re Bes [Paar ame Projection Welding of Nuts and Bolts [PART NUMBER Engineering Specification ESBMSA-1N265-AA, ate er] FR REVISIONS, oR. ox REFERENCES ESEAED-1A252.A8 ow 28, 2008| AC Inia! Release of Gabal Engnwatag Spoctioaton PREPAREDIAPPROVED BY [EB € 12179768 000 4 Larsson (VGO)_J Hover (FOE) CHECKED EY | CHECKED EY | T.Goon(FNA)_ | 8. Angot (NA) 'S Mowans (FNA) | 6. Mucter FOE) ‘CONCURRENCEAPPROVAL SIGNATURES Ford of Europe eT due LK aualy Ofice tee ty i (Cretan. § Mat Eng la. tuetiet 2 bYinrfoa | CONCURRENCEIAPPROVAL SIGNATURES Fora North America [PD Bog ana a a See 'p-Tempe ‘CONCUARENCEAPPROVAL SIGNATURES Yow Cars [Engineering Suncards Manager hg $7 FRAME 7 OF 24_(REVA PO. May 1986 3947a1e {Previous edtions may NOT be used)as [RamereToots eee Engineering Spe ESBMSA-1N265-AA OUTLINE I, GENERAL LI Scope of Engineering Specification, General Statement 1.2 Process Deseription ... 13 Design Guidelines ....... 13.1 Fastener Size Relative to Base Sheet Metal Thickness 13.2 Hole Size in Base Sheet Metal 13.3 Fastener Strength 13.4 Flatness of Base Sheet Metal 13.5 Location of Fastener 14 Applicable Materials 15 Joint Identification Symbols Il, SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS. III. TEST PROCEDURES AND REQUIREMENTS .. ILL1 Applicability of Test Procedures for PV- and IP-Test Phases ...... 111.2 Weld Parameter Monitoring .. 11.2.1 Introduction 11.2.1 Welding Current over Time [A] 11.2.2 Electrode Force [N] 113 Dimensional and Visual Inspect 1113.1 Introduction 1113.2 Gap between Fastener and Base Sheet Metal 1113.3 Burn Through into Base Sheet Metal 11.3.4 Deformation of Fastener Body 113.5 Cracks 1113.6 Flash on Threads 11.3.7 Metal spatter II1.3.8 Position of Nut on Component 113.9 Perpendicularity of Bolt n of the Welded Fastener 10 1s 15 16 16 PO, | 3947aze Nays it tare ooo Projection Welding of Nuts and Bolts [ esemstnsnn<> S§ Engineering Speci ation [Fame oF 2s REV-LET.[PARTHO. ESBNSA-TIOOSAA TILA Inspection of Section Cuts. 7 114.1 Introduction 1114.2 Gap between Fastener and Base Sheet Metal 1114.3 Penetration into Base Sheet Metal 114.4 Porosity UIL4.S Cracks 1114.6 Inclusions 11.4.7 Hardness ILS Destructive, Non-Destructive, and Functional Testing .. 19 ILS. Introduction IIL5.2 Static Tensile Test T1153 Torque Test I1L.5.3.1 Torque Test (Destructive) 115.32 Torque Test (Non-Destructive) 11.5.4 Push Out / Pull Out Test (Destructive) 1113.5 Hammer/Chisel Test 1115.6 Thread Test 1115.7 Leakage Test HIL5.8 Durability / Fatigue Test 111.6 Permissible Repair Methods .. 2B IV. REVALIDATION REQUIREMENTS. INSTRUCTIONS AND NOTES .... 4 VI. COMPILATION OF REFERENCE DOCUMENTS Projection Welding of Nuts and Bolts. | eseMsA-N26s-AA | eae]<> Ss Engineering Specification FRAME 4 OF 24 REV. LET. PART NO. ESBMSA-1N265-AA 1 GENERAL LI Scope of Engineering Specification, General Statement This Engineering Specification is issued to define design factors and performance requirements applicable to the joining of nuts and bolts using the projection welding process. It covers manual and automated projection ‘welding on sheet steel having a minimum of 0.5 mm and a maximum of 3.0 mm thickness. It covers metric dimensions up to M16 and property class 4.8 and 8.8 fasteners, but not fasteners of the property class 10.9. This Engineering Specification harmonizes the req applicable to new model programs. sments globally for Ford Motor Company and is This Engineering Specification does not replace the requirements of the Ford world-wide fasteners standards, which focus on the performance of the fastener itself, Instead, it defines the requirements for the projection ‘welded joint between the fastener and the base sheet metal. Applications that require special fasteners are not dealt with here and require a case-by-case approval by the appropriate Fastener, Body and Manufacturing, Engineers. This Engineering Specification is a supplement to the released part drawing, and all requirements herein must be ‘met in addition to all other requirements of the part drawing. Each section specifies the minimum measures necessary for documenting compliance with this specification, This Engineering Specification is intended to evaluate specific characteristics as a supplement to normal material inspections, dimensional checking and in-process controls, and should in no way adversely influence other inspection operations, Preparation and submission of an acceptable control plan are the responsibility of the manufacturing source. The manufacturing source will retain the original control plan and any later revisions per QS-9000 and provide a copy to the design responsible Product Engineering activity 1.2 Process Description Projection welding is a resistance welding process that produces a weld by the heat obtained from the resistance to the flow of the welding current. The resulting welds are