WELDING MANUAL

Index:
1. Training Requirements for Employees Involved with Welding Pg. 2
2. Quality Weld Inspection & Equipment Pg. 2
3. Proto-Type or Pre-Production Submission  Pg. 3
4. Weld Conformance For PPAP Approval  Pg. 3
5. Documentation and Visual Assessments  Pg. 4
6. Frequency of Weld Joint Inspection During Production Runs  Pg. 4
7. DFMEA and PFMEA Severity and Detection Pg. 4
8. ARC Weld Repair Procedure  Pg. 5
9. Allowable Rework to Remove and Replace Components Pg. 6
10. Batch & Hold Weld Verification Frequencies Per Commodity Pg. 7
11. 12 Step Guidelines for Weld Verification Pg. 8
Appendix A – Revision History Pg. 9
Appendix B – Definitions & Acronyms  Pg. 9
References:
GMW14058-GMAW, GMAB GMW14057
GMW16383 GMW 16939
GMW16804 GMW17330
GMW15563-MFG P.C

1. TRAINING REQUIREMENTS FOR EMPLOYEES INVOLVED WITH WELDING:

The complete training plan is documented reviewed and approved through GM Supplier
Quality. Training include topics relative to basic weld theory, reference to American
Welding Society (AWS) and GMW Weld Specifications requirements.

1.1. The New & Current Production Employees Involved with Welding
All New employees that will be operating weld cells are required to learn basic welding
theory, verification and GMW qualifying standards. Reference the standard automotive
industry practice and guidelines. Current employees are re-certified every 2 years.

1.2. Standardized Work

Lear standardize work instructions, visuals and Master sub-assemblies for each operation,
verification station and weld quality inspection process at each weld cell per the certified
quality systems guidelines.

1.3. Training Records

The Operator training records are documented and maintained according to the
requirements. This include but not limited to weld theory, customer specification, weld
quality, cycle time, inspection process, techniques, and recording methods.

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 1.4 In the case where there are Global or Regional Federal or Legal requirements, an
independent certification on Safety or High Severity weld applications must be compliant
using an accredited certification provider as defined by the individual countries guidelines.

2. QUALITY WELD INSPECTION & EQUIPMENT:

2.1. Optical Inspection System

The Inspection, measuring, & test equipment to perform the image analysis of the weld
cross-section and image archiving is capable of evaluating the specified criteria to an
accuracy of 0.01 mm. Weld cross sections is capable to examined with 15x magnification
minimum. Currently lear qualifies personnel who performs the welding inspection
according to the internal plan perform the cross-section analysis. Discrepant findings are
documented for immediate correction in the weld cells. Quality records of the exercise are
retained as required guidelines.

“ALL” welds found to be non-conforming to GMW weld specifications at any time during the
weld verification analysis are escalated to the Quality or Manufacturing leadership
immediately along with line stoppage to ensure proper containment activity is in place from
the point of discovery and corrected before moving the product forward. Corrective action
and start-up verification are documented, escalated and approved by the proper ownership
of the complete welding process.

Layered Process Audits (LPA) are scheduled to confirm corrective actions are followed and
documented as Lessons Learned and incorporated into future project planning.

2.2. Cut and Etch System

Weld locations are marked on the part corresponding to the weld drawing. All weld lengths
are measured prior to sectioning. Weld samples are sectioned from the component with
methods that do not alter the structure of the weld due to excessive heat. Typical
sectioning equipment such as a band saw, plasma arc cutting equipment or liquid cooled
abrasive cut off saw are used to cut the weld from the part. The weld are be further
sectioned and prepared using standard metallographic techniques as described in ASTM
E3.
Alternatively, the weld sample are ground to a 340-grit finish and macro etched per ASTM
E340. The selection of micro or macro sample preparation is at the discretion of the
supplier with GM approval. Physical weld samples shall be retained or digital imaged for
review prior to shipment.

2.3. Optical Training

Training for optical macro-scope analysis is include visual weld cross section assessment,
proper layout for reference imaging and measurement transfer. Visual imaging and

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 measurement transfer shall be supervised for proper accreditation in verifying accuracy of
the weld measurement procedure.

