GMW14058 - August 2018

Template For ENG STDS
WORLDWIDE
ENGINEERING Material Specification GMW14058
STANDARDS
Weld Acceptance Criteria and Repair Methods:

Arc Welded and Arc Brazed Joints
1 Introduction
Note: Nothing in this standard supercedes applicable laws and regulations.
Note: In the event of conflict between the English and domestic language, the English language shall take
precedence.
1.1 Purpose. This standard provides the acceptance criteria and repair methods for arc welds and arc brazes
in automotive products for which GM is responsible for establishing or approving product design.
1.2 Applicability. This standard applies to the following types of arc welding or arc brazing processes:
Arc Welding:
• Gas Metal Arc Welding (GMAW)
• Gas Tungsten Arc Welding (GTAW)
• Flux Cored Arc Welding (FCAW)
• Metal Cored Arc Welding (MCAW)
• Shielded Metal Arc Welding (SMAW)
• Plasma Arc Welding (PAW)
Arc Brazing:
• Arc Braze Welding (ABW)
• Gas Tungsten Arc Brazing (GTAB)
• Plasma Arc Brazing (PAB)
This standard applies to welded/brazed joints in all ferrous metals (steels) and non-ferrous metals (aluminum,
magnesium, copper, etc.) that are approved by GM. The criteria established in this standard become mandatory
when referenced on a weld design document. Deviations from any criteria provided in this standard must be
identified on a weld design document. Deviations from any criteria provided in this standard must be identified
on a weld design document for a program specific product and approved by peer review including the lead weld
engineer and arc welding subject matter expert (SME).
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
1.3 Usage. In this standard, the terms “braze and brazing” are used interchangeably with “weld and welding”
(unless specifically stated), however they are not evaluated in the same manner.
Welded structures are considered satisfactory when they carry the intended service loads for a required period.
Service loads on weldments in a vehicle are varied in both type and magnitude and cannot be addressed by this
standard. Therefore, while weld quality criteria of this standard are consistent with service loading requirements,
they have been established specifically for use in process and product monitoring. Any attempted application of
this document to other uses, such as post-crash braze/weld quality assessment, may lead to an erroneous result
or conclusion. Discrepant brazes/welds by retaining a portion of their engineering properties may still satisfy
product performance requirements.
1.4 Clarification. For clarification of this standard or editorial comments, email the GM Global Welding and
Joining Council at weld.council@gm.com.
Proposed changes to this standard must be presented to the GM Global Welding and Joining Council. To
suggest a change to this standard email the GM Global Welding and Joining Council at weld.council@gm.com.
© Copyright 2018 General Motors Company All Rights Reserved
August 2018 Page 1 of 59
Copyright General Motors Company Order Number: W2130815

Provided by IHS Markit under license with General Motors Company Sold to:ULIANA IND. METALURGICA LTDA [700171100488] - LUCIANA.SANTOS@ULIANA.COM.
Reproduction, distribution or publication of these standards is expressly prohib Not for Resale,2018-12-10 11:36:06 UTC
GM WORLDWIDE ENGINEERING STANDARDS Template For ENG STDS GMW14058
2 References
Note: Only the latest approved standards are applicable unless otherwise specified.
2.1 External Standards/Specifications.
None
2.2 GM Standards/Specifications.
9984532 GMW15563 GMW16804
GMW14057 GMW16383 GMW16939
GMW14085 GMW16435 GMW17330
2.3 Additional References.
Note: Some of the following references are limited to internal distribution within General Motors and shall not be
distributed outside this company. Contact the GM Lead Engineer for further instructions.
• CG4352 Gas MIG Braze Welding Certification
• GM Global Quality Requirements for Corrective Action and Nonconforming Material
(https://gmweb.gm.com/quality/oq/QR/Lists/Quality%20Requirements/Global%20Quality%20Manual.aspx)
• GM Information Lifecycle Policy – Record Retention Schedule (https://gmrrs.gm.com/GMRRS/)
• Joining and Dispense Process Control Procedure” (for non-GM manufacturing facilities) and PQRS process
control plans (for GM manufacturing facilities) (https://pqrs.gm.com/secured/index.html)
3 Requirements
There are several attributes that are used to evaluate arc welding/brazing quality. These attributes are divided
into three groups: general, visual, and measureable.
3.1 General Acceptance Criteria.
3.1.1 Categories of Welds. There are two categories of arc welds: Structural Welds/Brazes and Process
Welds/Brazes.
3.1.1.1 Structural Welds. Structural welds are required for performance of the welded product. All welds are
structural unless specifically noted as process welds on the weld design document.
3.1.1.2 Process Welds. Process welds are installed to facilitate in-process assembly, but are not required for
structural performance of the product. Process welds must be approved by Product Engineering and shown on
the weld design document.
3.1.2 Evaluation of Welds/Brazes.
3.1.2.1 Structural Welds/Brazes. Structural welds/brazes shall be evaluated to the requirements of 3.1.3, 3.2,
and 3.3.
3.1.2.2 Process Welds/Brazes. Process welds/brazes shall be evaluated to the requirements of 3.1.3, 3.2.1,
3.2.2 and 3.3.1. Process welds/brazes shall also be evaluated to 3.2.4, 3.2.17, and 3.3.3 with respect to
interference with product performance and subsequent assembly processes. See also 3.4.3.
3.1.3 Filler Metals. The filler metal specified in the product weld design document shall be used. An approved
list of filler metals (when not specified in the weld design document) is shown in GMW16939. An assembly with
a weld/braze that does not use the filler metal specified in the weld design document or repair method (authorized
by product engineering) does not conform.
3.2 Visual Acceptance Criteria.
3.2.1 Surface Cracks. Portions of continuous welds (not brazes) with any surface cracks that are visible without
the aid of magnification are discrepant. Continuous brazes (not welds) with transverse surface cracks that are
visible without the aid of magnification and are < 20 mm apart are discrepant. See 5.1, Glossary.
See also 3.3.2.
• Discrete welds/brazes with surface cracks that are visible without the aid of magnification are discrepant.
• Process welds with surface cracks shall have their process adjusted to the qualified setup to eliminate this
condition.
3.2.2 Burn-through. Assemblies with welds/brazes containing burn-through do not conform. See 5.1, Glossary.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