localized at predetermined points by local or annular projections. Figure | shows the sequence of the projection welding process. = tl __y ample of Projection Weld Sequence yor | 3947aZ@ |novzn20e | | Projection Welding of Nuts and Bolts | esemsa.nzes.aaSs Engineering Specification Figure 2 shows the representative weld fasteners covered in this document. Fasteners not shown here are not covered by this engineering specification and need to be treated on a case: PART NO. ESBMSA-1N265-AA neular projections (b) Weld bolt with “banana” projections (©) Weld bolt with four circular projections (NOT recommended for new FORD designs) 10us ring projections The Pitot 7 . = Ct projections projections (@_ Flanged round weld nut with thiee circular (Flanged hexagon weld projections (&) Flanged hexagon weld nut with continuous ing | () Flanged round weld nut with continuous ring projection projection Figure 2: Projection Fasteners Covered by this Specification hyo | 3947a2e Projection Welding of Nuts and Bolts | essmsa-1n255.0a [Mave Sav etaneovo<> Ss Engineering Specification [FRAME 6 oF 24 REV.LET. | PARTNO. ESBMSA-1N265-AA 13 Design Guidelines The following design guidelines describe the generie conditions for the proper projection welding application of huts and bolts. It is the Design Engincer's responsibility to determine the design requirements for the weld fastener necessary to achieve the design objective. Many factors influence the choice of fastener type, such as loading conditions, sheet thickness and grade, manufacturing preferences, quality assurance, etc. In general, weld nuts ate preferred over weld bolts. One should thoroughly consider the funetionality of the fastener, whether itis intended to carry high static and/or fatigue loads, or only serve as an attachment point for earth wirings (grounds). [tis important to establish which part of the fastener joint system is the limiting factor (thread strength or the fasteners attachment to the sheet part) in order to avoid expensive over-dimensioning. For lower loads and small thread sizes (M6 and M8,) mechanically joined fasteners and weld fasteners could be considered as equal in their ability to carry load. In which case, the manufacturing process may dictate the type of fastener to use, For higher loads and larger thread sizes, a welded fastener is recommended. For these condi important to locate a weld nut on the side of the sheet component which is opposite to the loading direction, With such a design, the occurrence of weld discrepancies are of minor importance to the performance of the {joint 2s the fastener has to be pulled through the sheet or nut plate. For high fatigue loads, fasteners with a continuous ring projection are the best choice, although these are also more difficult to weld. 13.1 Fastener Size Relative to Base Sheet Metal Thickness ‘Table 1.3.1 lists the permissible range of base sheet thickness for the respective size and type of nut and bolt. Minimum ~ Maximum Sheet Metal Thickness fl TonndHleregon | Rouai/Hexagon | Round Uiexagoa Thread Size | SavareNat_| "Nivand Bolt” | -Nutand Bolt” | _-Nutand Bot Four | Tires Banene- | Contauows Ring] Three Cireular Peojertions_| Shaped Projectons | Projection Projections M6" 0.5 - 1.5 0.75 - 1.25 0.5 -1.5 05-08 Ms 0.75 -2.5 09-20 0.75- 2.57 0.8-2.0 aio —[ “075-35 Tas 3 U5 28 25-30 TiewtNF | — 15-30 S30 MI2 1.0-3.0 3.0 10-30 15-22 MI4 15 -3.07 15-307 15-24 MIG 1.5 -3.07 15-3.0” Ty These values san be used for an Ms read applied on an Ms nut body. 2) Currently under validation in test program. Can be used until further notice 3) Weld Nas only ‘Table 1.3.1: Minimum and Maximum Sheet Metal Thickness for Various Weld Fastener Sizes, Note: Banana projections are assumed to match WES02 size requirements and circular projections are assumed to match WES00 size requirements. Deviations from these guidelines require the approval of both the relevant Body and Manufacturing Engineering departments, For optimum performance of non-standard fasteners: # Projection diameters/widths should be at least 2.5 times the attaching sheet thickness «Projection heights should be at least 0.5 times the attaching sheet thickness He Teen | 3847a2@ | won nm | Projection Welding of Nuts and Bolts | esausa-in2es.anFRAME 7 OF 24 REV. LET. Engineering Specification PARTNO. ESBMSA-1N265-AA 13.2 Table 1.3.2 lists the applicable she hole diameter for flanged and piloted weld nuts and weld bolts, Hole Diameter for Weld Nuts [mm] | Hole Diameter for Weld Bolts mm] Thread size Flanged Nut” Piloted Nut +05/-00) 015/00 +057-000) Me 7 o0 63 Ms 95 13.0 83 M0 na 15.0 103 7716-20 UNF 4 103 MIZ Bo 17.0 123 Mig 15.9 19.0 MIG 18.0 1) The category "Flanged Nat” includes Square Nu, Table 13.2: Hol 1¢ for Various Weld Fasteners 13.3. Fastener Strength After the welding process, weld bolts and nuts must still meet the tensile