NA Welding Specification WS-5 Weld Testing & Procedures Section A: Resistance Spot Welding

GMNA Controls, Robotics & Welding
NA Welding Specification
WS-5 Weld Testing & Procedures Section A:
Resistance Spot Welding
May 2002
DOCUMENT MANAGEMENT INFORMATION
Authors: Approval:
Al Turley NA CRW
Mike Hebert - NA CRW Weld Council - NA CRW
John Lewerenz - NA CRW weld.council@gm.com
Sponsoring Group:
GMNA Manufacturing Center – Controls, Robotics & Welding
Forward Questions and Comments to:
Chairperson GM Weld Council at weld.council@gm.com
Copies of WS-5 Weld Testing & Procedures Section A: Resistance Spot Welding
Any printed copy of this document is considered an “uncontrolled” copy. Access to the controlled
document can be made through the GMNA internal website, Socrates, at http://crw.gm.com by
selecting Standards and Specifications and then the specific welding document. Access from
outside the GM internal network can be made at the GM Supply Power website at
http://www.gmsupplypower.com.
The pdf file may be read using Acrobat Software on most Microsoft Windows-compatible computers.
Document Expiration Date:
This document will expire May 2006. It may be revised, reaffirmed or withdrawn prior to this date.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

May 2002 Released Consolidated Manufacturing Development Specifications (MDS) 247 and
597. Updated to FS-1 (Nov. 2001 Release)
Copyright 2002. General Motors Corporation. All rights reserved.

