Non-destructive method developed for

testing spot welding joints

A NON-DESTRUCTIVEmethod
for evaluating spot welding
joints, suitable for use in the
automotive industry, has been
developed in Germany.
Despite the widespread use
of spot welding in the car
industry, it has lacked a reli-
able, non-destructive method
of testing the completed joints.
Instead, the joints have been
tested using a hammer and
chisel. That could soon be a
thing of the past, however, as
scientists at the Fraunhofer
Institute for Non-Destructive
Testing in Saarbficken have
developed a measurement
technique which determines
the exact size of the welding
spot during the welding pro-
cess itself.
Although the technique
uses ultrasound, it does so in
a quite different way to its role
in existing testing applica-
tions. It measures the input
and duration of heat, and
ascertains the molten volume
of the welding spot. From this
data, the size and durability of
the joint can be deduced.
The measurement unit makes
use of transverse waves, which
do not readily expand in
liquid media, to register the
slightest changes in the weld-
ing point’s transmission of
ultrasound. Since the coeffi-
cient of transmission depends
on the temperature at any
given moment, the changes
recorded can be used to calcu-
late the temperature within
the welding joint, as well as
the size of the welding spot in
the process of formation.
Moreover, the developers
have intesated the measure-
ment procedure within the
welding process itself. As
soon as a welding robot at-
taches the electrodes, it auto-
matically triggers the quality
test. A prototype has proven
effective in numerous trial
runs under authentic manufac-
turing conditions.
Automatic quality assess-
ment and documentation of
spot welding joints is also
incorporated. Real time analy-
sis of the welding process
allows source values to be
ascertained so that welding
parameters can be adjusted
accordingly for optimum per-
formance. Thus, for the first
time, basic technology exists
for the development of an
ultrasound welding current
control unit.
German engineering giant,
Bosch, a market leader in
welding control equipment,
has acquired the licensing
rights. Bosch is currently refin-
ing the technique for series
production, and plans a mar-
ket launch in two years.

North America’s car companies take

steps to improve air bag safety
THE American Automobile
Manufacturers Association
@AMA), along with the Motor
Vehicle Manufacturers Asso-
ciation of Canada, is to imple-
ment a series of major
initiatives designed to further
improve air bag safety for
to permit depowering as well.
In August of this year, AAMA
petitioned the US government
to allow for improved, slower
deploying and is continuing to
work with the National High-
way Traffic Safety Administra-
tion (NHTSA) on the

vehicle occupants. Air bags
and safety belts save lives,
but for children, air bags can
be deadly.
The AAMA, made up of the
‘Big Three’ car companies, will
improve labelling and launch
an education campaign to in-
form drivers of the dangers of
air bags, as well as taking steps
to “depower” the systems. The
car companies believe that
slowing the speed, and thereby
reducing the force, with which
air bags deploy reduces the
risks posed by air bags. The
AAMA says depowering offers
the best near-term solution to
mitigate air bag risks for all
vehicle occupants. Chrysler,
Ford and General Motors, are
all volunteering to depower
driver and passenger side air
bags ln Canada, where there
are no regulatory constraints to
doing so.
They are also urging the
USA to take immediate action
depowering issue.
Chrysler, Ford and General
Motors will voluntarily include
additional air bag warning
labels in all new vehicles. These
labels will alert drivers and
passengers to the risks asso-
ciated with air bags as well as
emphasize proper use. The
companies will work with
NHTSA to define label content
and determine placement in
the vehicle consistent with
government recommendations.
Additionally, the compa-
nies are sending letters to
current owners of vehicles
equipped with passenger side
air bags to remind them of the
risks inherent with air bags
and to advise them how to
optimize air bag effectiveness.
In addition, AAMA and
its members will continue to
support and encourage com-
prehensive air bag education
through the Air Bag Safety
Campaign.
a
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. . including metals, alloys,
@ carbides, refractories and
* *
chemicals. We also offer particle
TESTING
No. 1091
sizing and can perform
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Our laboratory runs a three shift system 5 days a week in
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For furtherdetails contacf
Jim WrightM.I. Ref. Eng.
(LaboraforyBusinessManager):
LONDON 81SCANDINAMAN
METALLURGICAL CO LIMITED
Fullerton Road, Rotherham,
South Yorkshire, S60 1 DL, England.
Tel: 01709 626500
Fax: 01709 630391

8 MPR December 1996