and/or proof load values for the property class specified in the Worldwide Fastener Standards or on the individual part drawings. ‘© Actual proof load values for bolts - as referenced in the Global Fastener Standard WA960 - are tabulated in ISO 898-1 for various property classes. Actual proof load values for nuts - as referenced in the Global Faste in ISO 898-2 er Standard WE960 - are tabulated Figure 3 illustrates three potential loading conditions for fasteners that need to be considered in design. ‘Although the figure shows normal loading, actual design may require off-normal loading. | et 1 — ee (a) Push-Out (b) Pull-Out (©) PullThrough Figure 3: Potential Loading Conditions for Welded Fasteners 13.4 Flatness of Base Sheet Metal FFigure 4 outlines the area condition needed to robustly weld a fastener to the parent sheet metal Ry Outer radius of the weld fastener fees (aut size dependent, but typically ee 15 mm for MS, M6, and MB nuts; Tes ) Functional hole diameter [mm] according to Table 1.3.2 ‘Area with flatness requirements where O, = 2x (Ry + 2) [mm] Figure 4: Flatness Requirements [ho 3947 AZ | sn 2e 200 ANZB5-AA ro oz38 208s agp_| Projection Welding of Nuts and Bolts | EspMsA-1N205-AA,<> Ss Engineering Spe: [FRAME 8 OF 24 REV.LET. | PARTNO. ESBMSA-1N265-AA ] 13.5 Weld Equipment Clearance The product design shall provide sufficient clearance for the electrodes of the production weld equipment. The two zones to consider are above and below the welded fastener. The upper electrode is applied on the same side as the fastener, while the lower electrode is applied on the opposite side of the fastener. Figure 5 illustrates various joint geometries. Tables 1.3.5-1 and -2 define the required clearances for different fastener types and sizes, Option 1 Option 2 NOTE: Option 3 is NOT available with Weld Bots Figure 5: Electrode Clearance Requirements for Various Configurations Fastener Type [ A> B> D> H< I> Square Weld Nuw 30 oo 180 30 Ta) Flanged Weld Nuts |__38 76 60 200 30 140) Weld Bolts 30 o @ NA Ed TwO+ 07 [Nominal length of bol Table 135-1: Required weld equipment clearances for yensions A-D, H-L. All values in mm. ‘Square Weld Nuts ‘Thread Size and Weld Bolts E> 16 F> G> ex Ge Me a7 D 5 Eg 18 MB 40 20 40 45 20 3 Mid 8 22 aS 45 23 23 M12. 46 23 30 30 25 25 Mit ® 25 30 30 25 25 MiG 32 26 60 oo 30 30 Table 1.3.5-2: Required weld equipment clearances for dimensions F and G. All values i Deviations from the recommended clearances require the approval of both the relevant Body and Manufacturing Engineering departments. The possibility of using special electrodes to get into smaller spaces may be considered, but this will lead to higher equipment or operating costs. 3047a2e PO Ee Now 28 2008 Projection Welding of Nuts and Bolts | esamsa.1Nz6s-AaGP & FRAME 9 OF 24 REV. LET. PART NO. ESBMSA-1N265-AA Engineering Specification 14 Applicable Materials Base Sheet Metal ecification This Engineering Specification covers the use of the following steels categories in uncoated and coated condition: FORD MATERIAL SPECIFICATION NO CATEGORY | TYPES OF STEEL “Applicable to ‘Applicable to Ford of Europe, VCC Ford North America MS | Mild Steok, Hot and Cold] WSS-MIAS4-ATAT WSD-MIASSSAVAZASAT Rolled, Low Carbon WSS-MIASMS-AVAYASIAG DR ent Resistant Siecls WSS-MIAMI-ATADIAWAW | WSS-MIASIT-ATADATAN including Bake Hardening, | AS/AO/A7/AB/ ASIALO ASIA! ATIASIASIAI0 High Strngth IF, Isotropic and Rephosphorised Steels HSLA | High Strength Low Alloy | WSSMTASIOATARAS WSEMIATISET AT Steels WSS-MIAMT-AVANAS DPT] Dual Fhase Seals WSS-MIAMEATADAZAW ] WSSMIAMEATATATAT |AG/ATIAR/AD ASIAGIATIASIAS TTASST-ATAD WSS-MIASS-ATANAD Tsp, WSS-MIATESD. WSSMIASIEAS WSB-MIAI22-AT (Uncoated) WSS-MIA357-A1 (Coated) WSS-MIA3S8.A1 (Coste) Tae Boron Steeks BORON T) DP. Trip. MSW, and Boron Steels are included in this Engineering Specification within a linited applicability. Use of these materials needs to be checked with he relevant Body and Manufacturing Engincering Deparuments ona case-by~ case bass 2) WSS-M99P39-A /A2/A3/A4 performance specification must be called out with these Boron steels ‘Table 14-1: Applicable Categories of Base Sheet Steels Covered by this Specification ‘The text of the referenced Ford material specifications is available from the Following web link bttp://www.mats.ford.com/mats/seripts/spee_by_miICat,html, Metals 1A-99A. New steel types are under constant development, In the case of steel types not covered by Table 7 of this Engineering Specification, the relevant Body and Manufacturing Engineering departments shall be contacted. Laminated stee! applications are not covered by this Engineering Specification and need to be treated as special case. For such application its preferred to use the punched fastener rather then a welded one, Standard e Sheet Metal Coatings Projection welding of fasteners