—Uncontrolled When Printed—
Weld Testing & Validation Procedures (WS-5)
Section A: Resistance Spot Welding
General Motors Corporation NA Controls, Robotics & Welding
TABLE OF CONTENTS
Section Description Page
1. General ............................................................................................................................................. 1
1.1 Scope ....................................................................................................................................... 1
1.2 Purpose.................................................................................................................................... 1
1.3 Audience .................................................................................................................................. 1
1.4 Deviations ................................................................................................................................ 1
1.5 Definitions ................................................................................................................................ 1
1.6 Normative References ............................................................................................................. 2
2. Weldability Procedures ................................................................................................................... 3
2.1 Apparatus................................................................................................................................. 3
2.1.1 Welding Equipment ................................................................................................... 3
2.1.2 Electrode Caps and Water Flow ............................................................................... 3
2.1.3 Instruments................................................................................................................ 3
2.2 Material Requirements............................................................................................................. 3
2.3 Selection of Process Parameters ............................................................................................ 4
2.4 Electrode Alignment................................................................................................................. 4
2.5 Test Sequence......................................................................................................................... 5
2.5.1 Conditioning Welds ................................................................................................... 5
2.5.2 Hold Time Sensitivity Test......................................................................................... 5
2.5.3 Weld Lobe Generation .............................................................................................. 5
2.5.3.1 Minimum Button Diameter Curve.............................................................. 5
2.5.3.2 Expulsion Curve........................................................................................ 6
2.5.3.3 Weld Lobe Interpretation .......................................................................... 6
2.6 Rejection Reasons................................................................................................................... 6
3. Electrode Cap Life Performance Procedures ............................................................................. 10
3.1 Apparatus............................................................................................................................... 10
3.1.1 Welding Equipment ................................................................................................. 10
3.1.2 Electrodes Caps and Water Flow ........................................................................... 10
3.1.3 Instruments.............................................................................................................. 10
3.2 Material Requirements........................................................................................................... 10
3.3 Electrode Alignment............................................................................................................... 11
3.4 Test Sequence....................................................................................................................... 11
May 2002 i
1. General
1.1 Scope
Section 2 establishes the requirements and procedures used to determine the resistance spot
weldability of certain sheet steel stackups. The requirements outline the selection of test conditions,
equipment and instrumentation as well as the parameters used in developing and interpreting
weldability lobes. The procedures are used to determine the practical limits of weldability by the
resistance spot welding process, utilizing weldability lobes in conjunction with data from destructive
test methods.
Section 3 establishes the requirements and procedures used to determine electrode cap life relative
to other electrode caps, and also to determine cap life associated with a certain material and or sheet
steel stackups.
1.2 Purpose
The purpose of this specification is to evaluate the resistance spot weldability of any or all of the
following:
1. electrode cap life performance of resistance spot welding electrode cap materials
2. new steels
3. various proposed production stackups
4. various welding conditions
1.3 Audience
This specification is intended for Steel Manufacturers, Material Engineers, Design Release
Engineers, Design Follow-up Engineer, CRW Weld Engineers and other individuals that are
responsible for selecting steels, electrode caps, and production material stackups that are used in
vehicle design that GM is responsible for.
1.4 Deviations
Any deviations from this specification require the advanced written approval of the GMNA CRW
representative responsible for the project in question. Any approved deviations shall only apply to
that specific instance, and it shall not be considered a change to this standard.
1.5 Definitions
Button: That part of a weld, including all or part of the nugget, that tears out in the destructive testing
of spot, seam or projection welded specimens.
Brassing: After a spot weld is made on galvanized, the copper of the electrode and the zinc of the
galvanized coating combine to form brass. This “brassing” is visually detectable on the electrode cap
and at the weld surface.
GMT: an acronym for Governing Metal Thickness.
NIST: an acronym for National Institute of Standard Testing.
Nugget: The weld metal joining the work pieces in spot, seam, or projection welding.
May 2002 1
Weldability: The attribute of a material to be welded to itself, other steels and in various stackups
under imposed limits determined by its welding lobe and electrode cap life performance.
Weld Lobe: Graphical representation of the numerous combinations of weld current and weld time
that produces satisfactory welds with a specific set of conditions.
1.6 Normative References
The following normative references contain provisions that, through reference in this text, 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.
GM4488M, Automotive Resistance Spot Welds.
GM WWG-002, Weld Gun Design Standards.
GM WS-1, Welding Principles, Section A: Resistance Spot Welding.
GM WS-4, Welding Verification Procedures, Section A: Resistance Spot Welding.
May 2002 2
2. Weldability Procedures
The procedures outlined below are used in determining the resistance spot weldability of body sheet
steel materials and various stackups.
2.1 Apparatus
2.1.1 Welding Equipment
The following equipment is required to complete the weldability procedures outlined in this section:
• a resistance spot welder with an air-operated cylinder that is capable of reliably producing the
required weld forces within the parameters described in WS-1 Section A, paragraph 5.2.
• a suitable welding transformer that is capable of delivering the required weld current (i.e.,
approximately 20,000 A), at the electrodes, for the specified machine secondary circuit and throat
opening.
• a welder control that operates in the “Current Regulation” mode as described in WS-2 Section A
or Section D.
2.1.2 Electrode Caps and Water Flow
The standard electrode caps are GM MWZ-6006 Cu-Zr, 5/8-inch O.D. (16 mm) mounted on open
shanks. The cooling water parameters to be used per cap are 68 +9° F (20 +5° C ) at 0.5 gal/min.
(2.0 liters/min.).
2.1.3 Instruments
The following instruments shall be used to perform the weldability procedures:
1. calibrated current analyzer (e.g., Miyachi Model # MM-326B or equivalent)

