RP Enoincering specication . pane ‘Steel Tailor Weused Rian ~ Gtobal ES EGAUGA-T7IO0G4AA = iP Ae ik cs a_i fT 5. [7s \e heft fe fis fie fie _fie_per_ fiefs ur A El Be es _[e7 i ff revinicns oa | or SE Cr (ALL nla laesea OF Gebal TWB Engeotny Spechcatcn | RA EBAS71-1K261-88 (EU) cee ri fi ES FEAR A2TG-AA Junea ES FE7B-1A705-AA lotNerth Ameen (UBA) AB E-F1 184748000 a 7 7 =, rie | A.=p Engincoring Specification FRAME 20 OF 20 ‘| REV.LET. PART NC. E5-4USA.4710064-AA, Attachment A -Mash Scam Welding Process (Europe only) AV REVALIDATION REQUIREMENTS see 1V. REVALIDATION REQUIREMENTS inthe main pat of this Engineering Specifleation. (Certain process parawsetors will have a great influence on the final weld quality ofa mesh seam weld. The ‘control plan, au defines in Fad QS-S000, fs ax essential part ofa quality product, Some recnmamencied proce variables specific tn naush-texm welding to include in the control plan are: © Welding Cument © Electrode Force © Welding Speed (© Blank Overlap Bead Width AVI COMPILATION OF REFERENCE DOCUMENTS ‘A. 05-9000, Quality System Requiseenents B, DVS Paper 2914, Mach Seam Welding OF Thin Steel Sheets ©. DINEN 895, May 1999, Destrecive Testing Of Wels in Metallic Mascrals D.ISOIFDIS 14271:2000), Vicbers Hardaces Testing, Of Resinance Sper, Projection And Scam Wells (Low Load And Miero-Handaess) uw 394TR2E neem moetED _Enginesring Specification Attachment A - Mash Seam Welding Provess (Europe only) ALIL3 Weld Strength Teats (comt) ANI32 Pliers Test(oont.) ‘Ths pliers tis performed to fest the siength ofthe weld and chock wictber the blancs seperate fm cach ter by beading them in opposite directions. Two plirsare used a9 shown in Figure ATL3.2. The west shall be performed on either ends of the Wek “The meexplance cxterie ae as follow: («The weld i ancepeabla, ifthe fall oocurs inthe hase marcia only, > Failures in the weld are not acceptable, AULS3 Axial Tension Test Perfoem axial tension tet on 2 tapered metal strip cut ftom a Hank in scoordanen with DINEN £95, Destructive Testing Of Welds In Metalic Matzils. Alig the weld bead perpeadicalee tthe Joading nection. No rework of hs weld Caeling the teil pileup in the fvsion-zos) is ello wed on the test sales). ‘The sample ant fil outside inthe bese material prin the Adhntioa Zool (aca Figaro A.112.2).A. ‘racture in the Fuslon Zooe a (oce Figuav AIIL.2.2} is woscccplable. AII3.A Hapinges Inoesse ‘igrcacas increases primarily ar th result ofthe material compnsition, especally ofthe carbon conteat Hiardnessinereases can considerably increase the likelinond of cracks daring cooling o subsqnent processing ofthe chaet metal. In the mashsean welding process the likelihood of the cracks eam for the ‘cot prt be reduced by using alteonetive matesials. In general, sels with a carbon conteat of upto 0.12 % can properly be mush-ream Welded, whereas those with s caton coment of wp to approximately 02% rei special mensures. In particular high evel of sufphoe, phosphors, copper and Iced may rest in considerable weld imperfections. ‘Test the micws hartuess per ISO 1427:2000 on metallographic crst sections, prepare perpendisulat 1 the -veld bead from samples cot fom the ban. The muaxinum ox peak weld seu micré-hardness in base snateral to base taterial micro-hardnoss traverse shall wot exesed 350 HIV. Duvistion fm this limit are ‘pemnsble under the provision thatthe stamping sour porters pxt-speiT focaabiityty-outs zd that Body Engineering passes part-specii tiga tos. ‘The uelectlon of measuring points shall ensue thet tae hardness variation along a trrversa perpendicular to ‘the wali bead is sfiently caprured. Hardness shail be reported in Vickers, Bm SBATALO cen emer men>> Engineating Specification [Fewe_ea or ae [revue Attachment A - Mask Seam Welding Process (Europe only) ‘AIDS Weld Strength Toots (owt) ATI