supports the following coatings in all combinations: ification Type [Specification No. | Coating Type (GOG60G EL, S0G50G EL | WSS-MIPOS-A Flectro-galvanized SSAS5A HD WSS-MIPO4-A Galvannealed {60G60G HD, 30G30G HD | WSS-MIPOA-A, Hot Dip Galvanized WSD-MIA395-A2 | Hot Dip Aluminized Table 1.4-2: Standard Base Metal Coatings Covered by this Specification, ‘The use of coatings not listed in Table 4-2 requires the approval of both, the relevant Body and Manufacturing Engineering departments, [fs von | 3947a2e Projection Welding of Nuts and Bolts | EseMss.1N265-4ALD = Engineering Specification FRAME 10 OF 24 REV. LET. PART NO. ESBMSA-1N265-AA See Identification Symbols ‘The identification symbols shall be in accordance with the individual requirements of the Ford Motor Company brands as outlined below: © Ford ‘The current Ford Engineering CAD and Drafting Standard D-3 (Welding Symbols and Specifications) does not require a specific identification of nuts and bolts welded in accordance with this engineering specification. + Volvo Car Corporation ‘The fastener symbols shall be in accordance with Volvo Car Corporation standard VCS 5027.4, Indication of single and combined joints, available at http:/wwww.tech.volvo.se/standard/eng/stdnum.himl Il, SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS Production Validation (PV) tests are used to obtain an initial estimate of the process potential to produce parts ‘that conform to engineering requirements, and to identify causal or predictive relationships between significant design and process characteristics (to be used for process control). The tests must be completed successfully using initial parts from produetion tooling and production process before Part Submission Warrant (PSW) approval and authorization of production parts can be issued. Sampling plans for PV testing must be included in the control plan, In addition, tests can be done on prototype level parts or vehicles to the same extent as outlined for PV-testing. This does not replace the necessity to run PV-phase testing as described above. In-Process (IP) tests are used to further understand the relationship between significant desian and process characteristies and to establish a basis for continuing improvement. Tests must be completed with production parts on an ongoing basis. Sampling plans for both IP testing and evaluation of the significant process characteristies must be included in the control plan. When the process is found to be out of control or the test acceptance criteria are not met, the reaction plan approved in the control plan shall be invoked. Welded fasteners that do not meet the requirements outlined in Seetion IL., Summary of Production Validation and in-Process Tests, and Section IIL, Test Procedures and Requirements, of this Engineering Specification need to be repaired following the reworking procedure as outlined in Section II. ‘The tables that follow summarize the various PV and IP tests and the acceptance parameters for each. They form the basis on which to develop a complete control plan for these and their related significant process characteristics. The control plan will include frequencies, sample sizes and reaction plans; see Ford Qu: System Requirements, QS-9000. 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(dD) 820044-U] pue (Aq) woHEPHEA YoRIMporg 405 soAMpadoad 189.50 GNGEHAdY 1-1 SINFNAMINOTY ANY SANNGIION LSAL “TT VV-S92NI-VSWES3 “ON LUVd | aT nae | uoneoyjseds Buyeeul6u3 eS Sa ve 40 Sb aWvus<2 Ss Engineering Specii aan 16 OF 2 REV LET. [PARTNO. ESBNBATWRBE-AK 111.2 Weld Parameter Monitoring 112.1 Introduction Projection welding equipment used for the production of parts according to this Engineering Specification shall be equipped with a built-in weld parameter control and monitoring unit. ‘The target values and the upper and lower tolerance limits for the parameters below shall be determined in Product Validation (PV) tests individually for each projection welding application. They shall be included in the process control plan and later be applied on the basis of a 100 % sampling rate for In Process (IP) conformance testing. Non-conforming welds should be marked and processed for additional inspection and possible rework 11.2.2. Welding Current over Time [A] During [P-monitoring, the welding current over time shall stay within the welding current window as defined in PV-testing individually for each projection welding application. 11.2.3 Electrode Force [N] During IP-monitoring, the electrode force shall stay within the fore window as defined in PV-testing individually for each projection welding application. Note that 100% sampling may only be possible if the weld ‘Bun is equipped with a load cell or transducer. 