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SCOPE:
This specification defines the requirements of spot welds used in the fabrication of assemblies
comprising two or more thickness of steel of the same or different gauge.
It is additional information of resistance spot welds on drawings or defined by CAD Data. The
definition excludes items, which are already described in Ford Engineering CAD & Drafting
Standards and/or Manufacturing Standards (U-WX 012).

APPLICATION:
This Engineering Specification applies to steel sheet, strip or plate in the uncoated condition and
also with coatings of zinc, tin, nickel, terne alloy (tin & lead). It also applies to steel coated with
temporary coatings for rust prevention and paint primers providing the coating does not
effectively interfere with the welding process.

It applies to the following categories of steels:

CATEGORY TYPE OF FORD MATERIAL

STEELS SPECIFICATION No.
Category A Mild Steels, Hot & WSS-M1A344-A1/A2
Cold Rolled, Low WSS-M1A345-A1/A2/A3/A4
Carbon
Category B High Strength Low WSS-M1A346-A1/A2/A3
Alloy Steels WSS-M1A347-A1/A2/A3
Category C Dual Phase Steels WSS-M1A348-A1/A2/A3/A4/A5/A6/A7

The text of the referenced Ford Material Specifications is available from the following weblink
http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html, Metals 1A-99A.

1. WELD IDENTIFICATION
The weld symbols shall be in accordance with Ford Engineering CAD and Drafting Standard
D-3 (Welding Symbols And Specifications) as outlined in the Cadmethods weblink
http://www.cadmethods.ford.com/cad_methods/welding/weld_namnum_eu.html.

2. DEFINITIONS

2.1 Button
Figure 2.1 shows a button that is pulled out of one of the welded components as the result of a
chisel (peel) test as described in Section 7.4. A button typically occurs in those cases where the
chisel tests leads to either a peel fracture or a combination fracture as shown in Figure 2.2 below.

Figure 2.1: Button As A Result Of A Peel Test

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2.2. Button Diameter dp

In the cases of a peel fracture and a combination fracture, the button diameter dp is the
average of two diameters measured at right angles to each other when one of the diameters is the
apparent minimum. See Figure 2.2, sections a) and c) for a detailed illustration.

Figure 2.2: Button & Fracture Face Diameters dp

2.3 Shear Fracture Face

• Category A- and B-Steels
A shear fracture typically occurs in the case of different gauge combinations and on larger spot
welds.
• Category C-Steels
A shear fracture may also occur on joints made of Category C-sheet steel combinations due to the
metallurgical changes in the metal during the welding process.

Figure 2.2, Section b) illustrates a typical shear fracture face. It is characterized by a lack of a
button. The occurrence of the shear fracture is acceptable provided that there is evidence of good
metal adhesion at the weld i.e. the fracture face is crystalline and there is metal distortion in the
parent metal around the weld.

The shear fracture face diameter (also indexed as dp) is the average diameter of the fractured
surface without the adhesion zone (also called “ring zone” as shown in Figure 2.2, Section b)).

2.4 Nugget
The nugget is the fused metal forming the weld. It is visible in a section cut only.

Figure 2.4: Weld Nugget

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2.5 Weld Penetration p

The weld penetration p is the depth of the nugget in any one sheet, strip or plate compared with
the thickness of that sheet, strip or plate. Figure 2.5 shows the scheme of a nugget in a section cut
exemplary for a 2-gauge combination.

Nugget
p1
t1

t2
p2
-
Ring Zone
dL

Figure 2.5: Weld Penetration And Nugget Diameter

The acceptance criteria for the weld penetration p are as follows:

p1 p
• 2 - Sheet Combinations: 0.4 ≤ ≤ 0.8 and 0.4 ≤ 2 ≤ 0.8
t1 t2

p1 p p
• 3 - Sheet Combinations: 0.3 ≤ ≤ 0.8 and 0.3 ≤ 2 ≤ 0.8 and 0.3 ≤ 3 ≤ 0.8
t1 t2 t3

2.6 Nugget Diameter dL

The nugget diameter dL in a section cut as shown in Figure 2.5 shall comply with the following
requirements:

Thickness Of Minimum
Thinner Sheet NUGGET DIAMETER dL
as shown in Figure 2.5
[mm] [mm]
0.5 - 0.79 3.1
0.8 - 0,99 3.5
1.0 - 1.24 3.9
1.25 -1.59 4.4
1.60 - 1.99 4.9
2.0 - 2.49 5.5
2.5 - 3.14 6.2
3.15 - 3.54 7.0
3.55 - 3.99 7.4
4.0 - 4.49 7.8
4.5 - 4.99 8.3
5.0 - 5.59 8.7
5.6 - 6.0 9.2

Table 2.6: Minimum Nugget Diameter dL

2.7 Sheet Metal Thickness

Sheet metal thickness as referred to in Table 6.2.