2. calibrated digital read-out force gage capable of reading up to 2,000 lbs. (8.9 KN)
3. bench vice grips (e.g., Channel Lock #148-14 or equivalent) and wire cutters for removing excess
base material from the buttons
4. calibrated dial caliper (e.g., Mitutoyo Model # CD-6C or equivalent) to measure weld button
diameters
2.2 Material Requirements
A minimum of 30 sq. ft (approximately 3 sq. m) of flat production intent material is required for the
weldability procedure.
Steel sheets shall be sheared into 1.5 in. x 5 in. (approximately 38.0 mm x 127.0 mm ) coupons. See
Figure 2-1 for overlap dimensions, weld placement and spacing.
May 2002 3
2.3 Selection of Process Parameters
1. Weld Force: The weld force is selected from Annex I of WS-4, Welding Verification Procedures,
Section A: Resistance Spot Welding.
2. Governing Metal Thickness (GMT): The GMT is obtained from Section 4.1 of WS-1, Welding
Principles, Section A: Resistance Spot Welding.
3. Weld Time Range: Nominal weld time is selected from WS-4, Welding Verification Procedures,
Section A: Resistance Spot Welding, based on the GMT and material welded.
Note: Minimum and maximum weld times are selected at time intervals above and below the
nominal weld time.
Example 1: Given a GMT of 1.0 mm galvanized to galvanized, the nominal weld time from WS-4,
Section A, is 14 cycles. Selecting a weld time range of 12, 14 and 16 cycles should produce a
lobe in a region of interest.
Example 2: Given a GMT of 2.0 mm galvanized to galvanized, the nominal weld time from WS-4,
Section A, is 28 divided into 4 pulses of 7, yielding 28 total cycles. Selecting a weld time range of
6, 7 and 8 cycles with 4 pulses yields a weld time range of 24, 28 and 32 cycles, which should
produce a lobe in a region of interest.
4. Minimum Spot Spacing: Minimum spot spacing should be referenced from column A of the
minimum spot spacing chart located in Section 4.3.1 of WS-1, Welding Principles Section A:
Resistance Spot Welding.
5. Weld Schedule: The weld schedule encompasses a squeeze time of 30 to 60 cycles, and number
of pulses, weld time, cool time, and hold time, as determined using Annex I of WS-4, Welding
Verification Procedures, Section A: Resistance Spot Welding.
6. Minimum Button Diameter: The minimum button diameter is based on the GMT by referring to
Table 1 of GM4488M, Automotive Resistance Spot Welds.
2.4 Electrode Alignment
The alignment of the electrode caps must be verified by making carbon imprints as shown in Figure
2-3 and comparing the imprints for overlap of the carbon circles.
Note: If the electrode cap alignment does not meet the requirements outlined in WG-002 Appendix
948, realign the shanks until the carbon imprints have acceptable overlap before beginning testing.
May 2002 4
2.5 Test Sequence
2.5.1 Conditioning Welds
After the electrode caps are aligned, 100 conditioning spot welds are produced using a weld current
that yields minimum sized buttons using the nominal weld time. These conditioning welds reduce the
scatter of test data. For galvanized coated steel, the weld current shall be increased gradually to
obtain a brassing condition on the test coupons.
2.5.2 Hold Time Sensitivity Test
The hold time sensitivity test is only used in instances where the possibility of hold time sensitivity
exists (e.g., high strength steels). Weld tests are initially conducted on the test metals to determine
whether any interfacial separations exist due to rapid quenching (e.g., 60 cycles hold time). Hold
time-sensitive steels exhibit interfacial separations when peel tested.
Using the WS-4, Section A specified hold time, perform the following steps:
1. Spot weld three sets of coupons as shown in Figure 2-1 at the maximum weld time.
2. Peel test the second weld of each coupon as shown in Figure 2-4 to determine the welding
current required to obtain the minimum weld button diameter per GM4488M. This will be Point 1
on the graph shown in Figure 2-2.
3. Readjust the hold time to 60 cycles.
4. Spot weld three more sets of coupons at the same welding current that produced the minimum
size button diameter (Point 1 on the Weld Lobe). If interfacial separations or partial interfacial
separations occur, the test steel is considered to be hold-time sensitive.
2.5.3 Weld Lobe Generation
2.5.3.1 Minimum Button Diameter Curve
1. Using the maximum weld time and current regulation, increase the weld current (in 100 A
increments) to obtain the minimum button size required.
2. Peel the coupons as shown in Figure 2-4 to verify the button size.
Achieving three consecutive samples with a minimum button diameter establishes Point 1 on the
graph shown in Figure 2-2. If the minimum criterion is not met in three consecutive coupons,
continue to increase the current using 100 A increments until the minimum button diameter is met
on three consecutive coupons.
3. Repeat the above procedure for the nominal and minimum weld times respectively.
4. Make five chisel samples at the nominal weld time (Point 2 of Figure 2-2) using overlapping
coupons as shown in Figure 2-5.
5. Make three welds (e.g., A, B and C) on each coupon as shown in Figure 2-5.
6. Insert the coupon into a vise and pry it apart using a hand or pneumatic chisel. Record the weld
button diameter.
Note: For coupons that do not separate, record whether the base metal deformed around the
weld, which indicates the presence of a weld.
May 2002 5
7. Produce five tensile samples at nominal time according to Figure 2-6. Tensile test samples and
record tensile-shear values.
2.5.3.2 Expulsion Curve
1. Using maximum weld time and current regulation, increase the weld current (in 200 A
increments) until a flashing condition is observed on the second spot weld of the test coupon.
This establishes Point 4 on the graph shown in Figure 2-2.
2. Make only one sample at the flashing condition to determine the expulsion point.
3. Repeat the above procedure for the nominal and minimum weld times respectively.
2.5.3.3 Weld Lobe Interpretation
A weld lobe is a means of graphically expressing the numerous combinations of weld current and
weld time that produce satisfactory welds with a specific set of conditions. Weld current values are
plotted on the X axis as shown in Figure 2-2. The left boundary of the lobe displays the combinations
of the weld current and weld time that produce the minimum acceptable button diameters. Points to
the left of this curve will produce button diameters less than the minimum specified. The right
boundary of the lobe displays the flashing point. Points to the right of this curve result in welds with
excessive heat energy evidenced by heavy expulsion, electrode indentation and electrode sticking or
any combination of these occurrences. Points between the two curves result in welds of satisfactory
quality. The distance between these two boundaries at a given weld time is referred to as the
“current range.” A wide current range indicates that the metal stackup would be tolerant to changes
in the manufacturing process [e.g., tip geometry, voltage fluctuations, metal contamination (rust or
sealer), and changes in the weld equipment due to normal wear of parts].
2.6 Rejection Reasons
The following conditions serve as reasons for rejecting a new steel or proposed production stackup.
1. Hold-time Sensitive:
If the material is determined to be hold-time sensitive, it is rejected.
2. Narrow Weld Range:
If the minimum current range requirements (as follows) cannot be met, the material is rejected.
For steels < 1.0 mm nominal thickness: Minimum acceptable current range = 1.8 kA.
For steels > 1.0 mm nominal thickness: Minimum acceptable current range = 2.0 kA.
3. Inconsistent Button Samples:
If consistent button samples cannot be pulled, the material is rejected.
4. Excessive Indentation of Weld Coupons:
If indentation exceeds 50% (per GM4488M), the material is rejected.
5. Laminated Base Steel:
If de-lamination of the steel is observed during the peel tests, the material is rejected.
6. Weld Lobe Position on Graph:
If weld lobes do not overlap sufficiently with those previously developed for approved steel
sources, the material may be rejected.
7. Chisel Test Samples:
If two or more of the 15 spot welds on the chisel samples exhibit interfacial separations, the
material may be rejected.
May 2002 6
Figure 2-1: Spot Welded Coupon Peel Test Dimensions