Poel Test (co) . pane rare K 2 Lean l, IG WF} AN32 Flare Test x Engineering Specification [recs sor oo [evr [panroceemmrimmean | Attachment A -Mash Seam Welding Process (Europe only) AJIL2 —Dimeasoual Inspection / Formabifty (cont) AUI2A Minimum Forming Ratios tox ‘The smallest formable redins perpendicular to the weld beed shall comply with the olowing requirenent; ran det, In texwile stress est perpendicular to he weld bent, the fmciume is supposed t occur inthe thinner sheet cory. Tensile stress testa inthe direction of the weld bead have fo coraply with Ford Motor Company's mutta voquicemanta for the thinnee blanc, ANIL3 Webi Stremgth Tests AMI1 Peel Test ‘The pec! tent a performed ona test orp, approximately 50 mm wide and 70:mmn long; taken from the ‘Welded blanc. The weld seam shall be within the ceaner ofthe sip. For the text set upand west sample (pesmetry refer to Figure AOI. 12 and A.11,3.(b on the following pages. Tnaett two cuts nto the thinner shoct, approninustely 20 mm apart, reaching within 5 mm of the seam using celtber sect shears or a lund or Hbbon sn. Bend the two side tabs ofthe tianee sheet down by 90 degrees. esshowm in figure A.013.la and securely clamp them ina vise. Peel the ceoter section upwards by bending it into the appomite direction using plier te ether eultble tools. The peel operatien shall be performed any con the uppar-tide sheet. ‘The acceptance ceteris ae as ftlowes (abe Figure A.IL3.1.b, pats 1) 0 4): © Acensplete peel offen shown ia part 1) of Figure A.IL3.1b i unsooopsclo, © A purl peel off ws sown i put 2) of Fgce A.II.3.1) ts accepiatle as long as the height b of chose thier bark segment that tick with the thicker bm fulls te requiraneat h 208 *t- Fractures perpendicular ta the weld bead slong the tes forthe centr sri thaestand it the Chlckee matera are acceptable as long as the centct stip (thimer material) won't pool ofF he thicker imuerial (see part 3) of Figure AIIL3.1). + A basak in tho bane masta pall] to the weld bead is accept (oe part 4) of Figure AIIL.2.1.5) Be 3P8TE29 pectorisEP _Enginooring Specification FRAME 26 OF 30 | REV.LET. Attachment 4- Mash Seam Welding Process (Europe only) AJIL2 —Dimeusfoss] Iaupoction / Formbility (cout) ‘ANTL22 Bead Width foontd Fusion Zoos, ‘The Joad bearing eapaity of the weld depends exciusively onthe quality and the geometry ofthe fasion zone. The Fusion Zone a shall expend across the entre thickness t, of the thimer blank sad shall be free of any unsccepinble discontinuities. Wo width shall eamply with the following requinement: z3att ‘The ovn pavectinetalaahnets ane Joined together baned on the following two effeets: material melting that results in ligud weld bead and/or the formation of new gals esullog ina pasty zone aloay the contacting surftcea ofthe parent sheet ructals. The Ittr can be cbscrved at ow magnifiertion levels ‘more or lex clear eutIins. The effets of fation can be observed using maghifieation of upto SOQx anly. ‘Adlseslon Zone'b ‘The Adhesion Zone b - lovatod s{jacent to the Fusion Zone a ~ is well-process specifi and thersfnee scceptable tis chansctetized by the effect of incomaslete fusion and ax such can not be concidered as a load ‘bearing svtion Lully it thicker than the total thickuess of the pore mural sheets dus toa material pile up daring the weldlog operation (sec A.11L2.3). Ede Zone ‘Daring the mash ream welding operation, the edge of the thicket short metal is defyrmed dus to-msteral laplacenaee kaving a gap borweea the parcat metal surfaces. This Edge Zone c is weld-process specific nd therefore accepubie, AML23 Thiknow Ineowe Wm Figure ATIL2.3 : Wold Geometry ‘Th thickness increase on the side of the thinaer lank shall not exceed 18 * 6. (On the sida of te thicker blank, thickness increase shall wot exceed (t4.)