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2.8. “Weld Joint”

A “Weld Joint” (weld-line) is defined as all of the welds that weld a specific set of parts
which creates a structural unit for providing the specified body strength.
(Ref: http://www.be.ford.com/avt213/procs/03063/weld_strategy.htm)

3. WELD HARDNESS
3.1 Category A- and B- Steels
The material used and the welding techniques employed shall be such that the hardness of the
weld shall not exceed HV 400.

3.2 Category C- Steels

The material used and the welding techniques employed shall be such that the hardness of the
weld shall not exceed HV 460.

4. DISTANCE BETWEEN WELDS

The pitch of the welds shall be considered to be the distance between centres of adjacent spot
welds. For spot welds set with automatic welding machines the general tolerance on the pitch is
+ 10% (unless otherwise specified). The general tolerance on pitch for manual spot welds is
- 40% and the excess number of spot welds allowable, related to this tolerance, is 20 %.
The minimum distance of spot welds is defined in the manufacturing standard U-WX 012.

5. DISTANCE FROM EDGES & FLANGES

The centers of the spot welds shall be in the middle of the flange.
The tolerance will be such that the edge of the weld shall be at least 1/2 dp away from the edge or
the flange radius (dp = button or fracture face diameter as specified in Table 6.2 below). The
minimum flange overlap is defined in the manufacturing standard U-WX 012.

dp

min
dp / 2

Figure 5: Distance From Edges & Flanges

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6. WELD PROPERTIES & QUALITY

6.1 Button Size

The weld size as specified on the drawing, in the CAD Data file, or in Table 6.2 of this
specification, shall refer to the button or fracture face diameters dp which are revealed as a result
of the chisel test described in Section 7.4. The acceptance criteria for this test are shown in Table
6.2 as it lists the minimum button or fracture face diameter dp relative to the thickness of the
thinner sheet of the combination.

6.2 Shear Strength

Static tensile testing shall be performed in accordance with DIN EN ISO 14273 to determine spot
weld shear strength.

6.2.1 Category A- and B-Steels & Their Combinations

Category A- and B-steels and their combinations have been analyzed in generic tensile testing
with regards to shear strength. The welds shall have the guaranteed minimum shear strength
values given in Table 6.2 below. This table applies to uncoated and zinc-coated material only.

Thickness of Minimum Minimum Shear

Thinner Sheet BUTTON or FRACTURE Strength
FACE DIAMETER dp
as defined in
Sections 2.2 and 2.3
[mm] [mm] [kN]
0.5 - 0.79 3.6 2.5
0.8 - 0,99 4.0 3.2
1.0 - 1.24 4.5 4.0
1.25 -1.59 5.0 5.0
1.60 – 1.99 5.6 6.3
2.0 - 2.49 6.3 8.0
2.5 - 3.14 7.1 11.2
3.15 – 3.54 8.0 16.0
3.55 – 3.99 8.5 19.0
4.0 - 4.49 9.0 22.4
4.5 - 4.99 9.5 26.5
5.0 - 5.59 10.0 31.5
5.6 – 6.0 10.6 35.5

Table 6.2: Minimum Button Or Fracture Face Diameter dp And Shear Strength For
Category And B Steels And Their Combinations (dp˜ 1.15*dL)

6.2.2 Combinations Involving Category C- Steels

Combinations involving Category C-steels shall comply with the minimum button or fracture
diameter requirements as outlined in Table 6.2 above.

6.3 Weld Defects

6.3.1 All Combinations Of Steel Categories With The Exception Of B-C, C-C
The fracture surface of the button or fracture faces shall be metallic bright and free from
evidence of hot cracking. A weld shall be classed as defective if it shows any evidence of burn
through or porosity. No cracks are allowed in any part of the weld.