3.2.3 Meltback. Discrete welds/brazes or portions of continuous welds/brazes containing meltback are
discrepant and cannot be counted in the effective weld/braze length. See 5.1, Glossary. See also 3.3.2.
3.2.4 Melt-through. When a weld/braze exhibits melt-through extending more than 2 x tmin (the thinner metal
being welded/brazed) beyond the bottom surface and there is no interference with product performance or
subsequent assembly operations, the welding/brazing process shall be adjusted to the qualified setup.
Whenever melt-through interferes with product performance or subsequent assembly operations, the excessive
weld/braze metal shall be removed and the welding process adjusted to the qualified setup. A weld/braze with
melt-through is not discrepant. See 5.1, Glossary.
3.2.5 Missing Welds/Brazes. All welds/brazes shown on the weld design document must be present. When
fewer discrete welds/brazes exist than are specified on the weld design document, the welds/brazes do not
conform.
3.2.6 Extra Welds/Brazes. The number of welds/brazes installed shall not exceed the number specified on the
weld design document. When the number of welds/brazes installed exceeds the number specified, the process
shall be adjusted to the qualified setup. Extra welds/brazes are neither discrepant nor nonconforming.
3.2.7 Crater. A crater that does not meet the cross-sectional requirements in 3.3.2, is a discontinuity that cannot
be counted in the effective weld/braze length. See 5.1, Glossary.
3.2.8 Direction of Weld/Braze. When the direction of welding/brazing is specified on the design document, the
process shall follow the direction specified. Discrete welds/brazes or portions of continuous welds/brazes that
deviate from a specified weld direction are discrepant. See also 3.3.2.
3.2.9 Wrapped around Corners. Welds/brazes that are shown to wrap around corners on welding
documentation shall wrap around the corner – regardless of length tolerance. Discrete welds/brazes or portions
of continuous welds/brazes that do not wrap the corner when specified are discrepant. See also 3.3.2.
3.2.10 Starts and Stops. Welds/brazes that are shown as continuous beads on welding documentation shall
be welded/brazed in a continuous bead without additional starts and stops – regardless of length tolerance.
Discrete welds/brazes or portions of continuous welds/brazes with additional starts and stops are discrepant.
See also 3.3.2. Joints shown on the weld documentation as welded/brazed completely around a circular path
shall have the end overlap the start such that the entire path is continuous.
3.2.11 Visual Appearance. When a weld/braze exhibits spatter or a change in shape, the welding/brazing
process shall be adjusted to the qualified setup.
Visual Appearance Zones with additional requirements are given in Appendix E. These requirements are purely
aesthetic and do not affect structural integrity.
3.2.12 Skip. A skip is a discontinuity. The total length of skips cannot be counted in the effective weld/braze
length. See 5.1, Glossary. See also 3.3.2. Portions of welds/brazes with skips are discrepant.
3.2.13 Rollover. The length of weld/braze bead containing rollover is a discontinuity and cannot be counted in
the effective weld/braze length. See 5.1, Glossary. See also 3.3.2.
3.2.14 Notching. Discrete welds/brazes or portions of continuous welds/brazes containing notching are
discrepant. Welds/brazes that are not shown in design documentation to extend to the sheet edge but actually
extend to the sheet edge shall have their processes adjusted to eliminate the condition that leads to notching.
See 5.1, Glossary.
3.2.15 Fill Requirements for Arc Spot Welds. Unless otherwise specified in the engineering documentation,
all arc spot welds shall be filled to the surface of the top sheet. An arc spot weld that is not completely filled is
discrepant.
3.2.16 Visual Requirements of Twin-Plug Slot Brazes.
3.2.16.1 The weld toe of a twin-plug slot braze shall consume the entire radius of the slot ends. A plug whose
toe does not consume the entire radius of the slot end is discrepant (See Figure 1).
3.2.16.2 The center of each plug braze shall be located within the slot.
3.2.17 Spatter. Welds or brazes exhibiting spatter shall have its process adjusted to the qualified setup. Spatter
that interferes with function of the product or any subsequent assembly operations shall be removed.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure 1: Filling Slot Radius on Twin-Plug Slot Welds
3.3 Measurable Acceptance Criteria.

3.3.1 Location. A weld/braze is properly located when installed within 6 mm from the location indicated on the
weld design document. A discrete weld/braze or portion of a continuous weld/braze that is not correctly located
is discrepant. A process weld/braze that is improperly located shall have its process adjusted to correct location.
Weld templates may be used to determine weld location. See 5.1, Glossary.
3.3.2 Effective Weld/Braze Length. The effective weld/braze length (Le) of a weld/braze is acceptable if it is
greater than or equal to the required weld/braze length (Lr, as described in Table 1) and the maximum allowable
discontinuity value listed in Table 1 is not exceeded. Effective weld length is the actual weld length (La) with the
combined discontinuity lengths (Ld) deducted. (See the notes following Table 1.) Discrete welds/brazes that do
not have an effective weld/braze length greater than or equal to the required weld/braze length (as described in
Table 1) are discrepant. Assemblies with continuous welds/brazes that do not have an effective weld/braze
length greater than or equal to the required weld/braze length (as described in Table 1) do not conform.
Welds/brazes exceeding the maximum allowed length (Lw + 2Lt) shall have the welding process adjusted to the
qualified setup. See Figure H1 in Appendix H.