+ 0.10 *t.. Bee SPATA20 — ermmneteemyn ms> Engineering Specification CR Attuchaneat A -Mash Seam Welding Process (Europe only) ‘ATL2 — Dimumtousl Inapectinn / Formability AII21 Bink Overlep oa 8 2 a Figure A.11L24 : Position Of The Blanks Prior To Welding AMIL21 Blesk Overlap (ent. Inpreparation for welding, the following reference values forthe blank overiap I sbull be met to ensure trend wth 2 defined in A.TEL22- L= 2¢ 4.» 39 withavaristion oft5% ‘A pecprodicule cutis recosmnend for ¢ sheet metal thickness of up to 2 mm, Blanted edges will most Hkely redune the lead bearing capacity ofthe weld. all22 Bedwion ‘A.mumb-coma weld consists of theen pearnettical znnes as shoo below, that ar inspected on the basis ofa. Sr ‘Figure A.1L22 : Weld Gesenstry @ + Fudon Zone b: Adhesion Zone ©: Edge Zone 4: Weld Thickness 11,12: Thickness OF Parent Metal Sheets a eyED _Enginooring Specification FRAME 23 OF 90. | REV.LET. PART NOL ERAUEAATIOORLAA Attachment A -Mash Seam Welding Process (Enrape only) AJIL1 Visual ispectiona (oust) AMLIS Casts (Cracks in the weld bead (metallographic eroas section cut) and inthe heat-affected zone, observable using ‘magnification of up to 32X, are unscosptzble. Micro-cracks inthe center of the weld bead usually domnot indjuonoe the strengfh of the weld. ‘Transverse crs across the seam (metallographic Jongfutinal section ext) - unless they are rurface cracks only - forthe most part are the result of material solidification. They indicate reduced formability ad poruihly mulbrtuntial hardnuon increase in the weld and are unacceptable. AIL14 impurities ‘teapyd foreign sold mutcals much simpurice and costings in be sect mca strive rally beve ‘vey lite ince on te weld suengta dost Me high iio of beet eta veri to sheet ital thickness. They are evidently observable in the mash-team welding operetion of coated blanks. [arepg coating murah forthe mont put arc apheccally or ic shaped voli laments with an iherat strength, Fosed othe shet material they conrite 10 tela bearing chamcedadcof th weld end re therefore permissible, AULIS Wels chips ‘Weld chips cannot he peeverted eatiely, especialy om oomed shes, aad shall be removed wer weling. “he inane appearence of chipe indo tot he weld pmmtn ed to baad, Welds with chipa tammy ru out have good stent ceerrixitis, They my, however, Ina an increased parc (200 ALL) AuILLS SurhoeSlag/ Oxides ‘Slag ard oxides ane not permitted onthe welded blanks. The weld bead shouldnt present burr ie the comet aruas of the two blanks, Be SBSTARC certs> Engineering Specification FRAME 22 OF 30 | REV.LET. PART NO, ES-AUBA-1710060-4A Attachment A - Mash Seam Welding Process (Europe only) AMT TESTFROCEDURES AJTLA Visual Inapections AIDL1.. Holes, Porosity Cavity-sype disoontimatns (voids, holo) inthe Fusion Zou o (eee A TIL2.2, Bead Width for tbe efiniuen) affecethe performance ofthe Mankcin the seaming operation, ‘These decontimstias ano porenizathle under the feliowing conditions: 11,12, ..,Lns0.10* 8 igure A.ILL.1: Discontimitics In The Weld AMLL2 Lock OfFusion/ Penetration ‘The welding permmeters shall be sush thet the wold geometry complies with the mejuinumeets of A.22, Bead Wiad. Lack of fusion or Incomplee penetrauon are uneccepeable ‘An oafine-aurvelllace of the weld current and sll other relevent weld parsmieters (weld speed, electrode: yeazue (foro}) shell onaure tht tha blank complies with the requirements of this rpecication. Other comparable meaaurca fox qualty asgurmace are acraptable. i SOATZ0 pens=p Engineering Specification [Fewea or 0 [revue (ParTiG mavieairoweak | Altachment A - Mash Seam Welding Process (Earope only) al SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (CONT'D) fa fn Tow ‘Target Valeo | Upper Pretimimary Tolerance Toleranee | Conformance te | Contrel Flan Link Lie Parameters weATIST SeAIIST =F = a = = = a = =e ae reponse fob