2.4. Weld Qualification

All Welds produced free from any visual defects, and sample Cut & Etch results pass
GMW specification criteria. Separate measuring programs are required for convex,
concave, and or flared bevel welds. Measurement system is capable of measuring Leg 1 &
2 length, throat, penetration, gap, undercuts, and position. Welding process shall be
reviewed and approved prior to sourcing completion.

*Reference the GMW14058 Section 3 Requirements for Weld Process Failure Modes listed

3. PROTO-TYPE OR PRE-PRODUCTION SUBMISSION:

3.1. For the validation of welding a complete set of the results of visual evaluation of cut
and etch.  The complete data package will be available to be sent to GM. The data packet
review will be carried out during the PDT or on-site review before completing the shipping
requirements. (reference guidelines are shown in Section 11, page 7)

4. WELD CONFORMANCE FOR PPAP APPROVAL:

4.1. Minimum 50-piece continuous run with first off, last off and 10% stratified samples
with complete Cut & Etch on “ALL” weld locations to verify 100% conformance to
GMW specification. If discrepant welds detected, are carried out corrective action
plans clearly noted, confirmation of corrections and resubmitted for review and
approval. GM Supplier Quality and GM Product Engineering must approve “ANY”
deviation to GMW requirements. Sub-assembly components to be verified against
math data specifications prior to staging at the manufacturing weld cells for usage.
All weld cells are required to follow the weld verification standards. (reference
guidelines shown in Section 11 page7)

4.2. Robotic or Manual Welds require 3 minimum conformance tests per cell / per
operator, AIAG CQI – 15 Welding System Audit to be completed relative to the home-
line welding process after initial equipment has demonstrated process capability
along with health charts being in place.

4.3. Required PPAP attachments are required to be uploaded along with the standard
requirements.

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5. DOCUMENTATION AND VISUAL ASSESSMENTS:

5.1. Each individual weld joint requires specific measurement for overall “effective” weld
length, depth of penetration or fusion and visual assessment results for each Leg 1 &
2. The data summary report should be available for review upon request or on-site
PPAP readiness review scheduled during the respected scheduled PDT meeting.

6. FREQUENCY OF WELD JOINT INSPECTION DURING PRODUCTION RUNS:

6.1. All welds defined in the weld drawing or design record of the part are examined
according to GMW14058 by the “Cut and Etch” procedure described in section 3.2
respectively. Qualified weld inspectors that have successfully completed the certified
weld inspection-training program is perform the detailed weld examination procedure.

6.2. Supplemental mechanical testing such as Bend or Pry type testing, are used in
addition to standard “Cut and Etch” techniques. Bend or Pry methods are
supplemental examinations and cannot be substituted for the “Cut and Etch”
techniques described herein and required by GMW14058 & GMW 15563. The Bend
or Pry method defined as, cutting approximately a 25mm or one-inch strip of the
welded section, then bending or prying one layer 90 to 180 degrees back in one
motion. No weld or heat affected zone initiated fractures allowed.

6.3. All discrepant welds are documented and follow the standard escalation process for
immediate containment and corrective action verification. This batch of product is
“RED” tagged and placed into containment for disposition or corrective action.

7. FMEA SEVERITY AND DETECTION:

7.1. Weld controls and parameters are to be monitored and recorded during start-up and
throughout the entire production run to assure stability/capabilities of the weld cells
potential. All welds with a DFMEA Severity rating of 7 or 8 require a AIAG PFMEA
Detection rating of 7 or below. DFMEA Severity of 9 or 10 require an AIAG PFMEA
Detection rating of 6 or below. 100% in-line process parameter controls monitoring
are required in order to prevent the “RISK” of failure, and eliminate GM assembly
center disruption in the product. Detection features are standard within the weld
control software provided or software upgrades are required. (e.g. arc time, voltage,
amps, wire feed & speed, gas mixture, travel, component sensors for presence &
location). Effective source inspection or weld verification station is required to be
100% in-line with the process flow. This evidence should be clearly defined in the
required Weld Verification Plan submitted by all suppliers during the Global APQP
activities by week minus 75.