127.0 mm
25.0 See WS-1 for
mm spacing
38.0 mm
Second First weld

19.0 weld
mm
Figure 2-2: Weld Lobe
Minimum Button
Diameter Line
First Instance of
1 4 Expulsion on
Second Weld
Weld Time
(Cycles)
2 5
3 6
Weld Current
(kA)
May 2002 7
Figure 2-3: Electrode Caps Carbon Imprint
Figure 2-4: Spot Welded Coupon Peel Test
Grips
Second weld
(button)
Bench First weld

vise
May 2002 8
Figure 2-5: Spot Welded Coupon Chisel Test
WS-1
WS-1
Figure 2-6: Spot Welded Coupon for Tensile Test
May 2002 9
3. Electrode Cap Life Performance Procedures
3.1 Apparatus
3.1.1 Welding Equipment
The following equipment is required to complete the electrode cap life performance procedures
outlined in this section:
• a welding fixture capable of welding the material at WS-4, Section A, weld schedules at a rate of
30 welds/min.
• a welding transformer that is capable of delivering, at the electrodes, the applicable current levels
shown in Table 3 - 3
• a welder control that operates in the “Current Regulation” mode as described in WS-2 Section A
or Section D
3.1.2 Electrodes Caps and Water Flow
The standard electrode caps are GM MWZ-6006 Cu-Zr, 5/8-inch O.D. (16 mm) mounted on open
shanks. The cooling water parameters to be used per cap are 68 +9° F (20 +5° C ) at 0.5 gal/min.
(2.0 liters/min.).
3.1.3 Instruments
The following instruments shall be used to perform the weldability procedures:
1. calibrated current analyzer (e.g., Miyachi Model # MM-326B or equivalent)