contol pan Ioghucin ws te op rooney Sgrerng an er pope MAC A APE To Aan TA eva ualty Dea DDevitko from tt ent oe paresis under te preven ute susrprg roc pede pare Englnoering Spacification a TLS ——Corresion Proveetian ‘Suisenqueat tn the welding operation, the weld seam and HAZ, havo to be adeqasiely protected against corrosion (cg, by oiling). Ty. REVALIDATION REQUIREMENTS ‘Aay of te following conditions that affect weids or veldlag operations shail requlre w ve-run completely the produstion velidation teats, Revalidation ofthe PY testing is required oniy in affected aces, A. Procoss Chnnge ‘Any change inthe proccss which could aber it's capability to most the design soquiremeats or dursbility of the produet. This includes new, different, relocated o¢ rebabilitated production machinery fequipaert ; ny ‘change in subcontracted pradacts or services including the use cf enginecring-approved alternate materials. e-changes to sework methods. Process change alzo-jocludes changes inthe sequence of operations; and Hames in cheraical compounds such ns adhesives, seeders, lsccamss, ob. which ae part of the product. B. —_Encioecring Change ‘A change inthe pan(s)inttated by Ford Motor Company. C. Mamvial Change Acchange in the meterial, when optional musterials sre specified. D,_Subaupplir Change ‘Achanga in te sree cf subcomcte cocrponems. E, Adoring Oplons Pesizn ‘Achunge nt Design wi rupli incorporate optional designs specif oa remand domwing oro toe ES. Note: See Q8-9000, Contre] of Subcontracted Suppliers ; retention of Inspection und Test Samples; ntifnton of Completion of nspeedon and Tasting; Change in Mamifictiriag rosea, Change Approval Certain process parameters will have 2 great influence on the weld quality. The coatrol plan, as defined in Ford QS 9000, isan essential parcafa quality prochct Some reenmmenied process variables unc geameiry features to be included in the contol plan are: © Convery = Champing © Concevity © Bilge Quality = Mismatch = Sutfkce Clemliness ‘+ Gaps & Gsp TolenmceED —_Enatnooring Specification [rues or we [Revi [PTO eT | TA Handling Of Fintshed Paris (North-Amariea ony) (com ") Tet [Tet | Test | Acceptance Criera [Minimum Preliminary | Remarky Number | Churac- | Uae Conformance | Contrel Plan evition teTolerance | Parsnatert Tia —[Peresty —)FVIF | Unaraepabe obey | een = Seoeectho IT ca apecion Sedealls SS _ [Caveat [PVF | tnareapubleiroberaite'y | see * ‘Soeveion LT ‘isa Srdeaib, Tats? [FV IF Crascepabie obseranioay | a ET | Soersatan IIT ] Fabs vaua npecton rdeall WELT | Pine Lines | PIP} Sew LT ri = TGS (Cracks | PVF | Cnaccepable Fobeernalicty | __exe™ eee) Seeman ET sual agecion dels THIS [Tacka? —_| FLIP | Cimrowpebe fobeevtlaty | __ aa wee | See secien ICT Feson? ia pein Sedeall, Peartrston TLIO |ienoteh [FV IF | Cosreepabhe fobematlaby | __ oa ™ Fereenien ICT ina Speen fede THE [Beat Wai [PVF | The weld mer te beaded | eee ra sient ecb eo pat slag oc COR THEE | Ribenaes [PVF 00 a a Ba? [Face ana Toor lyzed epee | Upper Rend | PVF see za = rs See seaiea ILE Corey Grd THES | LowerBead | PV, IF | oS =r = Soe seclea HLT Goer ‘fr dace THE | Upner Bead [PVF | eT = at See sent TEE Coot ‘ez dot TRA —[Tomeread [PV TF [eee aT Fer) Se ein TEE Cooeanly fer dente TEE [Bea FOE | Tis bead mat co rT = Continalty ‘Saueoe wit ts ope ee eee (ara pete nthe pet aewing 1 [at PUCIE | The wa baad He ek = a Tocatne son Te fap en onto shown on ae part draving ‘ths ther i ‘He pet wing 2) Mimi ciara kon se si a feraney be trina by te memting trem sespoclle forte emul pln in cojaneio withthe design responsible Body Easioeing ety nd Sos RtarentesSubba Tein tsar S10 tale news Out peatED ss Engincoring Specification Gane Ge eae EES TLS Weld Strength Tents (cont'd) 13.3 Hanlneas Kncroane(coet."4) ‘The maximum or peak weld seam nicro-bardnea in abase meta 1 base mezal