Klass.-Nr./Class No.

04 87 1 September 2003

Norm vor Anwendung auf Aktualität prüfen/Check standard for current issue prior to usage.
Drawn Arc Welding of Panel PV
Segments 1604
Requirements and Tests
Konzernnorm
Descriptors: welding, arc welding, drawn arc, butt-welding
The English translation is believed to be accurate.In case of discrepancies the German version shall govern.

1 Scope
This standard applies to panel joints that are butt welded using the drawn arc method. This welding
method is comparable to stud welding according to VW 01107. A panel section/panel segment is
joined with an uncoated or surface-treated (e.g., electrolytically zinc-coated or hot-dipped) steel
panel of 0,5 to 3,0 mm thickness by drawn arc welding.
The Test Specification is applied in sample tests, acceptance tests, and series production monito-
ring tests and is used to evaluate the seam quality and strength of the welded parts.
The welding suitability of the materials used must be ensured. The dimensional stability and functi-
on of the component must be ensured after welding.
This standard deals with the weld's quality in terms of its strength. Other quality requirements may
be necessary, since arc welds are also subject to various requirements related to corrosion and
Numerical notation according to ISO practice (see VW 01000).

leak tightness, depending on their position and on the painting methods applied. Requirements
beyond the scope of this Standard must be specified in the drawing. Additional measures necessa-
ry to ensure warranties like "3 years for paintwork" or "12 years against corrosion perforation" must
be coordinated by the Planning Department, the Body-in-White Design Engineering Department,
and the engineers responsible for corrosion protection.
The requirements defined below must be met for all welds. Deviations from the Test Specification
must be entered on the component drawing.

2 Definitions
Drawn arc welding is designated below with the abbreviation DAW.

CROSS SECTION: l Weld length (see

For weld length l, drawing)
see drawing
b Weld width
t1 Thickness of the
base material
Weld metal t2 Thickness of the welded-on
panel segment
P Height of the panel seg-
ment after welding

Base material

Figure 1: Cross section

Form FE 41 - 01.03

Continued on pages 2 to 4
Fachverantwortung/Technical Responsibility Normung/Standards (I/EX-71)
I/GQ-32 Mr. R. Mayer Phone: 3 10 97 Phone: +49 841 8930965 Bauer
Vertraulich. Alle Rechte vorbehalten. Weitergabe oder Vervielfältigung ohne vorherige schriftl. Zustimmung einer Normenabteilung des Volkswagen Konzerns nicht gestattet.
Vertragspartner erhalten die Norm nur über die zuständige Beschaffungsabteilung
Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group.
Contractual partners shall obtain this standard only via the responsible Procurement Department.
 Volkswagen AG
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PV 1604: 2003-09

3 Requirements (series production monitoring tests)

3.1 Visual inspection (external findings)

The visual inspection is used to evaluate the welded joint for visible defects.
The shape, size, and uniformity of the weld metal and the freedom from cracks in the welding zone
are evaluated.
The amount of weld metal produced during welding must not be impermissibly large (for limit and
test, see Section 3.2). Lack of fusion, cracks, and excessively large melting material loss in the
weld and in the adjacent material as well as "burning through" and deformation of the panel occur-
ring in this connection are impermissible. The surface of the base panel must be sufficiently coated
after the welding process.
The face surface must be completely welded. A recess or notch in the weld and weld spatter are
not permissible.

3.2 Dimensional check of the weld width b, the weld length l, and the height of the panel
segment P
The weld length l and weld length b as well as other design specifications (e.g., angular position)
with associated tolerances must be implemented according to the drawing.
The following applies in general to the weld width b: t2 ≤ b ≤ 3 t2
The nominal dimension for the weld length and panel height of the welded-on panel segment (P)
must be obtained from the drawing. Process-related reshaping as a result of melting in the joint
area as well as manufacturing tolerances must be taken into consideration in the component de-
sign of the individual part (e.g., for RPS mountings → RPS = reference point system).

4 Requirements (laboratory tests)

The following tests are performed upon start of series production, long production standstill peri-
ods, and readjustments of the welding systems to determine and examine the system process pa-
rameters.

4.1 Tensile test or cross-tension test

In the quasistatic tensile test, the strength of the welded joint between the panel section and base
panel is tested.
To determine the fracture load, the welded components are loaded under axial tension until fractu-
re. The test is performed similar to DIN EN ISO 14272.
The welded joint is OK if
─ the component fails outside the weld zone (failure in the base material or panel segment)
─ the minimum tensile force required according to the drawing is achieved
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PV 1604: 2003-09

da = Clearance dimension between the

holder segments

The clearance dimension da depends on the

Panel segment contour of the component to be tested and
Holder
the panel thickness of the base material. The
clearance dimension (or clamping) must be
selected such that no additional interfering
bending or torsional torques are applied to
the test part during the test.

Recommended value for the clearance:

da = b + 10 [mm]
Base material

Clearance da for panel holders for tensile

testing devices

Figure 2: Clearance for panel holders

4.2 Bending test (practice-oriented supplementary test)

The strength of the welded joint produced by DAW can also be verified by means of an appropriate
bending test on the complete part or on sections of it (similar to tensile specimen form). During this
test, the panel flanges are bent toward each other by an angle of up to 180° depending on the de-
sign. The specimen must fail in the weld only after a defined angle (e.g., α = 75°, see Figure 3).
The responsible departments (Production, Quality Assurance, and Design Engineering) will decide
whether a DAW-produced component can be tested by means of a bending test for the particular
case.
A hammer, mandrel, pliers, or bending bracket can be used as aids.
The procedure and requirements for a bending test must be defined in a Production Department
Test Specification.

Panel 2 after bending test

performed

Panel 2
(welded-on panel
segment in the
initial position)

Panel 1 Base material

Figure 3: Bending test

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PV 1604: 2003-09

4.3 Metallographic test (internal findings)

The metallographic test is a destructive test. It can be performed on all load-bearing DAW welds
where a tensile test is not possible. The microsection allows the joint zone to be evaluated for pos-
sible weld irregularities.
Both longitudinal and transverse microsections must be performed and evaluated for the release
test.
The microsections must be inspected for cracks, lack of fusion, pores, and voids. None of the mic-
rosections must contain internal flaws (pores, lack of fusion, voids) that total more than 10% of the
weld metal area visible in the microsection. The face surface must be completely welded. The re-
quirements according to Sections 3.1 and 3.2 also apply here. Cracks in the base material or in the
weld are not permissible. The weld irregularities are classified according to DIN EN ISO 6520-2.
The weld irregularities are evaluated according to DIN EN 25817 (quality level B high).
The orientation and position of the microsections must be specified in a cutting pattern.

5 Referenced standards1
DIN EN 25817 Arc-Welded Joints in Steel – Guidance on Quality Levels for Imperfec-
tions
DIN EN ISO 6520 –2 Welding and Allied Processes – Classification of Geometric Imperfec-
tions in Metallic Materials – Part 2: Welding with Pressure
DIN EN ISO 14272 Specimen Dimensions and Procedure for Cross Tension Testing Re-
sistance Spot and Embossed Projection Welds
VW 01107 Arc Welding for Studs and Sheet Metal Segments

1
In this Section, terminological inconsistencies may occur as the original titles are used.