2. calibrated digital read-out force gage capable of reading up to 2,000 lbs. (8.9 KN)
3. bench vice grips (e.g., Channel Lock #148-14 or equivalent) and wire cutters for removing excess
base material from the buttons
4. calibrated dial caliper (e.g., Mitutoyo Model # CD-6C or equivalent) to measure weld button
diameters
3.2 Material Requirements
The electrode cap life performance procedure is used to evaluate several situations, and each
requires specific materials. See Table 3 - 1.
Table 3 - 1: Material Requirements
Evaluation Area Material Requirements

performance of an electrode cap material minimum of 100 sq. ft. (9 sq. m) of 0.8 mm
GMW-2 HD70G70GU
particular stackup or welding condition minimum of 50 sq. ft. (4.5 sq. m) of each
material involved
new steel materials minimum of 100 sq. ft. (9 sq. m) of the
material
May 2002 10
3.3 Electrode Alignment
The alignment of the electrode caps must be verified by making a carbon imprint as shown in Figure
2-3 and comparing the imprints for overlap. Imprints of the electrode caps should be made at the
start, at 200 welds, at 500 welds and every 500-weld interval thereafter. A record of imprints must be
kept for all tests.
Note: If the electrode cap alignment does not meet the requirements outlined in WG-002 Appendix
948, realign the shanks until the carbon imprints have acceptable overlap before starting the test.
3.4 Test Sequence
1. Set the weld force and weld time to the corresponding WS-4, Section A, values or the values
specified on the test request. Determine the weld current required to obtain a minimum weld
button as specified in GM4488M.
Note: The data outlined in Section 2 may be used to determine the minimum weld current
required. However, the current value should be taken from the low end of the lobe and verified
by welding a coupon before proceeding with the following steps of this test.
2. Add 500 A to the determined minimum value with the welder control in the “Current Regulation”
mode.
3. Weld the metal at a rate of 30 welds/min.
Caution: Do not make a weld on the “footprint” of a previous weld as this will cause faster
electrode cap deterioration.
4. At every 100-weld interval, make two welds on a coupon as shown in Figure 2-1.
5. Perform a peel test as shown in Figure 2-4 on the second weld on the coupon and record the
following information on the data sheet (see Table 3 - 2 for sample data sheet).
a. weld number
b. programmed current in kA
c. measured current in kA
d. weld button diameter in millimeters (measured according to the specifications of GM4488M)
e. profile of each button
f. comments (e.g., weld quality, button pulled or no button, excessive flashing, sticking and
imprints)
Note: If the button does not meet the minimum requirements at the 100 weld interval check,
increase the current in 100 A increments until the proper button size is obtained and record the
current on the data sheet.
6. Add 500 A to the new value and continue welding.
May 2002 11
7. Continue the test until one or more of the following conditions occur:
a. The metal sticks to the electrode cap, requiring a substantial force to free it (i.e., heavy
sticking).
b. The required button diameter cannot be obtained with weld current increases.
c. The required current exceeds the corresponding GMT Current Limit shown in Table 3 - 3 or
the limit specified by the NA CRW engineer.
d. The carbon imprint diameter (i.e., maximum dimension) of either electrode cap exceeds the
maximum allowable diameter as specified below:
Size 1 (1/2” o.d.) Cap - 8 mm.
Size 2 (5/8” o.d.) Cap - 10 mm.
Size 3 (3/4” o.d.) Cap - 12 mm.
8. Record the total number of welds at the termination of the test.
The final report should reflect the Weld Number (X axis) vs. Weld Current (Y axis). The weld number
should range from 0 to 8,000 in 1,000 weld increments, and the weld current should range from 6 to
27 kA in 1 kA increments.
Note: The NA CRW engineer should be notified if any modifications or errors are incurred during
electrode cap life testing.
May 2002 12
Table 3 - 2: Sample Electrode Cap Life Test Data Sheet
WS-5A Electrode Cap Life Test Data Sheet
Schedule Date ______ Page No. __of__