micro-sursess raven cut stl at exoeed 350 FV, Deviations fom this limitare permissible wader the peovisina thet the stamping sonreepeefor:par-specifc formality try-onta and tht Body Engineering (and in the cate of finished parts the part supplier (applizhlo » North Amerloa only) passes par-apecifcfaigua rst. ‘The distance between haxiness reautings must provide suficient eeolution af differences between the bese, HAZ.and weld bead. Hardness shall be reported in Vickers. JSA-ATIOOSA-AA 1134 Minimum Bending Redins ‘The main beading radius perpendicular to the weld shall comply with the following requirements in onderto ensurea proper formabilty of te welded biank (applicable oe scmdart sheet peal ppileations for BIW ooly}: ran 20*4, TLS Hanaling OFFinkthed Parts (Varte-Anasvica omy) Since manaficturing and/or purchaning stretegies may frequecly dictate thal finiahed stamping smulirtured fiom nulthplece welded blanka may be procured ftom “other” sources, this Enginearing ‘Specification includes the following PV- and IP-tsts (0 tamdardize the requirements of welded blenis, ‘where necestary to muppert these situations for Ford Motnr Company's North American Operations. Ii, bawerer; the revpousibilty of Body and Stamping Enginsering i Ldeatify parta apectfic dedlgn factors and. ‘oletances in individual drawings and Control Plaw inition to this Eagincciing Specification, Tet | Tost Tort | Avcoptanes Gritata | Winkwam [Preliminary | Remark ‘Nomber | Chara: | van Conformance | Camtrol Plan teviaticn toTelerance | Ferameters TI [Surace [PVP |Sueaseg/oitbetnipal [oT wa? | Wail rand Bae ff ering the mea ering weld net Fries ‘permet are oat pelle a) spervely ‘WHS | Bepaintar | PVIP_| Unasoopahle aborts by | __ oe" Tat | Geneon tied vised Eapecton mas Wake eile TS [Series [FIP | Urmsorpabie robert by | oor we J Yous ‘ea pecan ike 304720 pennsmernm resee Engineering Specification oC TIL2 Dimensional Inupection (cont) M27 Bead Contimsity “The weld eng are spot by the stumping surve onthe Hank or par daawicg. sare and mops of the ‘weld beat are pemnissibke in the offi] meas only. W128 BesdLooation ‘The weld position md tolerance are checked as jointly specified by body end stamping engineering aad ‘defined in the part speniSe procose sbect or ather controling documentation, TLS Wad Strength Tera 1113.1 Sireas / Forembility Test (Modified Erichron Cupping Ts ‘Perform Ball Punch Deformation Test on samples cat from the blank (ref. ASTM ES43.78 or ISO 8490). ‘The weld bead ls supposed to run thiough the ceater of the spherical part of'the punch, “The acceptance exter far the weld sean subjected to the cop teat areas SBUws: ‘Ifa break occurs in the weld or inthe beet wetad zme (HAZ) parle othe weld seam, the welds suacceptable. = fhe break seus inthe weld pespendiclar to the weld bead, be weld is aceptntle. 132 Axial Tession Test ‘Perform axial tension tot ou sample cu fom «blank (ref, ASTMES or DIN EN 895), Align the wold bead Derpeodicular to the loading direcion. No rewoek ofthe seam weld is allowed on the ex sample(s). The sample mus fil outside the weld bed inthe base metal. A finctue in the weld bea orn the heat affested ‘ene (HAZ) is unacceptable. 1033 Hanloess Increase ‘Feat the micrerhardhecs per 180 1427:2000 on exetallograpble cross sections, cut perpendicular tthe weld ‘bed, fiom snraples cot frum the welded blanks. Bee 89420 rete nsED —_sEngineoring Specification [rane 12 or so [revue [PARTNGL ER URRATHOO AA TZ Dimensiooal Inspection (come) 122 Weld Joint Mismatch () (oot) A vei joiismach ism defect and unaccepmble wh, ar any polar along th: weld Jon, the paren petal sunfices are oft by 2 value sreater than w mt mis Engineering Specification ‘Visuul, Optical and Uttravonts Tnspectens (ext) Lack of Fusion/ Penetration ‘Lack of fusion penetration that is detectable either by