8. ARC WELD REPAIR PROCEDURE:

8.1. All potential weld repairs noted are required to have the proper authorization from
GM Product Engineering and GM Supplier Quality in advance of initiating the

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 authorized weld repair, also the weld repair results must be verified prior to shipping
any of the batched product to the GM assembly centers.

8.2. Lear develop a detailed weld repair procedure approved by the GM Supplier Quality
and GM Product Engineering.

NOTE: All parts that require an approved rework or repair, have “TRACEABILITY”
identification that is clearly comprehend the following requirements along with GM approval
documentation:

• Description of repair method performed & location

• Julian Date including time & shift of repair
• Quantity repaired as shown on the GM approved document
• Method used to return certified repaired stock with documentation back into finished
goods

8.3. All repairs by welding are made with an approved filler material equal to that which
used on the original fabrication.
In addition to the GMAW (CV MIG) or GMAW-P (PULSE MIG) processes used for
automotive steel structure fabrication, the GTAW (TIG) or SMAW shielded gas ARC
welding process may be used by qualified individuals on these types of repair or
rework methods at the supplier location, but not recommended.

8.4. All weld repairs meet the applicable GMW specifications and comply or exceed
production quality standards. All welds repaired have a detailed inspection and
verification plan to support that the weld meets or exceeds the applicable
specification and standards for quality, quantities and spatter free zones meet the
GMW quality expectations respectfully.

8.5. Repairs of “Hole” size diameters of 10.0 mm’s or less can be made by ARC welding
the hole completely and grinding flush. For larger holes, a slug or plug shall be
required using the same alloy grade and thickness inserted and joined properly.
Additional joint preparation may be required for chamfering the hole or slug.

8.6. Base metal thickness reduction due to undercut at the “TOE” may be restored or
reworked included.

8.7. Welds that are missing or below specified length may be re-welded using approved
production weld procedures. Minor discrepant weld burn through, notching, skips or
insufficient throat dimensions will require additional preparation prior to welding.

8.8. Incomplete fusion, porosity, rollover, craters, meltback or under fill as shown in
GMW14058, can be repaired by grinding back to base material profile and re-
welding.

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9. ALLOWABLE REWORK TO REMOVE AND REPLACE COMPONENTS:

Lear is developing a procedure that guarantees the correct repair in case of replacing
components

10. BATCH & HOLD WELD VERIFICATION FREQUENCIES PER COMMODITY:

10.1. Lear demonstrate capability within the proper weld equipment potential by certifying
that all components or sub-assemblies are dimensionally correct with “DRIVE TO
NOMINAL” strategies in place before staging for usage. Requirements include Tier 2
sub-assembly weld verification if applicable.

• 1st off - Visual Inspection, Bend or Cut & Etch Methods per GMW 15563
• If acceptable to requirements, begin production runs
• Mid shift – Visual Inspection, Chisel Check, Pry Test or Cut & Etch per GMW 15563
• If acceptable to requirements, continue the production run and update production
run charts
• Last off confirmation by Visual and Cut & Etch to verify conformance according to
the Weld Verification Plan submitted and approved to specified requirements. If
correlation studies for Non-Destructive Testing methods are approved, this may be
considered an option if applicable
• If acceptable, move “BATCHED” product forward through the value stream

TABLE 1 - PER SHIFT OR BATCH SCHEDULE REQUIREMENTS:

SMT FIRST OFF (1) MID LAST OFF CUT & ETCH
COMMODITIY Production SHIFT/BATCH Weld PLAN
Chassis and Run Plan to (1) Production Assembly *100% Welds
Structures Start Run Plan to Confirmation *Severity 7 to
100% All Continue to Release 10
Welds per 100% All Welds Product
GMW15563 per GMW15563 100% All
Welds per
GMW15563

FRAMES Visual, Bend or 100% Visual & Cut & Etch Severity 7 to
Cut & Etch Bend 10
CRADLES Visual, Bend or 100% Visual & Cut & Etch Severity 7 to
Cut & Etch Bend 10
CROSS Visual, Bend or 100% Visual & Cut & Etch *100% Welds
MEMBERS Cut & Etch Bend
AXLES “ALL” Visual, Bend or 100% Visual & Cut & Etch Severity 7 to
Cut & Etch Bend 10
TRAILER Visual, Bend or 100% Visual & Cut & Etch Severity 7 to
HITCHES Cut & Etch Bend 10