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6.3.2 Combinations Of Steel Categories B-C And C-C

The fracture surface of the button or fracture faces shall be metallic bright and free from
evidence of hot cracking. A weld shall be classified as defective if it shows any evidence of burn
through or porosity.
Acceptance Criteria For Weld Defects
Minor cracks and inclusions may occur in combinations of High Strength Low Alloy Steels
(Category B) with Dual Phase Steels (Category C). Joints made of Dual Phase Steel
combinations (Category C-C) are also likely to a show minor occurrence of cracks and
inclusions. These weld defects are only detectable in micro-section cuts that shall be
performed as part of the pre-production welding trials.
During these trials, the acceptance criteria for the weld defect occurrence shall be as follows:
• Cracks
The overall length of one or several cracks shall not exceed 15 % of the nugget diameter
dL in a micro-section cut.
• Inclusions
The overall length of one or several inclusions shall not exceed 15 % of the nugget
diameter dL in a micro-section cut.

• Combined Effect Of Cracks & Inclusions

The overall length of cracks and inclusions shall not exceed 15 % of the button diameter
dL in a micro-section cut.

7. PRODUCTION VALIDATION & IN-PROCESS TEST REQUIREMENTS

7.1 Definition Of Production Validation (PV) & In-Process (IP) Tests

Production Validation (PV) tests are used to obtain an initial estimate of the process potential to
produce parts that conform to engineering requirements, and to identify causal or predictive
relationships between significant design and process characteristics (to be used for process
control).
The tests must be completed successfully using initial parts from production tooling and
production process before Part Submission Warrant (PSW) approval and authorization of
production parts can be issued. Sampling plans for PV testing must be included in the control
plan.

In-Process (IP) tests are used to further understand the relationship between significant design
and process characteristics and to establish a basis for continuing improvement.
Tests must be completed with production parts on an ongoing basis. Sampling plans for both IP
testing and evaluation of the significant process characteristics must be included in the Control
Plan.
When the process is found to be out of control or the test acceptance criteria are not met, the
reaction plan approved in the Control Plan shall be invoked.

Note:
The table that follows summarizes the various PV- and IP-tests and specifies their respective
applicability. Some tests are specified as mandatory tests (e.g. Visual Inspection).
Recommendations are issued in the case that multiple test choices exist (e.g. in the field of In-
Process Control). The ultimate test method shall then be selected on the basis of an individual
risk and test method capability assessment during PV-phase.

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Summary Of Production Validation (PV) & In-Process (IP) Tests

Test Test PV, IP Applicability / Limitations

No.
7.2 Visual Inspection PV, IP Mandatory inspection for PV & IP-testing;
Visual inspection must be complemented by
one of the following tests: 7.4 (Destructive
Chisel Test), 7.5 (Non-Destructive Chisel Test)
or 7.6 (Ultrasonic Inspection)
7.3 Macro-/Micro- PV Shall be conducted during PV-testing as a
Section Cuts method for concern root cause analysis
7.4 Destructive Chisel PV, IP Shall be conducted during PV-testing to
Test determine compliance with the min. button/
fracture face diameter requirements as listed in
Table 6.2;
IP-testing: Alternative test procedure in case
that neither 7.5 (Non-Destructive Chisel Test)
nor 7.6 (Ultrasonic Testing) can be applied (risk
& capability assessment)
7.5 Non-Destructive IP It is applicable for IP-testing only. Note: this
Chisel Test test procedure – in contrast to 7.4 (Destructive
Chisel Test) - is not suitable to verify
compliance with the min. nugget /fracture face
diameter requirements.
Limitations:
It applies to steel sheet having a gauge = 1.5
mm and/or Category A & B steels with a yield
strength less than 260 MPa only - with the
following exceptions:
• sheet steel with a hot dip galvanized
coating,
• joints with functional flanges (e.g. door
opening flange carrying the sealing)
• weld-bonded joints
• joints on Class 1surfaces

7.6 Ultrasonic PV Shall be performed during PV-testing alongside

Inspection 7.3 (Macro-/Micro- Section Cuts) and 7.4
Capability & (Destructive Chisel Test) in the case that
Correlation Tests ultrasonic testing is considered to be the suitable
test method for IP-testing
Ultrasonic IP Recommended test procedure for IP-testing
Inspection

Table 7.1: Summary Of Production Validation (PV) & In-Process (IP) Tests

7.2 Visual Inspection

Visual inspection is performed to detect obvious defects such as surface cracks, surface pores,
increased indentation, burn damage and spatter.