optical equipment or ulrasonie cquipmeat or ‘visually on be Weld five ot roo: or in a metllogaaphic ection rut uaing magnificaion of wp 10 37K Is igre IIL19 below. m2 ‘unacceptable, Sen Penetration Fusion Deptt Figure 1.9 Lack Of Fusden/Pesctration ‘Dintensional Ingpection ‘The following dimensions scales, gages or optical! electronic divi sda comely of ts orgie) ak Oleg peomeried earocom eo aya igure IIA. Weld Sean Geomseny - Equal Gauges Blanks 3047020 pmiceceinene nme, PART NO. EB-AUBA1710064.AA wearingep Engineering Specification [rome oor ce [evn [rane atari TL1 Visual, Optical aad Utraronte Inspections (con.) TIL1S Holes (cr Pissles) ‘Holes (Pinhofes) that are visually dctectable on the weld face and rost or ina mcullogrephic section cut ‘sing magnification of up i 12K are macoeptabie. LT Zine Lise Zins lines or lines of cing build-up pusllel to the weld bead jurt outside of the HAZ. Escessive heat ixput cooling/shielding gas flow mes may cause zinc lines, ‘Zinc lines are acoeptable unless otherwise specified on the part drawing or cartrol plan. Generally, zine ‘ines that are chservable by visual inspection withoat magnification onclass [or clase Il surfaces me nat ‘ocoxpiable. Metallogrephis capes sections ars not required wen inapocting forxino lines. Gee FigneoII1.7 below. 2s Les Welders ZZ 2I7OW Figere TLL? Zine Timon TLL Grcks ‘Acmck is afrectue-type dissoatinaty characteriza by a sharp tp and bigh ito of length and wih ‘opening’ Cracks that are detcciable ther by optical cquipmeal or ultesuniy equipmont or _viauily onthe Weld fice or root orn a meallographi section ext using magnification of upto 32K mre mucceptable, Bip SBATA2® enemasep Engineering Specification [rue or oe [nwo [anne renunsionean I, _ TEST PROCEDURES AND REQUIREMENTS TEL Virucl, Optical and Uieranoale Imspeetions ‘Visual, optical ant ultrasonic Lnspections are used ro check the laser Weld seam: for possible weld deers 28 jised below. Test equipment: magnifying glisses, lamps, optical or uitmsonic test equipment. TOL. Surface Slag ! Oxides ‘Sing and oxides are not permitted onthe blank. They coal be removed prlarto the forming operation The part's comirol pln must address this issn, 12 Shige Iotoites Wolds Sips hate detectable ether by optical equipment ox utmsonicrquipmen or by visa inspection are maccentable. 1HL13 Surface Voids Surtive Voids are cavity type clcocsiulie, typically Langer than porosty, foeated by sbrinkage during solidification. Surface voids tt me detectable ether by optical equipment or ultwsonic eauiproent ar by vindal inspection ane unacoepenble. 14 Porosity, Porosity that i detectable eitherby optical equipment or ultrasonic equipment or visually on the welé face ‘root or ina memo gaphic section cut using magnification of up to 32X is unacceptable, TLS Unde Undercut is x groove melted into the base metal adjuceatg the weld ine cr weld root aa Leff nied by ‘weld metal. Undereat appeare.at a sharp (generally fes than 50°) notch along the eds of he weld scam. Undereattet it deteetble efter by optical equipment or ullracenie equipment or visually on the weld fase trout or ina mdallogrephis ne-tion cut using cumgnificalion of up to 3ZX is unacceptable, See Figure ILLS below, Woll Tow Urleceat Figers ILLS Unsere Bee B94TR2B paren eeBD _Engincering Specification IL SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS fcont!) ‘Weld Strength Texts ist Test Ore | Low Tolerance | Target Valee Tope Miniewe_] Prelimioary Number Linu ‘Tolerance | Camiormance | Centrol Fina Limit___| in Telerance_| Parameters TESS PVP | Atak nthe wold terial | me eel Pepandicdar tothe dd mis mompeile Tosa Ww etapa at eid | oe we TSS | Hardee ieee | FY av, at we Td | Wislenar Beading [FY ut pected | —__ ow we sila Parpendcner ‘ToT Bead ©. Maina tesdbmats ta tnlarence, evplosta an reso ba dated