Table 1: Weld/Braze Length Requirements Note 1
Maximum Allowable Length Minimum Required

Specified weld/braze (mm) for Any Single Weld/Braze Length Weld/Braze Length
length (mm) Discontinuity listed in of Tolerance (mm) (mm)
Lw Appendix D Lt Lr Note 3
≤ 10 mm (Discrete) 0 3
11 to 40 3 4
41 to 100 5 6 Lw – Lt
8
> 100 +2 for every additional 25 mm 10% of Lw
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Note 2
Note 1: Effective weld/braze length = Le = La - Ld

Where:
Le = Effective weld/braze length
La = Actual weld/braze length
Ld = combined discontinuity lengths
Note 2: A single discontinuity may not exceed 16 mm for any weld bead.
Note 3: The Effective weld/braze length must meet or exceed the Minimum required weld/braze Length.
Le ≥ Lr
Lr = Lw - Lt
Where:
Lr = Required weld/braze length
Lt = Weld/Braze length tolerance
Lw = Specified weld/braze length
3.3.3 Convexity. There are no limits on the amount of convexity, provided that the part remains functional and
the convexity does not interfere with mating components. Whenever convexity interferes with subsequent
assembly operations, the excessive weld metal shall be removed and the welding process adjusted to the
qualified setup. See 5.1, Glossary.
3.3.4 Weld Cross-Section(s). The weld cross-section(s) shown in Appendix A, Appendix B and Appendix C are
typical weld beads used in automotive weld joint designs. Weld beads in other joint designs can also be
evaluated using the same methods shown in Appendix A, Appendix B, and Appendix C. The required number
and location of the representative cross-section sample(s) are determined by the specified weld/braze
length (Lw) as shown in Table 2.
3.3.4.1 Cross-Section Evaluation. An arc weld/braze whose measured cross-sections do not meet any of the
criteria in 3.3.4.2, 3.3.4.3. 3.3.4.4, 3.3.4.5, 3.3.4.6, 3.3.4.7, 3.3.4.8, 3.3.4.9, 3.3.4.10, 3.3.4.11, or 3.3.4.12 shall
have its process adjusted to the qualified setup so that all of the aforementioned criteria are met. (See 3.4.1.3
for Cross-Section Conformance.)
Table 2: Cross-Section Quantity and Location Requirements

(See 3.3.10.2 for Twin-Plug Slot Brazes)
Specified weld/braze length (Lw) Quantity of Approximate Location of
Cross-Section(s) Cross-Sections
Lw ≤ 40 mm 1 Midpoint of Weld/Braze
(Including Discrete welds/brazes
where Lw ≤ 10 mm) Note 1
At 1/3 the length of the weld/braze and 2/3 the
40 mm < Lw ≤ 100 mm Note 1 2
length of the weld/braze.
At 1/4 the length of the weld/braze, Midpoint of
Lw > 100 mm 3
the weld, and 3/4 the length of the weld/braze.
Note 1: For assemblies having only one weld/braze and this single weld/braze has Lw such that 25 mm < Lw ≤ 40 mm; two cross-sections
shall be examined – one cross-section at 1/3 the length of the weld/braze and the other at 2/3 the length of the weld/braze.

3.3.4.2 Leg Length (b). The leg length is the distance from the weld root to the weld toe of the weld where there
is evidence of fusion for welds or adhesion for braze welds. See 3.3.2, Table 3, Appendix A and Appendix B.
3.3.4.3 Throat Thickness (a). The throat thickness is the minimum distance minus any convexity between any
weld root and the weld face. See 3.3.2, Table 3, Appendix A and Appendix B.
Table 3: Minimum Requirements for Leg Length (b) and Throat Thickness (a)
Parts being Throat Thickness (a) Throat Thickness (a)

Process Leg Length (b)
Joined (non-Aluminum) (Aluminum)
≥ 0.7 tmin ≥ 0.6 tmin
Sheet-to- Arc Weld ≥ 0.9 tmin
See Note 3 See Note 3
Sheet
Arc Braze ≥ 1.0 tmin ≥ 0.7 tmin n/a
≥ 0.9 Z ≥ 0.7 Z ≥ 0.7 Z
Arc Weld
Sheet See Note 4 See Note 4 See Note 4
-to-Tube/Rod ≥ 1.0 Z ≥ 0.7 Z

Arc Braze n/a
≥ 0.9 Z ≥ 0.7 Z ≥ 0.7 Z

Arc Weld
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Tube/Rod See Note 4 See Note 4 See Note 4
-to-Tube/Rod ≥ 1.0 Z ≥ 0.7 Z

Arc Braze n/a
Arc Weld ≥ 0.9 tmin ≥ 0.7 tmin ≥ 0.7 tmin

Edge
Arc Braze ≥ 1.0 tmin ≥ 0.7 tmin n/a
Note 1: When the toe of a weld (not a braze) is on the horizontal surface of the top sheet use the following method to determine throat
thickness. (See Figures A2, A4 and A6).
a. Draw a horizontal line (from left to right) that is a continuation of the top sheet.
b. Draw a vertical line from the root of the top sheet.
c. If the intersection of these two lines falls within the bead, use this point as the toe for the top sheet. If the intersection of these two
lines falls outside the weld, use the point where the horizontal line intersects the weld face as the toe of the top sheet.
d. Draw a line from the toe (on the lower sheet) through the toe of the top sheet.
e. The shortest distance from any weld root to this line or to the weld face is the throat (t).
The throat must be ≥ 0.7 of the thinner material.
Note 2: When the toe of a braze (not a weld) is on the horizontal surface of the top sheet, use the following method to determine throat
thickness. (See Figures B1 (a), C2, C3, C5)
a. Draw a line from the toe (on the lower sheet) to the point that is tangent (touches) to the top edge of the top sheet. The point where
this line touches the top sheet is the toe of the top sheet.
b. The shortest distance from any braze bead root to this line or to the actual bead face (when it falls below this line) is the throat.
The braze bead throat must be ≥ 70% of the thickness of the thinner material.
Note 3: For a skewed weld joint, the minimum throat thickness is:
𝑎𝑎𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤 ≥ 0.9 𝑡𝑡𝑚𝑚𝑚𝑚𝑚𝑚
See Figure A15 and Figure B7
Note 4: For a sheet to tube or sheet to rod, the leg length is based on the metric “Z”.
𝐷𝐷𝑅𝑅𝑅𝑅𝑅𝑅 𝑜𝑜𝑜𝑜 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇
Z = 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 �( 𝑡𝑡𝑆𝑆ℎ𝑒𝑒𝑒𝑒𝑒𝑒 ) 𝑜𝑜𝑜𝑜 � ��
2
See Figure A17, Figure A18, Figure B9 and Figure B10.
3.3.4.4 Fusion Width (fw) or Adhesion Width (aw) in Filled Slot Joints. The fusion width (welding not brazing)
is the distance from weld root to weld root where there is evidence of weld fusion. The adhesion width (brazing
not welding) is the distance from weld root to weld root where there is evidence of braze adhesion. See
Appendix C. The fusion/adhesion width for a filled slot is equal to one of the legs and is limited by the leg length
requirements. (See 3.3.4.2.)