7.3 Macroscopic Inspection, Micro-Section Cut

A macroscopic examination at a magnification of 10 - 20 times at the weld surface, or a
microscopic examination on a section through the welds (polished specimen) should be conducted
in cases of doubt.

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7.4 Destructive Chisel Test

In this test, a tapered drift pin (or equivalent) is used to apply a peeling action between spotwelds
without cutting of the sheet metal or weld nugget at the interface.

7.5 Non-Destructive Chisel Test

In this test, a pry bar should be located near or between the spot welds. The pry bar shall be
driven without cutting sheet metal or weld until the metal adjacent to the weld is distorted. Welds
that hold will be classified as satisfactory welds. Welds that unintentionally pull buttons or
fracture face diameters equal to or larger than the minimum size defined in Table 6.2 shall also be
classified as satisfactory welds. Welds that fail without producing significant distortion of the
surrounding metal shall be classified as defective welds.

7.6 Ultrasonic Testing, Inspection Capability & Correlation Tests

Ultrasonic testing is the recommended test method in the case of Category A- and B- steels
having a gauge > 1.5 mm, Category C-steels and steel sheets with a hot dip galvanized coating.
Ultrasonic inspection capability and correlation shall be determined for individual joints during
production validation testing in conjunction with 7.3 and 7.4.

8. WELD EFFECTIVENESS AND TOLERANCE

8.1 Control Welds

Control welds are individual spot welds or groups of spot welds that are significantly important
for the structural integrity of the vehicle. As such they must be processed for optimum weld
integrity and maximum effectiveness (see Section 8.3.2).
Control welds shall be identified jointly between Body Engineering (Core & Vehicle Program)
and the Attribute Teams (Crash, Durability and - if applicable – NVH) on the basis of the
relevant Design-FMEAs, CAE-analysis and physical verification testing.
Control welds are identified by the word ’Control’ attached to specific spot welds in the
Metaphase data file. More information relative to the identification of control welds in I-DEAs
can be obtained from Section 5.3.6 of the following Ford Intranet web-link:
(Ref: http://www.cadmethods.ford.com/cad_methods/welding/weld_namnum_eu.html,.

8.2 Satisfactory Welds

Those welds tested and found to be satisfactory to the requirements of this specification.

8.3 Tolerance:
8.3.1 General Tolerance
The general tolerance for all Common Welds on the whole body shall be a minimum acceptance
of 80 % “Satisfactory Welds”. The same tolerance applies to any weld joint on a vehicle (see
Section 2.8 for the definition of a weld joint). Specific requirements apply to groups of 1 to 9 spot
welds as outlined in Table 8.3 below.

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8.3.2 Tolerance For Control Welds

Tolerance for Control Welds shall be a minimum of 90 % “Satisfactory Welds”. Specific
requirements apply to groups of 1 to 9 spot welds as outlined in Table 8.3 below.

Common Welds Control Welds

Number Of Common / Missing Undersized Missing Undersized
Control Spot Welds In A Welds Welds )*1 Welds Welds )*1
Weld Joint
1 - - - -
2 - 1 - -
3 - 1 - -
4 1 - - 1
5 1 - - 1
6 1 - - 1
7 1 1 1 -
8 2 - 1 1
9 2 - 1 1
)*1
The diameter of an undersized spot weld button must be minimum 50 % of the button or
fracture face diameter specified as “dp” in Table 6.2.
Table 8.3: Number Of Common / Control Welds In A Weld Joint

8.4 Defective Welds

Those welds which fail to meet any one or more of the requirements of this specification are
classified as defective welds (see Table 8.3). Missing welds are also classified as defective welds.
Defective welds will have to be corrected in accordance with appendix A under consideration of
tolerances mentioned in Section 8.3.

8.5 Crucial Welds

The following welds are classified as Crucial Welds:
• Welds that are adjacent.
• Welds that are separated by only one satisfactory spot weld.
• Welds that are common to two lines of welds at their intersection.
• Welds at the extremities of a line of welds (first and last spot of a joint).
Crucial Welds need to be reworked in any case - irrespective of the class and tolerance. Rework
shall be performed according to the components specific repair standard or – if no specific repair
standard exists – according to appendix A of this Engineering Specification.