by tho mats let peered rmpousie arte col as ©, —_Devielons ran is lint are peraitblo una shoprosiln ht th warping sous prix partes frmability ry-mut end Ut dy Pagneng (edn os of fdsed part part sapling to Newt Aron on) pes reaps: Spm ute ©, Aplin tard bt alee or BIW ey 3047220ED ___Engincaring Spoctfication [Pomec or 30 [nev.uet. = PARTI. eaaunaarimnean TL SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cout) Dimewtional inepections Tet | Tet ‘TertUse [Law Tolerance | Target Value Number Limit Coy Tend —| wort Soper erring = rated ro as kp =o Ty Sy =o SEO, =e we as Teepe a0 ESOT, = re as Tera a0 Seo, = wa ar Ba geal | — se OE era a a ica ct cm ae 7a rd ‘These praneter my vel poce- specie arg valve abd lance ire for efienca ey ‘Mixiaun cooformaace to icleance, pple sara reyenty be darned yo raefcung pant perm rerprae forthe cabal pan ft ete wi cee rpc od Eagan ey a rp inet nk pti Ter Anon) oo ©; Yad takenoe ni foe convert conceiy ae intialy mii Sr mc wl rotund eA ii fh ui pono wed fhe AND rox convey (or eonearayaeqpecy~ as pected ine provcus TW apectcon~ cot epete as ON noe Rypent ae weld dec, 2 384Ta2e rem emeenyeeyED _Enginooring Specification FRAME & OF 39 | REV.LET. PARTHO, ERU5A-A710004¢0A TL SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cont) ‘Visual, Opscal And UkrarcaticInapectiows ‘The quilty oftiw weld should profurably be monitored wing state ofthe art online surveilanse inspection techniques. These techniques ely on optical, ultrasonic or eter devicea tat can detect th weld iarperoctios Tinted in be tubs bekaw. Th weld imporfsctions typically result f aaninae decontinudty in Ge Wek fare oF ot, Inabsence of optical or ultmsonic surveillance equipment, visual inspection ofthe weld should be perforined using magnifying glanten frequired (we Section MT). Tet] Tor Fattwe [lew | Teg Vilee | Upper | Minimum | Proliinary—} Rember Tolerance Tolerance | Conformance to Limit Lint | Teterance = eee — ro =| tents | = =e | = = etceette et =| see emeebie [woo IE mt = [exe eewbie | — so = [ae certs | ro = [st cee a =e sere | Ter =e = Bie S84TaZ®— pminesataantoane=> Engineering Specification [renee oF so [rrv.ter.___[ PART. EEAUAAATIOOHAA IL SUMMARY OF PRODUCTION VALIDATION AND IN-TROCESS TESTS Pradaction Validation (PV) tent are used to obtsin an fra extmae of the pcan potential to pondnea pata tht confirm tm enginesingrequiremects, en! oidertity ena or profictivectanstips eiveen ‘ipifcar design nd process characrriics (fo be wed for process como). The teat mit be complied smuccessfilly axing initia! parts from production tnoling and prxdnction process before Pert Submission ‘Warare (PSW) speroval and euthorimtion of production parts ean he inswed. Sapling plana fer BV exting rust be included inthe contol plan. [neProceas (DP) tests are used to further underssund the relionship between significant design and process characteristics aod t establish s bass forcontinving iaprovemedt. Tests ast be completed with ‘Production pats on an ongoing bers, Sarapling plans for both IP toting end crelustion of the significant rovers characte ics must be inchufed in he Comral Plan. Whea the process s found m9 be oxt of como) ‘ortho tat acoeptaneecrteri are pot nt, the ection pln approved inthe Contol Pan stall be invoked ‘The supplice approved control plan must inchude aeacton plan specific tothe laser weld. (Na epprovred repaic papoedure eats far nser welded blanks. No rework is allowed to the lase-welded area, onthe Hanks for ary defect. [Body md subesearbly destructive Weld tet evahunions will nt comsldee the laser wed, ‘The tube that follows summurizes the various PY and IP tests ad the acceptance purameters for each. They form the basis on hich to develop n complete Conirel Plan for these and their elated significant provers charecteiatos, The Coarrol Plan wall inciude