Squeeze____ Weld__ __ Cool _______
Pulse __1____ Hold_____ Force ____ Test # _________________
Material __________ Engineer __ ___________________
Upper Cap __ Lower Cap ___ Technican ___ ___________________
Weld Stand #_____ Welder Control__ ___
Programmed Measured Button Dia. Minimum Button COMMENTS

Weld #
Current (kA) Current (kA) (mm) DWG (e.g., flash, sticking, imprints)
May 2002 13
Table 3 - 3: GMT Current Limit
At Faying Surface GMT Current Limit

(mm) (A)
0.70 - 0.80 11,000
0.81 - 1.08 11,000
Bare to Bare 1.09 - 1.35 13,000
1.36 - 1.58 14,000
1.59 - 1.78 15,000
1.79 - 2.10 16,000
2.11 - 2.48 17,000
2.49 - 2.80 18,000
2.81 - 3.40 19,000
0.75 - 0.80 14,000
0.81 - 1.08 14,000
Bare to Galvanized 1.09 - 1.35 15,000
1.36 - 1.58 16,000
1.59 - 1.78 17,000
1.79 - 2.10 18,000
2.11 - 2.48 19,000
2.49 - 2.80 20,000
2.81 - 3.40 21,000
0.75 - 0.80 18,000
0.81 - 1.08 18,000
1.09 - 1.35 19,000
1.36 - 1.58 20,000
Galvanized to Galvanized 1.59 - 1.78 21,000

1.79 - 2.10 22,000
2.11 - 2.48 23,000
2.49 - 2.80 24,000
2.81 - 3.40 26,000
May 2002 14

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Forward Questions and Comments to:

Chairperson GM Weld Council at weld.council@gm.com

Document Expiration Date:

Date Revision Revision History

Copyright 2002. General Motors Corporation. All rights reserved.

Section Description Page

GMT: an acronym for Governing Metal Thickness.

NIST: an acronym for National Institute of Standard Testing.

1.6 Normative References

GM4488M, Automotive Resistance Spot Welds.

GM WWG-002, Weld Gun Design Standards.

GM WS-1, Welding Principles, Section A: Resistance Spot Welding.

GM WS-4, Welding Verification Procedures, Section A: Resistance Spot Welding.

2.1.1 Welding Equipment

2.1.2 Electrode Caps and Water Flow

The following instruments shall be used to perform the weldability procedures:

1. calibrated current analyzer (e.g., Miyachi Model # MM-326B or equivalent)

2.2 Material Requirements

2.3 Selection of Process Parameters

2.4 Electrode Alignment

2.5 Test Sequence

2.5.1 Conditioning Welds

2.5.2 Hold Time Sensitivity Test

2.5.3 Weld Lobe Generation

2.5.3.1 Minimum Button Diameter Curve

2.5.3.2 Expulsion Curve

2.5.3.3 Weld Lobe Interpretation

2.6 Rejection Reasons

Figure 2-1: Spot Welded Coupon Peel Test Dimensions

Second First weld

Figure 2-2: Weld Lobe

Figure 2-3: Electrode Caps Carbon Imprint

Figure 2-4: Spot Welded Coupon Peel Test

Bench First weld

Figure 2-5: Spot Welded Coupon Chisel Test

Figure 2-6: Spot Welded Coupon for Tensile Test

3. Electrode Cap Life Performance Procedures

3.1.1 Welding Equipment

3.1.2 Electrodes Caps and Water Flow

The following instruments shall be used to perform the weldability procedures:

1. calibrated current analyzer (e.g., Miyachi Model # MM-326B or equivalent)

3.2 Material Requirements

Table 3 - 1: Material Requirements

Evaluation Area Material Requirements

3.3 Electrode Alignment

3.4 Test Sequence

Table 3 - 2: Sample Electrode Cap Life Test Data Sheet

WS-5A Electrode Cap Life Test Data Sheet

Schedule Date ______ Page No. __of__

Programmed Measured Button Dia. Minimum Button COMMENTS

Table 3 - 3: GMT Current Limit

At Faying Surface GMT Current Limit

Galvanized to Galvanized 1.59 - 1.78 21,000

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