3.3.4.5 Adhesion/Depth of Fusion. Depth of fusion shall be at least 10% of tmin for steel (and other non-
aluminum alloys) and 5% of tmin for aluminum. When depth of fusion is less than these limits, the process shall
be adjusted to the qualified setup. See 5.1, Glossary. Fusion in arc welds and adhesion in arc brazes must be
present. Depth of Fusion is not a requirement for braze welds (as brazing does not generally penetrate into the
parent metal).
3.3.4.6 Undercut. Undercut is a separate attribute that is not to be included in the maximum allowable
discontinuity length. Instead, undercut is evaluated separately. Undercut is acceptable provided that the criteria
in Table 4 are met. (See Figure 2.)
Figure 2: Undercut
Table 4: Maximum Undercut

Undercut in
Undercut in
Non-Ferrous Alloys
Steel Alloys
(Aluminum, Magnesium, Copper, etc.)
Undercut not permitted in first 13 mm Undercut not permitted in first 13 mm
Undercut not permitted in last 13 mm Undercut not permitted in last 13 mm
Undercut Depth ≤ 0.2 T for 12.5% of Length Note 1
Undercut Depth ≤ 0.1 T for 20% of Length Note 1
Note 1: T is the thickness of the sheet that is undercut.
3.3.4.7 Surface Porosity. Surface porosity is a separate attribute that is not to be included in the maximum
allowable discontinuity length. Instead, surface porosity is evaluated separately. Scattered surface porosity is
acceptable provided that the criteria in Table 5 are met. (See Figure 3.)
Table 5: Maximum Surface Porosity

Surface Porosity in Surface Porosity in
Steel Alloys Non-Ferrous Alloys
(Aluminum, Magnesium, Copper, etc.)
Max Pore ≤ 1.6 mm
Sum of Pore Diameters ≤ 6 mm in any 25 mm Length
When surface porosity is present, the welding/brazing process shall be adjusted to its qualified setup to minimize
the porosity. If surface porosity in a discrete weld/braze exceeds these limits, the weld/braze is discrepant. An
assembly with continuous weld/brazes having surface porosity that exceeds these limits does not conform.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Note: The diameter of an oval pore is defined as the sum of the pore length and pore width divided by two.
Figure 3: Surface Porosity
3.3.4.8 Internal Porosity. Internal porosity is acceptable provided that the criteria in Table 6 are met.
Table 6: Maximum Surface Porosity

Internal Porosity in Internal Porosity in Nonferrous, Internal Porosity in
Steel Alloys Nonaluminum Alloys Aluminum Alloys
Nonlinear distribution
Oval pores have a pore length that is not more than three times the pore’s width
Max Pore ≤ 0.5 mm for tmin ≤ 3.0 mm Max Pore ≤ 1.6 mm
Max Pore ≤ 1.0 mm for tmin > 3.0 mm
Total area of all pores is < 15% Total area of all pores is < 25%
for welds with Aluminum Castings
Total area of all pores is < 15%
for welds with all other Aluminum
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
The weld process shall be adjusted to the qualified setup when any of these requirements are not met. See 5.1,
Glossary.
3.3.4.9 Internal Cracks. The weld cross-section must not contain any cracks that are visible at 15x magnification
or less. Weld/brazes (evaluated in patterns) containing cracks are discrepant. See 5.1, Glossary.
3.3.4.10 Rollover. Rollover is acceptable provided it meets the requirements of 3.3.2. See 3.2.13 and
5.1 Glossary.
3.3.4.11 Fusion at the Root. The root of a weld shall extend beyond the joint root for all joints except those
involving flare, rod, tube, or wire. (See Figures A9 through A14, Figures A17 and A18). Welds (except with flare,
rod, tube, or wire) with unfused joint roots shall have their process adjusted back to the qualified setup.
3.3.4.12 Adhesion at the Root. The root of a braze shall show evidence of adhesion for all joints except those
involving flare, rod, tube, or wire. (See Figures B4 through B6, Figures B9 and B10). Brazes (except with flare,
rod, tube, or wire) with lack of root adhesion shall have their process adjusted back to the qualified setup.
3.3.5 Weld Size for Arc Spot Welds. The weld size is the fused diameter at each faying surface and is evaluated
using the determining thickness (DT). DT is defined as the thinner of the two sheets at each faying surface being
evaluated.
An arc spot weld is discrepant when the measured weld size at either faying surface is less than the minimum
acceptable weld size specified in Table 7. Arc spot welds are discrete joints and are evaluated in patterns.
Unless otherwise specified in engineering documentation, all arc spot welds shall penetrate into all adjoining
sheets – creating fusion at each faying surface.
Examples of arc spot measurement are shown in Figure 4. (DT is thickness t2 for both faying interfaces in this
example.)