11.3 Dimensional and Visual Inspection of the Welded Fastener 1113.1 Introduction Dimensional and visual inspection of welded fastener is performed as “naked eye-inspect scales or calliper gages can be employed to: and, if required, ‘© Verify that the number and the location of the welded fasteners are as outlined on the engineering drawing or the relevant CAD model. * Detect obvious discrepancies such as out-of-position conditions, unacceptable gap conditions, base sheet metal bumn-through or weld fastener deformation, 1113.2 Gap Between Fastener and Base Sheet Metal After welding, the fastener matching surface shall lie on the base sheet metal. However, a maximum gap of 0.1 mm may be allowed. 1113.3 Base Sheet Metal Burn-Through Not permissible. 11.3.4 Deformation of Fastener Body Plastic deformation of the fastener caused by over-heating is not permitted. Non metallic inserts in nuts shall not be damaged. UL3.5 Cracks Cracks in the base sheet metal are not permitted. 1113.6 Flash on Threads ‘The weld fastener or screw attachment is discrepant if weld flash ison the threads, or area to be threaded, results in excessive assembly driving-torque values. Poa | 3947aze Mayor at rare oe Projection Welding of Nuts and Bolts. | Es@M5A.1N265-AALDP Ss Engineering Specification [reine Earioetar REVIT, [PART NO. ESGUGA-ANEREAR 7] 1113.7 Metal Spatter Fasteners cannot be placed on Class | surfaces. For Class 2 (Class 3 or 4 for VCC) surfaces, metal spatter (molten metal that has resolidified) is not permitted, Metal spatter on Class 3 (Class 5 for VCC) surfaces should be avoided, but may be permitted if it does not affect internal or external customer requirements, 1113.8 Position of Nut on Component The position of a nut, including tolerance, must be specified on the engineering drawing or relevant CAD model Locating a nut outside of this position is not permitted. Visual check should be carried out to ensure no obstructions (shadowing) of base sheet metal due to off position of the nut. 1113.9 Perpendicularity Bolts should be welded perpendicular (90 degrees) to the base sheet metal. At a maximum, this type of fastener can be five degrees off perpendicular I1L4 Inspection of Section Cuts 11.4.1 Introduction Dimensional and visual inspection of a section cut gives an insight into the weld properties and could be used during the series of PV- or IP-tests. Section cuts should be analyzed as they help to detcct discrepancies such as large gaps, insufficient penetration, porosity, cracks, oF inclusions. 1114.2 Gap Between Fastener and Base Sheet Metal The projections shall be fully fused, However, a maximum gap of 0.1 mm may be allowed, as shown in Fig. 6. 0.1 mm Figure 6: Fusion with Maximum Gap of 0.1mm Pegg | SO47ARE | nessa | Projection Welding of Nuts and Bolts | esemsa-1n265.aaa s FRAME 18 OF 24 REV.LET. | PARTNO. ESBMSA-INZOS-AA ] Engineering Specification 11.4.3 Penetration into Base Sheet Metal Target is 50 % of initial projection height value, Minimum requirement is 30 % of the initial projection height value, Weld should not extend beyond 90% of base sheet metal thickness. P™ Depth of penetration [03thys P <05*hy Figure 7: Fusion with Penetration into Base Sheet Metal 1114.4 Porosity Pores are cavity type discontinuities formed by gas entrapment during solidification. Pores should not be Present, but are permitted in the center of the weld at an individual or cumulative size of 25% of the weld area. 1.4.5 Cracks Cracks are fracture type discontinuities characterized by a sharp tip and high ratio of length and width to ‘opening displacement, Cracks should not be present, but are permitted in the center of the weld at an individual of cumulative size of 20% of the weld width. 11.4.6 Inclusions Inclusions are foreign solid materials such as impurities entrapped in the weld. Inclusions should not be present, but are permitted in the center of the weld at an individual or cumulative size of 20% of the weld area. Figure 8: Fusion with Imperfections NOTE: The relevant Body and Manufacturing Engineering departments shall be consulted if these imperfections occur off the center of the weld and/or if more than one discrepaney occurs in a single weld. [ Mayeo | 3947a2e | rm me, | Projection Welding of Nuts and Bolts | esaMsa-1N20s-aAGB & [FRAME 19 OF 24 REV. LET. _| PARTNO, ESBMSA-1N265-AA Engineering Specification 114.7 Hardness Hardness testing shall be performed in accordance with ISO 14271 on weld section cuts to determine the \Vickers hardness (low-load range, HV 1) of the weld, the heat-affected zone and the parent sheet metal ‘Table 1114.7 lists the permissible increase in hardness based on the initial parent sheet metal hardness, Initial Parent Sheet Metal Hardness [HV 1) Hardness In Weld (av 1) <120 = 350 ‘The material used and the welding techniques = 10... <200 = 450 employed shall be such that the hardness of the 5200... < 300 =550 weld and the heat-affected zone do not exceed > 300 = 600 the