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 IP BEAMS Visual, Bend or 100% Visual & Cut & Etch Severity 7 to
Cut & Etch Bend 10
SEAT FRAMES Visual, Bend or 100% Visual & Cut & Etch *100% Welds
Cut & Etch Bend
EXHAUST Visual, Bend or 100% Visual & Cut & Etch *100% Welds
SYSTEMS Cut & Etch Bend
ACCEL. Visual, Bend or 100% Visual & Cut & Etch *100% Welds
PEDALS Cut & Etch Bend
BRAKE Visual, Bend or 100% Visual & Cut & Etch *100% Welds
PEDALS Cut & Etch Bend
CONTROL Visual, Bend or 100% Visual & Cut & Etch *100% Welds
ARMS Cut & Etch Bend
IMPACT Visual, Bend or 100% Visual & Cut & Etch Severity 7 to
BEAMS Cut & Etch Bend 10
WELDED Visual, Bend or 100% Visual & Cut & Etch *100% Welds
LINKS Cut & Etch Bend
SHOCKS Visual, Bend or 100% Visual & Cut & Etch *100% Welds
Cut & Etch Bend
STRUTS Visual, Bend or 100% Visual & Cut & Etch *100% Welds
Cut & Etch Bend

(1) Lear substitute standard cut and etch evaluation as a substitute for supplemental
mechanical testing described in 6.2. All proposed alternatives must be reviewed and
approved in advance by GM Supplier Quality and GM Product Engineering.

10.2. Frequencies and methods are subject to be modified based on the introduction of
new technologies, 100% In-Line performance features, Advanced Adaptive Weld
controls, etc. are required to not only detect process failure, but shall be capable of
shutting down the weld system cycle for proper analysis of the weld parameter
failure. Weld Verification process confirmation must include but not limited to
Stability & Capability results, Weld Health charts over time, zero PRR’s or GM Plant
disruption.

11. 12 STEP GUIDELINES FOR WELD VERIFICATION:

BEFORE WELDING BEGINS:

1. CONFIRM WELD STUDY FOR PROPER SIZE AND LOCATION OF

WELDS

2. ASSURE THE MATERIAL PROCESSED MEETS THE DESIGN INTENT

SPECIFICATION

3. CONFIRM ALL COMPONENTS ARE DIMENSIONALLY CORRECT –

PAST SCORE >90%

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 4. SCRIBE OR DRILL PANEL COMPLETED FOR VARIATION CONTROL
<.5MM (SPOT)

5. GAP STUDY - WELD JOINT GAPS FOR GAS/MIG WELDS ARE <
1.5MM (GMAW)

6. PROCEED TO RUN A SMALL CONSECUTIVE SAMPLE BATCH TO

DEMONSTRATE STABILITY – EXAMPLE 10 PC’S

AFTER WELD VERIFICATION HAS STARTED:

7. COMPLETE WELD TEARDOWN AND EXAMINATION REQUIRED PER

GMW SPEC’S

8. 100 PC CONSECUTIVE RUN TO CREATE 10 SUB-GROUP

TEARDOWN RESULTS

9. BEGIN TO RECORD RESULTS INTO A RUN HEALTH CHART –

CAPABILITY TRENDS

10. CONFIRM WELD SCHEDULES ARE CORRECT ACCORDING TO THE

SAMPLES

11. ADJUST SCHEDULES IF REQUIRED AND RECORD INTO A HISTORY

CHANGE LOG

12. IF ADJUSTMENTS ARE REQUIRED, GENERATE A CLEAR AND

CONSISE CONCENTRATION DIAGRAM (ROADMAP) SHOWING AREA
AFFECTED

Appendix A – Revision History

Appendix B – Definitions & Acronyms

Definitions
Acronyms
AIAG: Automotive Industry Action Group
APQP: Advanced Product Quality Planning
FMEA: Failure Mode and Effects Analysis
PPAP: Production Part Approval Process
eSOR: Statement of Requirements
SQE: Supplier Quality Engineer
T-WO: GM Temporary Work Order authorizing a product or supply chain change

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