Table 7: Minimum Acceptable Size for Arc Spot Welds

Determining Thickness (DT) Minimum Acceptable Weld Size
[mm] [mm]
0.60 to 0.76 3.5
0.77 to 1.00 4.0
1.01 to 1.26 4.5
1.27 to 1.56 5.0
1.57 to 1.89 5.5
1.90 to 2.25 6.0
2.26 to 2.64 6.5
2.65 to 3.06 7.0
3.07 to 3.51 7.5
3.52 to 4.00 8.0
4.01 to 4.51 8.5
4.52 to 5.06 9.0
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
dS = Spot Size
dI1 = Weld Size at Interface No. 1 (Top Interface)
dI2 = Weld Size at Interface No. 2 (Bottom Interface)
Figure 4: Spot Diameter and Interface Diameters for Arc-Spot Welds
3.3.6 Weld/Braze Size for Arc Plug Welds/Brazes. The weld/braze size is the interface diameter (dI) at the
faying surface. Standard nominal hole sizes (dn) are shown in Table 8. Arc plug welds/brazes are discrete joints
and are evaluated in patterns. Examples of arc plug weld/braze measurement are shown in Figure 5. Twin-Plug
Slot Brazes are not evaluated as plug welds/brazes; see 3.2.16 and 3.3.10.
An arc plug weld/braze is discrepant when the interface diameter (dI) is not at least as large as the nominal hole
diameter (dn). The spot size (dS) should be at least 3 mm larger than the nominal hole diameter (dn). See also
3.3.4.11 and 3.3.4.12.
The hole size in the top sheet of a 2T sheet metal combination is dn.

The hole size for the second sheet in at 3T sheet metal combination is dn2.
The hole size for the top sheet in at 3T sheet metal combination is dn1 or dn2 + 2 mm; whichever is larger.
Table 8: Minimum Acceptable Size for Arc Plug Welds, and Arc Plug Brazes
(Not Twin-Plug Slot Brazes)
Thickness of Sheet T2 and T3 both Nominal Hole Diameter Nominal Hole Diameter
with Hole (T) Have Ultimate Tensile dn for 2T Note 1, Note 3 dn1 for 3T Note 2, Note 3,
[mm] Strength dn2 for 3T Note 2, Note 3 Note 5
550 MPa or Lower?

0.60 to 1.00 Yes 6.0 mm 8.0 mm
1.01 to 2.00 Yes 8.0 mm 10.0 mm
2.01 to 3.50 Yes 10.0 mm 12.0 mm
3.51 to 4.50 Yes 12.0 mm 14.0 mm
0.60 to 1.00 No Note 4 8.0 mm 10.0 mm
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
1.01 to 2.00 No Note 4 10.0 mm 12.0 mm
2.01 to 3.50 No Note 4 12.0 mm 14.0 mm
3.51 to 4.50 No Note 4 14.0 mm 16.0 mm
Note 1 (2T): ds ≥ dn + 3mm
dI ≥ dn
Where: dS = Spot Size
dn = Nominal (original) Hole Diameter
dI = Weld Interface Diameter
Note 2 (3T): ds ≥ dn1 + 3mm
dI1 ≥ dn1
dI2 ≥ dn2
Where: dS = Spot Size
dn1 = Nominal Hole Diameter in Top Sheet
dn2 = Nominal Hole Diameter in Second Sheet
dI1 = Weld Interface Diameter at interface 1 (top of second sheet)
dI2 = Weld Interface Diameter at interface 2 (top of third sheet)
Note 3: When the nominal hole diameters for three-thickness arc-plug welds and brazes are specified in product documentation; the
hole sizes shall follow that documentation and not the sizes in Table 8.
Note 4: When either the second or third sheet in a 2T and 3T stack has ultimate tensile strength of more than 550 MPa, the filler wire
is no longer AWS A5.18/ER70S-3 or AWS A5.18/ER70S-6 wire (per GMW16939) rather use AWS A5.28/ER120S-G.
Note 5: The hole in the top sheet of a 3T sheet metal combination must always be at least 2 mm larger than the hole in the sheet
below it. If the tabulated value of dn1 is equal to or smaller than that for dn2, the hole size dn1 is dn2 + 2 mm

Figure 5: Spot Diameter and Interface Diameter for Arc-Plug Welds and Brazes
3.3.6.1 Fill of Arc Plug Welds/Brazes. Plug welds/brazes (not twin-plug slot brazes) shall not exhibit under-fill
that exceeds the value shown in Table 9 when measured from the surface of the pierced sheet. A plug weld/braze
whose under-fill exceeds this value is discrepant.
Table 9: Maximum Under-fill for Arc Plug Welds/Brazes