limits listed in Table 11.4.7. ‘Table 1114.7; Hardness Increase Limits NOTE: Consult the relevant Body and Manufacturing Engineering departments in case these limits cannot be met TILS Destructive, Non-Destructive, and Functional Testing HL5.1 Inteoduetion ‘Weld strength tests are performed as PV- and IP-tests to ensure that the projection weld joint meets the individual performance requirements in terms of static and dynamic loads, For destructive tests, the acceptance criteria are based on the theory that the application of the weld process shall rot weaken the integrity ofthe joint in any way. For steel with tensile strength >, 600 MPa and/or high material ‘gauges relative to the fastener size, a fracture during a test can occur. Fractures in welds shall show evidence of ‘good metal fusion, ic. the interfacial fracture face is crystalline, with possible distortion of the parent metal around the weld For non-destructive tests, the load or torque applied shall indicate the fastener is fused to the base sheet metal ‘without partial or complete separation of the joint. 11.5.2 Pull Through (Destructive) This test consists of tearing the fastener completely ofT the sheet by pulling the fastener using a machine specifically set up for this purpose. The test specimen is loaded gradually and continuously until separation ‘occurs. The load to separate should exceed the proof value for specified fastener. MIL.5.3. Push-Out / Pull-Out Test (Destructive) This test consists of tearing the fastener completely off the sheet by pushing or pulling the fastener using a machine specifically set up for this purpose. The push-out test device shall be shaped as a tool with a pin for each nut size and a flat tool to press on the threaded-in serew head. Examples are shown in Figures 9 and 10 The test specimen is loaded gradually and continuously until separation occurs. ‘¢ Fasteners with > 3 weld projections ~ no more than one discrepant projection is allowed. ‘© Continuous ring projection fasteners — at least 70 % of total ring shall be fully welded. PO gn | 9947aze | nar nee Projection Welding of Nuts and Botts | ESBMSAINZS5-AA ‘|GP Engineering Spec FRAME 20 OF 24 REV. LET. PART NO. ESBMSA-1N265-AA _ To be designed in accordance with the Press, Nut a b { Size (mm) | (mm M6 45 8 M8 65 10 b MIO 80 ul MI2 95 2 le Mia io [4 _ MI6 125 18 9: Example of Nut Push-Out 01 Table HII.S.3: Relationship Between Size of Push-Out Tool and Nut Size Example of Counterhold to Pressing Tool ‘* For HP nuts M6 and M8 and unthreaded ground nuts UTG M6 and UTG M8, the inner diameter of the counterhold is 24 mm, For HP nuts M10 and M12, the inner diameter of the countethold is 30 mm For subframe nuts M12, M14 and M16, the inner diameter of the counterhold is 50 mrn, 3mm Edge broken 50 mm 10 mm. 20 mm jure 10: Example of Counterhold to a Pressing Tool Majo | 9947 Az | EetEyaon_[ Prlecton Welsng of ts and Bots | anna naeeaaPp § Engineering Specification Trrame’21 oF 2 REV. LET. PART NO. ESBMSA-1N265-AA ISA Torque Test ‘The strength of a projection weld joint can be tested with torque applied to the nut or bolt. A torque wrench that contacts the fastener shall be tailored to suit the fastener geometry. The torque wrench shall be included in the tool control plan, 11.5.4. Torque Test (Destructive) Destructive torque tests are performed to verify the integrity of the joint. When a destructive torque test is, performed, the torque shall be applied gradually and continuously until separation oceurs. No partial or complete separation of the welded joint shall occur before the minimum destructive torque value listed in Table HILS.4.1 is exceeded. After separation the joint shall be inspected visually to check compliance with the discrepancy limits listed below. See IILS.1 for the permissibility of a fracture in the weld. The relevant Body and Manufacturing departments shall be contacted if the applied torque results in excessive deformation of the base sheet meta. In this ease, the push out test shall be the preferred test method. ‘Table 1 © Fasteners with > 5.4, jum Inspection Torque [Nm] icing Square and Hexagon Nut__[ Weld Bolt ‘Weld Bolt ize Three oF Four Projections; y Coutnares Ning Projeetos | Css” | Clams Me 20 75. re MB. 0 16 33 Mio 70 33 70. 716-20 UNF 70 33 70 Miz 130 Mit 200 16 300 an be found in current designs, but fs not to be used in new models Minimum Torque Values for Destructive Testing, 3 weld projections ~ no more than one discrepant projection is allowed © Continuous ring projection fasteners ~ at least 70 % of total ring shall be fully welded. 