Destructive Testing of Weld Connections

VA Test Intervals and Test Methods

Issue: 2
A_PG_029_Anl_08 Substitute for:
A_PG_029_Anl_08 / 08.10.2004

Prepared: date: Released: CF_QM, CF_MTP on:

Scherp, Markus 17-850 21.01.2008 Sign Dr. Olszewski, Hr. Streubel 03/03/2008

Correction note to this edition: Changes for documentation, Testing sequences, Macro Sections, description destructive testing.

1. Standard testing methods

A/ Shop Floor method:

The preferred procedure (bend test, turn-over test, tensile test, compressive test, torsion test, chipping test,
torque, etc..) will be determined product-specific by the project team
The procedure has to ensure that in any case the basic material is damaged. No adhesive-bonded joint is
allowed in the welding connection; crystalline breakage in the weld is permitted.
For resistance welding, the welded connection must peel from the basic material. For spot welding, the spots
must not be exploded!
The result of the examination has to be recorded in quality rule cards.

B/ Grinding test (macro-sections):

In order to control the welding processes and to evaluate the internal irregularities of the weld seam, macro
sections are essential. The locations of the macro sections are part of the weld drawing.
Cross sections are permitted only at the effective weld seam, i.e. that cross sections must not be placed within
10 mm of the start or the end point of the weld seam and next to tack points.

The required penetration usually is fixed by the customer. If there are no requirements of the customer the
definitions of Annex 9 must be used. The results of the test must be documented in a quality control chart. This
can be done on paper or in digital form. On components without critical characteristics, a visual check of the
macro section (effective weld seam cross-section and seam height) is sufficient.
The required dimensions have to be considered from the valid weld drawing or the Annex 9.

C/ Photographic documentation
At weld seams with special requirements (e.g. critical issues CCs/ BCCs) the macro sections must be
documented additionally with a photographic documentation system.
The following information must be recorded with the picture: penetration, effective weld seam thickness,
component number and the number of the macro section.

Notice
The testing method has to be defined by the project team.
If there is no decision by the project team, the standard method A/ will be applied.

Additional testing methods

Non-destructive testing methods like ultrasound, X- Ray, magnaflux, leakage tests etc. can be determined by
the project team as additional tests.

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 Destructive Testing of Weld Connections
VA Test Intervals and Test Methods

Issue: 2
A_PG_029_Anl_08 Substitute for:
A_PG_029_Anl_08 / 08.10.2004

2. Testing intervals
Testing intervals for prototype manufacturing
See VA “Prototype Manufacturing (at product groups and plants)”

Testing intervals for series production

are specified by the project team.
In series production the intermediate box has to be smaller than the stock between production and delivery.

Minimum requirements:

Phase Manufacturing Test Shop floor test Macro section

(quantity) (quantity) (Part-Nr.) (Part-Nr.)
I: Parameter 10 4 5; 6 1; 2
determination
II: Milestone PPAPR
(run@rate) 300 7 1;15;50;150; 300 25; 225
III: production start 300 4 100; 300 1; 200
IV: production start 1000 4 250; 750 1; 500
V: production start Week 1/Shift 1/Day
(min. 3 month)
Series production Week 1/Day * 1/Month**

To *:
a) 1 welding fixture/ day, but with a fixed sequence of the fixtures
e.g. 3 welding fixtures:
Week 1: A-B-C-A-B
Week 2: C-A-B-C-A
Week 3: B-C-A-B-C
etc.

b) At production lines with identical welding cells with only one fixture, the cells have to be tested in a fixed
sequence, i.e. they are treated like fixtures in example a).

c) Final assemblies and sub assemblies are tested separately as described under topic a). On final
assemblies, only the weld seams between the sub assemblies have to be tested.

To **.
a) Additional demand for macro sections has to be taken out of the same welding fixture. On this component
only the not-ok weld seam has to be tested.

b) Critical or uncertain weld connections must be tested in a higher sequence, e.g. every 4 h or directly before
the batch delivery.

c) Macro sections has to be carried out after the following process changes:
Change of the welding speed, welding direction, position of manipulator, welding sequence, change of
welding torch and power source.

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 Destructive Testing of Weld Connections
VA Test Intervals and Test Methods

Issue: 2
A_PG_029_Anl_08 Substitute for:
A_PG_029_Anl_08 / 08.10.2004

3. Handling in case of deviations‚ ‘not ok test result’

Prototype manufacturing:
see procedure ‘Prototype manufacturing (in the product groups and the plants)’.

Series production:
For a ‘not ok’ result of the macro-section test, the documentation of the destructive shop floor testing method
has to be checked immediately, the respective connection has to be crosschecked by means of the shop floor
test, and a visual inspection of the affected weld seam in the intermediate box of the series process has to be
executed.
For re-release of production after optimization, a macro section has to be repeated for the affected weld seam
to prove the effectiveness of the taken measures. The result has to be documented.

For a ‘not ok’ result of the shop floor method, the complete intermediate box and, if necessary, the in-house
stock have to be blocked.

Test of the blocked intermediate box:

The error starting point has to be determined by stepwise testing the components in reverse order of the
production sequence.
All parts produced before the error start can be released again (see QM_Blatt 48‚ Freigabe von Schweißstraßen
(Zerstörende Prüfung )’ German)
The parts produced after the error starting point can, depending on the severity of the error, be reworked or
have to be scrapped.

Note: In some cases, it is not allowed to rework welding errors due to customer instructions or internal
determinations (risk step resulting from the FMEA).
These parts must be scrapped immediately!
The serial numbers of the scrapped assembly have to be documented.

Errors in the dispatch inventory:

If n.o.k. parts are also parts found in the shipping area, it has to be assumed, that possibly parts already have
been delivered to the customer. In this case there must be a decision about the further procedure in
coordination with the QM Management, in critical cases additionally with the Business Management as well
(e.g. information of the customer).

Documentation of the measures:

All measures concerning special tests of the blocked intermediate box as well as the measures for corrections
of the series production must be documented on the back of the rule card with reference to the detected ‘not ok’
result.

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 Destructive Testing of Weld Connections
VA Test Intervals and Test Methods

Issue: 2
A_PG_029_Anl_08 Substitute for:
A_PG_029_Anl_08 / 08.10.2004

4. Description of the destructive testing methods

Bending test:
The specimen must be prepared in such a way,
that the weld seams can be bent by hammer or
special tools. The cuts must be deeper than the
weld seam, ensuring that only the weld seam is
tested and not the base material. The specimen
must be bent parallel to the surface of the
component.

Pull Test:

The specimen must be prepared in such a way,

that only the weld seams in the same direction
and with the same boundary conditions like weld
seam dimensions and material thicknesses are
tested in one step.
Welding of additional brackets to the specimen
may be useful to connect the hook.

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 Destructive Testing of Weld Connections
VA Test Intervals and Test Methods

Issue: 2
A_PG_029_Anl_08 Substitute for:
A_PG_029_Anl_08 / 08.10.2004

Squeeze test

The components are squeezed under a hydraulic

press.
These process is favoured for circular
components. The parts must be pressed
completely to block height.

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