(Not Twin-Plug Slot Brazes)
Top Sheet Thickness (T) Maximum Under-fill
[mm]
0.60 to 2.20 0%
2.21 to 4.50 10%
3.3.7 Weld/Braze Size for Skewed T-Joints. Skewed T-joints whose oblique dihedral angle (ψ) falls between
120° and 150° cannot be evaluated as either a T-joint or as a lap-joint. The minimum required throat (a) of a
welded skewed T-joint is 0.9 tmin as show in Note 3 in Table 3. Examples of throat (a) and leg (b) measurements
in skewed joints are shown in Figure A15 for welds and Figure B7 for brazes. A joint whose dihedral angle falls
between 90° and 120° is evaluated as a T-Joint. A joint whose dihedral angle falls between 150° and 180° is
evaluated as a lap joint. (See Skewed T-Joint Figure in Glossary.)
3.3.8 Weld/Braze Size for Edge Welded/Brazed Joints. The minimum throat (a) and leg (b) requirements for
edged welded and brazed joints are shown in Table 3. Examples of throat (a) and leg (b) measurements in joints
involving rods, tubes, and wire are shown in Figure A16 for welds and Figure B8 for brazes.
3.3.9 Weld/Braze Size for Sheet-to-Tube, Sheet-to-Rod, Rod-to-Rod, and Rod-to-Tube Joints. The
minimum throat (a) and leg (b) requirements for welded and brazed joints involving rods, tubes, and wire are
shown in Table 3. Examples of throat (a) and leg (b) measurements in joints involving rods, tubes, and wire are
shown in Figure A17 and Figure A18 for welds and Figure B9 and Figure B10 for brazes.
3.3.10 Weld Size for Twin-Plug Slot Brazes. The weld size of a twin-plug slot braze is assessed by measuring
the spot diameter and by metallographic analysis.
3.3.10.1 Spot Diameter for Twin-Plug Slot Brazes. The spot diameter on the surface of a twin-plug slot braze
is the smallest diametric measurement of the brazed plug. The surface spot diameter (C) for each brazed plug
shall be at least 2 mm wider than the width of the slot before brazing. For example, a 4 mm x 20 mm slot shall
have brazed plugs with surface diameters that are 6 mm or larger. A plug braze whose surface spot diameter is
smaller than this minimum size shall have its process adjusted to the qualified setup.
3.3.10.2 Metallographic Sectioning of Twin-Plug Slot Brazes. Metallographic sectioning of twin-plug slot
brazes shall be made down the major axis of the slot. Leg and throat requirements shall meet the criteria
established in Table 3 for sheet-to-sheet joints. A plug braze whose throat or leg requirements are shorter than
the criteria established in Table 3 is discrepant.
Metallographic sectioning shall also be used to ensure that there is adhesion at the joint root (See 3.3.4.12).
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure 6. Cross-sectioning Twin-Plug Slot Welds
3.3.11 Joggle Joints and Welded V-Groove Joints with Backing. The evaluation of throat leg and face for
joggle joints and welded V-groove joints with backing are shown in Figure A19. See 3.3.2 and 3.3.4 for evaluation
of weld length and weld cross-sections, respectively.
3.4 Disposition/Repair Procedure.
3.4.1 Conformance. Manufacturing acceptance of product is based on all continuous joints conforming and all
patterns (of discrete joints) conforming. Welds properly repaired (See 3.5) conform (if they meet the general,
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
visual, and measurable criteria described in this standard).

Note: Disposition of product not conforming to this standard shall be handled in accord with GM Global Quality
Requirements for Corrective Action and Nonconforming Material. (This may include repair per Appendix D, E.)
3.4.1.1 A continuous arc welded/brazed joint conforms when all of the general, visual, and measureable criteria
of this standard are met.
Note: An assembly with a discrete or continuous weld/braze that contains a through-hole (burn-through) that is
visible without the aid of magnification does not conform. All welds/brazes with holes shall be repaired.
3.4.1.2 Discrete Pattern Conformance. Discrete joints are evaluated in patterns. A pattern is a collection of
discrete joints to which a tolerance is applied to meet structural requirements and for determining manufacturing
acceptance of the product. The default pattern (when not otherwise stated on the weld design document) is all
structural discrete joints on the structure installed at the same manufacturing plant. The quantity tolerance for
the single default pattern (when not otherwise stated on the weld design document) is no more than 5% of the
total joint/weld count being discrepant. However, any weld pattern may have at least one (1) discrepant weld,
regardless of the pattern tolerance percentage. (This affects patterns of fewer than 20 welds where the default
percentage of 5% would be less than one (1) weld.)
Manufacturing acceptance of product is based on all patterns conforming. Patterns conform when the number
of non-discrepant discrete joints/welds (per the requirements of GMW14057, GMW14058, GMW14085,
GMW16383, GMW16435, GMW16804, or GMW17330) meets or exceeds the pattern tolerance. Disposition of
product nonconforming to this standard shall be handled in accord with GM Global Quality Requirements for
Corrective Action and Nonconforming Material. (This may include repair per Appendix D, E.)