111,5.4.2 Torque Test (Non-Destructive) Non-Destructive torque test are performed to verify that the fastener can robustly withstand the assernbly torques used in production, When a non-destructive torque testis performed, the torque shall be applied gradually and continuously to the minimum torque value shown in Table II1,5.4.2. ‘The tests shall verify no partial or complete separation of the welded joint and no cracks occur before the mini num non-destructive torque value is exceeded. The maximum torque shall not exceed 110% of the torque defined in Table 111.5.4.2 and be limited to preclude the risk of permanent deformation of the fastener or the base material The relevant Body and Manufacturing departments shall be contacted, in case that the applied torque results in deformation of the base sheet metal. Note: The minimum and maximum torque values shall be documented in the contro! plan. [ho 3947 a2 | vo 2,208 Mayo eit arc one Projection Welding of Nuts and Bolts ESBMSACINZ05-A8,asa Engineering Specification FRAME 22 OF 24 REV.LET. | PARTNO. ESBMSA-1N265-AA ‘Non-Destructive - Minimum Inspection Torque [Nm] Square" and Hexagon Nut_| Weld Bolt Weld Bolt ‘Three or four projections | Class 4.8 Class 8.8 MG, 11 6 115 MB 28 2 28 M10 35 27 58 7716-20 UNF 35 27 55. M2 = 2 z Mid 153 MI6 230 Bul is not fo be used in new models Table 1115.42: Minimum Torque Values for Non-Destructive Testing NOTE: For hexagon and round body weld nus, the wb torque shall be applied to the body. Alternatively, if one this isnot possible, it can be applied to a screw mounted 1 in the nut (see Figure 11). The serew shall have a head ina that fully overlaps the weld nut oH Figure 11: Example of Assembly Tool The non-destructive torque testis less suitable for weld nuts and bolts with a continuous ring projection. In this case, destructive testing is mandatory. Non-destructive testing shall always be supplemented with destructive testing when changing electrodes as well as in connection with new installations and audits, UIL5.5 Hammer/Chisel Test The strength ofa projection weld joint can be tested with an impact force applied to the fastener. A hammer or chisel is used to tap the fastener to ensure it is fused to the base material l1L5.5.1 Hammer/Chisel Test (Destructive When the hammer/chisel test is performed as a destructive test, the impact is applied until the fastener separates from the base sheet metal. Fracture of the specimen is acceptable in the base metal, HAZ, or fastener. Fracture in the weld is not acceptable. See Section III.5.1 for permissibility of fractures. U11.5.5.2 Hammer/Chise! Test (Non-Destructive) When the hammer/chisel testis performed as a non-destructive test, the impact is applied to the fastener in a way that precludes the risk of permanent deformation of the fastener or the base material. No partial or complete separation of the welded joint is permitted 1115.6 ‘Thread Test Functional tests on threaded nuts shall be performed with thread gages. An example of one is shown in Figure 12. ‘The gage would be applied through the sheet panel and all the way tothe top of the nut. The test shall be applied to detect spater on the threads, damaged threads due to overheating, and bad top thread due to damaged electrode, . Figure 12: Example of a Thread Gage PO Mayor Projection Welding of Nuts and Bolts | ESBMSA-IN265-AA<> 3 [Fae 23 oF 20 REV_LET[PARTNO._ESBWEACINZOSAA Engineering Specification 11.5.7 Leakage Test Functional leakage test shall be performed in accordance with VCS $911,79 or locally-approved procedure. 1115.8 Durability / Fatigue Test Full vehicle durability testing according to CETP 00.00-R310 (PASCAR test) shall be performed on a test vehicle equipped with the relevant welded joints. These joints shall be welded to mect all requirements of this specification. No fatigue cracks in the welded seam and no lack of compliance to full vehicle PASCAR Phase | ‘and completion of half of PASCAR Phase 2 - testing. 11.6 Permissible Repair Methods If possible, repair is done by projection welding a new weld nut or weld bolt. Alternatively, gas metal are ‘welding (GMA-W) can be used if approved by the responsible Design Engineering department. Two fillet ‘welds are required, each 25% of the circumference of nut or bolt outer diameter and located on opposite sides of the fastener. The wire use shall conform to ESB-M4A170 (AWS A5.18M Grade ER70S-3 or -6) welding wire for North America or WSS-M4A182-A for Europe. NOTE: Leak tight applications may require special repair considerations that need to be agreed upon by Body and Manufacturing Engineering departments, IV. REVALIDATION REQUIREMENTS, Any of the following conditions that affect the Projection welding operation require a re-run of Production Validation (PV) tests as agreed upon by the relevant Body and Manufacturing Engineering Departments, © Process Change - Any change in the process which could alter its capability to meet the design requirements oF durability of the product. This includes: (© New, different, relocated, or rehabilitated production machinery or equipment ‘© Any change in subcontracted