frequencies, sample sacs and reaction plans; sex Ford Quality ‘System Requinments, Q5-9000. Be SBATE2© — cmmnwurenn mineap Engineering Specification FRAME 3 OF 90 _| REV.LET. PART NO. E®-{USA-1710004AA, ] 1 GENERAL ‘This Enginearing Specification aestaa the steal Tailoc Welded Blanes, ‘This Eagioeeing Speviliation defines design actors wl iolemces nrocasry to conte ths product quality (function and appearance) of body sruceure components made fom a xmniti-piee tank whi hes been butt Seam joined mgetber by using a Taser welding process. ‘This Enginccring Specification is a supplamct tothe reieascd drawing or Carumoe-Daia-Bare-File (CDBF) ‘on the above blanicDar, and all requirements bereln must be met in edition to all other requirement of he ‘blunicpart drawing or CDBP, Each section species the minimum mesures necessary for documenting compliance tothls specification, ‘This Engineering Specification is intended to evaluste specific characteristics ax 8 aupplemect to nomnal ‘mateelal inspections, dimensional checting, and in process coetrols and should in no way adversely influence other inspection operctions. ‘Prepacation snd submission of m scoeptuble Control Fim ae the responsiblity of the manufwcturing ‘source, The menafactaring sours will retain the original contre] plan and any later revisions per 0.5000 sand providea copy tothe dacign responeisle Product Enginsering activity. ‘Platehed Parte (ose TILA. Fld A mertea ‘The amin foeus of this Engineering Specifiction is on steel welded blanks, Ford of Eorope trucks the quality of blanks within the Ford Quality System by assigning a part umber to ‘cech blank. This ls noe common practico at this poinr of tito within Fard Motor Company's North ‘American Operarions and recuires thar ofthional queens for finished pert are autined explicitly for ‘Narth America, Its the respansibiity of Body und Stunping Engineering in North America to identify design factoss and (tolerances for finished parts in individual dramings anc Contwol Plans in edition to this Engineering, ‘Specification. For thoes generic requiemeas that are applicable t finished parts wee vection ITA, ‘Handling Of Flatbed Parts, Mosk Soam Welding Process (Ford Of Bi Attechmont, "The masfrscan weldlog proccss Is appt to Ford OF Europe. Asackment A to this Englncering, ‘Specification outlines design factors and tolerances, that apply to msh-seam welded blanks, ‘This Eaginsoring Spectication covers the use oF carbon and high strength Jow alloy (HSLA) sheet eels ‘thar ae elther costed or uncouted and do oot require preheat or portheat weatmneni. The shee seels re often. ‘of differeat thickness, coatings and grades of steel The carbon cowteat ofthese sttel8 must not exceed (0.12 percent carbon, andthe yield strength must be less dum or equal o 400 MPu unless otherwise specified. Pig SBRTE20 ceesannen tineRD _Enysinearing Specification [rome aor se [REV [Rare eeirnmeaa OUTLINE 1 GENERAL Ik SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS. UL TEST FROCEDURES AND REQUIREMENTS. OL Visaul, Optica) And Ultrmonic Iaspectians TLL Surtice (Slag Oxides TILL2 Skipg Inset Welds TIL13 Surface Volds M14 Porosity TLS Underat TILLS Hlakes(oc Pinkales) MLL7 Zine Lines La Cracks TLL9 Leck OfFosion / Penevetion TILLJ0 Weld Joi Mieromch LI —Dimeasloon! Inspections 2) Beod Width 22 Well font Mismach 123 Weld Face Convery 124 Weld Rox Convedty M125 Wed Fuce Concavity T26 Weld Root Coocwvity TL27 Beed Comionity M28 Bend Lecatioa 10131 Sueas/ Formabiity (Cop) 132 Axl Teasloo Tert 11133 Hardness Increase T1134 Mint Beading Radtes Perpendicular To Tha Bead LA Handling Of Fiabbed Perts (Vorthdrmerice only) TLS Cormcon Protection TV. REVALIDATION REQUIREMENTS ¥, INSTRUCTIONS AND NOTES YL COMPILATION OF REFERENCE DOCUMENTS Attachmest A: Masb-Soom Welficg Process (Earapa oxy) Pe ESE gee