3.4.1.3 Cross-Section Conformance.

3.4.1.3.1 Welded Assemblies from GM Chassis Suppliers and Global Propulsion Systems (GPS). Welded
assemblies shall have 100% of all welds in specification. Quality control and measurement methods shall be in
compliance to CG4352. Any deviation must be reviewed and approved by the GM supplier quality engineer and
responsible product engineer prior to implementation by GM Supplier Quality and GM Engineering. Note: for
missing welds/brazes, see 3.2.5.
3.4.1.3.2 Welded Assemblies from GM Body Assembly Suppliers and GM Manufacturing Plants. For
assemblies having 13 or more cross-sections (for welds/brazes performed in a single manufacturing facility on
a single assembly), 92% of all cross-sections shall meet all measurable cross-sectional requirements (3.3.4.2,
3.3.4.3, or 3.3.4.9). For assemblies having 1 to 12 cross-sections (for welds/brazes performed in a single
manufacturing facility on a single assembly), a single cross-section not meeting the cross-sectional requirements
is allowed; more cross-sections not meeting cross-sectional requirements (3.3.4.2, 3.3.4.3, or 3.3.4.9) are not
allowed. Assemblies exhibiting fewer cross-sections meeting all measureable cross-sectional requirements
(3.3.4.2, 3.3.4.3, or 3.3.4.9) do not conform. Furthermore, assemblies exhibiting two or more adjacent cross-
sections (for welds/brazes performed in a single manufacturing facility on a single assembly) that do not meet
all measureable cross-sectional requirements (3.3.4.2, 3.3.4.3, or 3.3.4.9) do not conform.
Note: For missing welds/brazes, see 3.2.5.
For assemblies having 13 or more cross-sections (for welds/brazes performed in a single manufacturing facility
on a single assembly), 92% of all cross-sections shall meet all measureable cross-sectional requirements
(3.3.4.2, 3.3.4.3, or 3.3.4.9). For assemblies having 1 to 12 cross-sections (for welds/brazes performed in a
single manufacturing facility on a single assembly), a single cross-section not meeting the cross-sectional
requirements is allowed; more cross-sections not meeting cross-sectional requirements (3.3.4.2, 3.3.4.3, or
3.3.4.9) are not allowed. Assemblies exhibiting fewer cross-sections meeting all measureable cross-sectional
requirements (3.3.4.2, 3.3.4.3, or 3.3.4.9) do not conform. Furthermore, assemblies exhibiting two or more
adjacent cross-sections (for welds/brazes performed in a single manufacturing facility on a single assembly) that
do not meet all measureable cross-sectional requirements (3.3.4.2, 3.3.4.3, or 3.3.4.9) do not conform.
Note: For missing welds/brazes, see 3.2.5.
3.4.2 Structural Welds/Brazes. All known nonconforming continuous welds/brazes shall be repaired/handled
per 3.4.1. All known discrepant discrete welds/brazes and other discrepant discrete joints in a nonconforming
pattern shall be repaired shall be repaired/handled per 3.4.1. Whenever welds/joints are missing, the missing
welds/joints shall be installed/handled in accord with GM Global Quality Requirements for Corrective Action and
Nonconforming Material.
3.4.3 Process Welds/Brazes. Process welds/brazes that do not meet the criteria of 3.1.3, 3.2.2 and or cause
interference with respect to 3.2.4, 3.2.18, and 3.3.3 must be repaired. Process welds that do not meet the
remaining requirements of 3.1.2.2 should have the weld process adjusted to the qualified setup. See also 3.1.2.2.
3.5 Weld Repair Methods for Arc Welds and Arc Brazes.
3.5.1 When weld/braze repair is required (See 3.4), the repairs shall follow the repair method authorized by the
responsible product engineer (usually documented on the Weld Repair Sheets). In the absence of an
engineering approved repair method, the repairs shall following the methods shown in Table F1 in Appendix F
for welds and Table G1 in Appendix G for brazes. Exceptions are permitted when approved and documented by
the responsible Product Engineer.
3.5.2 Welding/brazing repair equipment and process parameters must be validated prior to rework. Manual
welding/brazing repair personnel are also required to demonstrate their ability to perform repairs that meet the
requirements of this standard. The fabrication source is responsible for the manufacture of the welded/brazed
components shall retain documentation confirming qualification of welding/brazing repair personnel (in
accordance with the GM Information Lifecycle Management policy– Record Retention Schedule).
4 Manufacturing Process
4.1 Process Control. The fabrication source is responsible for establishing practices and test methods to assure
that the criteria of this standard are met and are consistent with GMW15563 “Joining and Dispense Process
Control Procedure” (for non-GM manufacturing facilities) and PQRS process control plans (for GM
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
manufacturing facilities).

4.2 Process Qualification. All welding processes must be qualified (during initial weld verification or subsequent
requalification). A qualified welding process must meet all of the requirements in Section 3. Process qualification
must be documented (e.g., in the Welding System Qualification Status Spreadsheet) and retained per GM
Information Lifecycle Management policy– Record Retention Schedule.
5 Notes
5.1 Glossary.
Acceptance Criteria: The defined limits for discontinuities/discrepancies in an assembly to assess product
conformance.
Actual Weld/Braze Length (La): The distance measured along the weld centerline from the weld start to weld
end.
Adhesion: In this standard, adhesion refers to metal-metal adhesion in which the surfaces of two dissimilar
metals (e.g., brazing alloy and steel) bond.
Adhesion Width: The distance between braze toes in a filled slot joint where there is evidence of metal-to-metal
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
adhesion. (Compare to Fusion Width.)
Arc Braze Welding: A process that bonds two or more pieces of metal by using a dissimilar filler metal that is
melted with an arc, wets the metal surfaces, and adheres to the metal surfaces. The brazing filler metal has a
melting temperature that is > 450 °C and below the melting temperature of all of the metals being joined.
Arc Plug Welds: Arc welds made inside a prefabricated circular hole in one member of a lap joint – fusing that
member to another member.
Arc Spot Welds: A GMAW or GTAW process in which the torch dwells and melts a spot on the surface of one
sheet and penetrates through that sheet into the underlying sheet(s) – fusing them together. (See figure under
Faying Surface.)
Arc Welding: A group of welding processes that produce coalescence of metals by heating them with an arc,
with or without the application of pressure, and with or without the use of filler metal.
Attributes: Attributes are specific identifiable characteristics in either the surface appearance or geometric
structure of a weld. Examples are undercut, porosity and cracks.
Base Metal: Used to refer to the parts, sheets, components, materials, or structures being welded or brazed.
Braze: The joint produced in Arc Braze Welding. See also Weld.
Braze Root: The portion of the joint to be brazed where the members are in closest proximity to each other. In
the cross-section of a braze, the braze root(s) are locate where the braze metal draws deepest into the gap.
Where this braze metal intersects each sheet metal surface at these locations are the braze root(s). (See open
circles in Figures B1 through B10 and Appendix C.) For braze joints with deep wetting, a Theoretical Braze Root
is used in calculation of throat.
Burn-through: Excessive melt-through resulting in a hole through the welded joint (such that light will pass
through). See Discontinuity for figure.
Coalescence: The growing together or growth into one body of the metals being welded.
Concavity (of a Weld or Braze Face): A state when the actual weld face lies below the theoretical weld face.
When used as a measurement, concavity is the maximum distance between the two.