9. WELD FINISH

The surface appearances after spot welding are classified into the following categories
The class of finish and the actual surface of the component will be identified on the drawing, or in
the CAD Data file, and applies to the visible side if not otherwise specified. On surfaces where no
class of finish is specified, class 3 finish applies.

9.1 Class 1-Finish

This weld finish classification covers sheet metal surfaces that must be free from surface markings
or imperfections after metal finishing to the extent that they are not apparent after painting and
within the limits as described below. Class 1 welds for subsequent metal finish to a class 1 metal
surface should be held to the least possible marking on the surface to be metal finished. Weld
marking must not exceed a depth such as can be removed by metal finishing.

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Metal finishing shall not remove more than 10 % of the surface thickness, or marking on excess
of 10 % of surface sheet thickness must be filled prior to metal finishing. No surface expulsion of
metal will be acceptable:

Welds on hemmed flanges or doors - decks - hood - glove box doors - tailgates which are
specified Class 1 will be governed by the following exceptions:

Satisfactory welds will have a minimum slug diameter of 2.5 mm. Slug will be pulled from either
the inner panel or turned over flange. Fusion between inner panel and surface sheet is not
required.

9.2 Class 2-Finish

This weld finish classification covers a minimal marked welded surface and shall be used where a
minimum amount of metal displacement is acceptable (a max. 10 % above and a max 15 % below
normal surface). Surface expulsion (weld whiskers) will not be acceptable. .
Outside surface sheet metal assemblies in which Class 2 welds are required, will be governed by
approved “specific” visual samples. “Outside Surface Sheet Metals” are defined as those surfaces
that are visible from the outside of the vehicle in its normal running condition.

9.3 Class 3-Finish

9.3.1 Category A- and B-Steels & Their Combinations

The surface indentation shall not exceed 25 % of the specified thickness of that sheet. Where
metal expulsion or displacement of the metal above the normal surface is unacceptable for safety,
appearance, fit or other reasons on a general finish class of weld, the assembly drawing, or CAD
Data shall specify “flash free” for each weld of this type. This will require that any excess metal
so formed above the surface is removed.

9.3.2 Combinations Involving Category C-Steels

Sheet metal combinations involving Category C-steels are sensitive to joint gap related effects of
indentation, specifically in combinations with Category A- and B-steels. The acceptance criteria
for the indentation in joints involving Category C-steels are as follows:
Ø Scenario A: Part Matching Stays Within Common Production Tolerances.
In this case, the same acceptance criteria as outlined in Section 9.3.1 apply.
Ø Scenario B: Part Matching Exceeds Common Production Tolerances
In this case, deviations from the acceptance criteria outlined in Section 9.3.1
can be granted on a case-by-case basis in a joint effort of Body &
Manufacturing Engineering as well as Craftsmanship. In any case, the
indentation should not exceed 40% of the thickness of the thinnest sheet.

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APPENDIX A:

REPAIR OF DEFECTIVE SPOT WELDS:

Spot welds which do not meet the requirements in clauses 8.1 - 8.5 must be repaired by one of the
following methods, agreed by Product Development Engineering. The preferred method will be
method “A“. Specific permission must be obtained to use other methods but agreements may be made
to cover general situations.

A. Resistance Spot Welding

Additional effective spot weld placed as near as possible halfway between the existing spot welds.

B. Plug Welding
A plug weld may be used as a repair for a single spot weld or two plug welds for two adjacent
spot welds. A plug weld involves drilling a hole in the top component which is filled by fusion
welding, preferable MIG or MAG. Only two thicknesses may be permitted to be repaired.

C. Shielded Arc Spot Welding

A single shielded arc spot weld may be used as a repair for a single spot weld, or two shielded
Arc spots may be used for two adjacent defective spot welds. Only two thickness of material may
be permitted to be repaired. The spots must be of at least equal size to those specified and can
only be used in well fitting areas and before painting, MIG or MAG welding preferred.

D. Fusion Fillet Welding

If allowed, details must be agreed with the component Engineer.

E. Gas Brazing
If allowed the details to be agreed by the Product Engineering Development.

F. Gas-Shielded Metal Arc Brazing

If allowed the details to be agreed by the Product Engineering Development.

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