Sealer Application (see Appendix A, Figures A1 and A2).
The product is non-conforming if incorrect material is being applied.

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3.1.2 Substrate Condition. Cleaning of the faying surfaces is not required unless visibly contaminated by dirt,
dust, corrosion, or other foreign matter. Preparation of the faying surfaces is not required unless specified in
the material specifications.
3.2 Visual Acceptance Criteria.
3.2.1 Bead Location. The bead position along the flange, including the start and stop location are to be in
agreement with the design release and/or the Process Data Sheet for Sealer Application (see Figures A1 and
A2). Beads not properly located require the process to be adjusted to the specified start and stop locations as
well as bead position along the flange. Bead position across the flange may be adjusted to achieve wet out
and to minimize or eliminate excess material squeezed out of the joint (see Figures A4 and A5). Squeeze-out
of weld-through sealant is not allowed in locating holes, fixing holes and tooling holes. For other types of holes,
e.g., clearance holes, drain holes, etc., small amounts of squeeze-out can be accepted as long as functionality
is not degraded and work environment and wash-off problems do not occur. Local squeeze-out towards the
paint shop side of the flange shall be used to prevent pockets or undercuts where there is a risk of moisture
intrusion between a paint shop seal and a weld-through sealant. Missing or mislocated beads cause the
product to be non-conforming.
3.2.2 Wet Out. Wet out is defined as the “footprint” of sealer surface area on each of the flanges in a joint the
sealer covers. It is required that both flange surfaces exhibit evidence of sealer contact (flattening of the
dispensed bead) after separation. Actual transfer of sealer during this separation may or may not occur (see
Figure A5). On flange surfaces that do not exhibit some evidence of sealer “footprint” on both flanges, the
process is to be adjusted to eliminate the condition (see Figure A4).
3.2.3 Wet-Out Width. The wet-out width is to be a minimum 7 mm wide to a maximum of 100% of the flange
width (see Figures A3 and A5). It is to be measured on the bead application flange surface at the narrowest
place. If the wet-out width is less than 7 mm at the narrowest place, then the bead is to be adjusted to
eliminate the condition.
3.2.4 Voids, Skips or Interruptions. Any voids, skips or interruptions in sealer bead applications cause the
product to be non-conforming.
3.3 Measurable Acceptance Criteria. Not applicable.
3.4 Disposition/Repair Procedure.
3.4.1 Disposition. All known and suspect product with non-conforming sealer applications must be repaired.
Refer to Appendix B - Table B1 to determine when a weld-through sealer application is non-conforming. When
required, sealer applications shall be repaired according to the procedures specifically authorized by the
appropriate Product Engineer.
3.4.2 Repair Procedure. Beads that are non-conforming with this standard can be repaired with suitable
methods, e.g., placement of a new bead of sealer conforming to this standard, and/or application of paint shop
seal.

4 Manufacturing Process
4.1 Process Control. The welding source is responsible for establishing practices and test methods to assure
that the criteria of this standard are met and are consistent with the GM Joining and Dispense Process Control
Procedure, GMW15563.
4.2 Sealer Bake Control. The painting source is responsible for establishing practices and test methods to
ensure that the cure and/or post-cure cycle criteria are met and are consistent with the applicable material
specifications.

5 Notes
5.1 Glossary.
Faying Surfaces: Pre-bonded pair of close-fitting surfaces that are to be connected.
Product Quality Standard (PQS): Measurable requirements for product characteristics which, when satisfied,
ensure the product meets internal and external customer requirements. (Refer to GMS Operating Guidelines
and Global Launch Manual, Section B4.)

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5.2 Acronyms, Abbreviations, and Symbols.

BFO Bill of Material Family Owner
BOM Bill of Material
MPD Master Process Document
PQS Product Quality Standard

6 Coding System
This standard shall be referenced in other documents, drawings, etc., as follows:
GMW16536

7 Release and Revisions

This standard was originated in February 2011. It was first approved by the Global Weld Council in July 2011.
It was first published in August 2011.
Publication Description
Issue
Date (Organization)
1 AUG 2011 Initial publication.

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Appendix A

Figure A1: Process Data Sheet for Sealer Application

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Figure A2: Visual Aid for Sealer Application

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Figure A3: Wet Out Test Measurement

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GMW16536

Figure A4: Bead Location and Appearance

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Figure A5: Wet Out

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Appendix B

Table B1: Determining When a Weld-Through Sealer Application is Discrepant

Does Non-
conformance Corrective Action(s)
Attribute Criteria Disposition
Make the Bond Required
Discrepant?

Replace with Correct

Wrong Material Refer to section 3.1 Yes Material and Purge Refer to section 3.4
System

Contaminated Substrate Refer to section 3.1 No Clean Substrate N/A

Missing Bead Refer to section 3.2 Yes Adjust Process Refer to section 3.4

Mislocated Bead Refer to section 3.2 Yes Adjust Process Refer to section 3.4

Wet Out Refer to section 3.2 No Adjust Process N/A

Voids, Skips or Refer to section 3.4

Refer to section 3.2 Yes Adjust Process Note 1, Note 2, Note 3, Note 4
Interruptions
Note 1: Non-conforming Body shop applications in closed joints that are secondary seals where paint shop application is the primary seal
shall be considered remediated by definition.
Note 2: Voids, skips or interruptions which may be closed-out during the wet-out process or by material expansion during cure do not
require repair. During qualification, evaluate and document according to local procedures and maintain a representative boundary sample.
Note 3: Localized disruptions resulting from the welding process (or other mechanical fastening) do not require repair. During qualification,
evaluate and document according to local procedures and maintain a representative boundary sample.
Note 4: Localized thinning and/or minor interruptions at sheet metal transitions and sharp corners/radii do not require repair. During
qualification, evaluate and document according to local procedures and maintain a representative boundary sample.
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