products or services including the use of engineering-approved alternate materials ‘© Changes to rework methods (© Changes in the sequence of operations (© Changes in chemical compounds such as lubricants, which are part of the product \gineering Change - Any change in the part(s) initiated by Ford Motor Company Material and Coating Change - Any change in the material or coating, when optional materials or ccoatings are specified. This includes: ‘© Aswitch from mild stecl to high strength steel with a yield strength > 260 MPa © Acchange in steel supplier for steels having a yield strength equal to or exceeding 310 MPa (representing DP600) in the “as received condition” Sub-Supplier Change - Any change in the source of subcontracted components. Adopting Optional Design - Any change where the supplier incorporates optional designs specified on the released engineering drawing or relevant CAD model. NOTE: See QS-9000, Control of Subconsracted Suppliers; Retention of Inspection and Test Samples; Notification of Completion of Inspection and Testing: Changes in Manufacturing Process; Change Approval Certain process parameters will have a great influence on the weld quality. The control plan, as defined in Ford QS 9000, is an essential part of a quality product. Some process variables to include in the control plan could be: + Electrode force + Weld current over time PO, | 3047A2e | revs, | Projection Welding of Nuts and Bolts | esoMsa.nzosan23 cngiancng species [Frane_20 oF 2 REVLET. | PARTNO._ESENGAANDSSAK ] V. INSTRUCTIONS AND NOTES Control plans address all significant design and process characterstie, which include all ES tests and Control Item characteisies. They describe the process potential studies that wil be performed for product validation (including PV tests) and the ongoing product and process evaluation for continuing improvement (including IP tests). They include acceptance criteria, sample size, frequencies, data analysis methods and reaction plans. ‘The control plan is developed, and updated as necessary by the manufacturing source in conjunction with the design-responsible produet-engincering activity and other appropriate functions such as Supplier Technical Assistance (STA). The control plan defines the management of the upstream production process and part variables (significant process characteristics) that affect the outcome of the ES tests or other significant design characteristics. The control plan also identifies the specific ES tests, with their sample sizes and frequencies that will be performed in order to Confirm whether the process is being managed effectively Further identify significant process characteristics Evaluate performance of marginal processes Better anticipate the customer effect of proposed process improvements. For any part on which ES tests have been specified, the manufacturing source must present the control plan and any revisions to the design-responsible product-engineering activity for review. This Product Engineering activity has flexibility to honor business relationships with suppliers having proprietary processes. Examples of formats for control plans are shown in Quality System Requirements, QS-9000. Internal reference documents can also be found in procedure VOPQUG-0SI (Control Plans ~ Vehicle Operations Procedure — Global). VI. COMPILATION OF REFERENCE DOCUMENTS A. QS-9000, Quality System Requirements B. Ford Material Specifications available at httpy/Avww.mats.ford.com/mats/scripts/spec_by_mtlCat,htm|, Metals 14-994. . Volvo Car Corporation Standards available at hitp://www.tech, volvo se/standard eng/stdnum.htm! + VCS 8632,49 - Projection Welding of Weld Nuts * VCS 5027.4 ~ Joining of Thin Sheet Metal Structures (Symbolic Representation) D. Ford Engineering Specification - Sheet Metal Surfaces and Edges (ESF7SB-11007-AA) available at hitp:/forddoc.secure24,ford.comv E, JoinNet Database available at hitp:/abwux0 4 gothenburg.vec.ford.convintdatab/joinnet F. 180 1427122000, Vickers hardness testing of resistance spot, projection and seam welds G. Vehicle Operations Operating procedure VOP QUE-612, Uniform test and Evaluation Program For Welding and other joining Operations; available at hitp//www.vogoeu.ford.com 1H. ISO 898: Mechanical properties of fasteners made of carbon steel and alloy steel. States property requirements for threaded bolts and nuts 1. Ford Worldwide Fastener Standards available at hitpsi/wivw.tc2,ford,com/ts/METS/Shared%20Documents/Standards/fastener_standards_ te J. EUCD Technical Bulletins (referred to as "Red card") available at hupi/www.rd.volvocars.ford.com/std/fastidoc/eued tid 046.pdF K. Weld Quality Program Procedure, VOPSSN-008, available at hitp:/www.vo.ford.com/ss/procedures/procd- files/ssn008e.paf Mayoo | 394726 | nc: 0, | Projection Welding of Nuts and Bolts | ESBMsa.1N205-A connect.him