Conform: To comply with the general, visual, and measurable criteria of this standard.
Continuous Joint (Weld or Braze): A continuous joint is a complete joint that extends without interruption from
one end of the joint to the other. A weld/braze in which back-step welding/brazing is used is considered
continuous. Joints shown as welded/brazed completely around a circular path are considered continuous. A
continuous joint is evaluated independently of other joints. A linear or curvilinear weld/braze that has a length
component > 10 mm is continuous. Arc spot welds, plug welds, twin-plug slot brazes are not continuous joints.
(See Discrete Joint.)
Convexity (of a Weld or Braze Face): A state when the actual weld face lies beyond the theoretical weld face.
When used as a measurement, convexity is the maximum distance between the two. Convexity is not included
in the throat dimension.
Actual Weld Face
Theoretical Weld Face
Crack: A fracture-type discontinuity characterized by a sharp tip and high ratio of length-to-width of opening
displacement.
Crater: The unfilled area at the end of a weld bead where the arc is extinguished and the cross-sectional weld
acceptance criteria are not met.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Depth of Fusion (e): The maximum distance that fusion extends from the surface into the base metals during
welding.
Discontinuity: An interruption of the typical structure of a material, such as lack of homogeneity in its
mechanical, metallurgical or physical characteristics. A discontinuity is not necessarily a defect nor does it
necessarily make the weld/braze discrepant/nonconforming. See, Burn Through, Improper Leg Length, Improver
Throat Thickness, Internal Porosity, Longitudinal Crack, Meltback, Rollover, Skip, Surface Porosity, Transverse
Crack, and Undercut. Some examples of discontinuities in Arc Welds and Brazes are shown in the following
illustration.
Discrepant: Discrete welds/brazes or portions of continuous welds/brazes that are inconsistent with criteria in
this specification are discrepant. Discrepant welds/brazes may conform.
Discrete Joints: Discrete joints are evaluated in patterns. Discrete arc welded/brazed joints include arc spot
welds, arc plug welds, twin-plug slot brazes (each plug is a separate discrete joint) and other arc welds that are
10 mm or shorter. (See Continuous Joint.)
Effective Weld/Braze Length (Le): The actual weld/braze length (Lw) minus the lengths of weld/braze bead
containing discontinuities.
Evidence of Fusion: Any measurable amount of fusion produced during the welding process.
Faying Surface: The mating surface of two members that are welded. (Arc Spot Weld shown.)
Fillet Weld: A weld of approximately triangular cross-section joining two work piece surfaces approximately at
right angles to each other in a lap joint, T-joint or corner joint. (Typical features of cross-section shown.)
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Flux Cored Arc Weld (FCAW): An arc welding process with an arc between a continuous tubular filler metal
electrode and the weld pool. Shielding is provided by a flux contained within the tubular electrode. This process
may also use additional external shielding gas. This process is used without the application of pressure.
Fusion: Melting together of filler metal and base metal (or base metals only) to produce a weld.
Fusion Width: The distance between weld toes in a filled slot joint where there is evidence of weld fusion
(Compare to Adhesion Width.)
Gas Metal Arc Welding (GMAW): An arc welding process with an arc between a continuous solid filler metal
electrode and the weld pool. Shielding is obtained entirely from an externally supplied gas. This process is used
without the application of pressure.
Gas Tungsten Arc Welding (GTAW): An arc welding process with an arc between a tungsten electrode (non-
consumable) and the weld pool. Shielding is obtained entirely from an externally supplied gas. This process is
used without the application of pressure.
Interface Diameter: The fusion/adhesion diameter measured at the faying interface of an arc-spot weld or an
arc-plug weld/braze.
Joint Root: See Root.
Lap Joint: A joint type in which the non-butting ends of one or more workpieces overlap approximately parallel
to each other. See Appendix A, Appendix B and Appendix C. See Fillet Weld Figure.
Leg Length: In a weld/braze cross-section, the leg length is the length of fusion/adhesion in the parent metal
measured between the weld toe and the weld root. Leg length is indicated by “b” in the figures in Appendix A,
Appendix B, and Appendix C. See Fillet Weld Figure.
Longitudinal Crack: A crack that runs through the length of the weld/braze.
Meltback: A situation where the base metal melts back from an edge but does not become part of the weld.
This condition leaves a void between the weld deposit and the base metal. See Discontinuity for figure.
Melt-through: Weld metal visibly extending through the opposite surface being welded or at the weld root.
Metal-Cored Arc Welding: An arc welding process with an arc between a continuous tubular filler metal
electrode and the weld pool. The tubular electrode is filled with a mixture of metal powder that assists the
process. Shielding is obtained entirely from an externally supplied gas. This process is used without the
application of pressure.
Notching: A heat related burn-back of the material at the end of the joint resulting in a notch. Notching is similar
to burn-through, but at the end of the joint.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Nonconforming: See Conform and discrepant.

Pattern (Weld/Braze/Discrete Joint): A collection of discrete joints which a tolerance is applied to meet the
structural integrity and for determining the manufacturing acceptance of the product.
Penetration: See Depth of Fusion.
Plasma Arc Welding (PAW): An arc welding process similar to GTAW that – in addition to the shielding gas –
uses a secondary gas which is ionized to produce a plasma stream that transfers the electrical arc to the weld
pool. Unlike other arc welding processes, PAW can be focused to produce a deep, narrow penetration. This
process is used without the application of pressure.
Plug Weld/Braze: A filled weld/braze made inside a circular hole in one sheet and joins that sheet to another.
Pore: A single cavity discontinuity; see porosity.
Porosity: Cavity type discontinuities or surface openings resulting from gas entrapped in or escaping from the
weld pool during solidification. There are two types of porosity: surface and internal.
Qualified Setup: The weld parameters established and documented during the last process qualification (Weld
Verification or subsequent Requalification). All qualification must be documented (e.g., in the Welding System
Qualification Status Spreadsheet) and retained per GM Information Lifecycle Management policy.
Required Weld/Braze Length (Lr): The specified weld/braze length minus any allowable tolerance. See
Table 1.
Rollover: The protrusion of weld metal that is beyond the weld toe or weld root and is not fused to the base
metal. This condition exists when the weld face intersects the base metal at an angle > 90° (as shown in the
following illustration).
In cross-section, the joint root may be a point, a line or an area. Joint roots are indicated with a non-filled square
in the Figures in Appendix A, Appendix B, and Appendix C. See Fillet Weld illustration.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Shielded Metal Arc Welding (SMAW): An arc welding process with an arc between a covered metal electrode
and the weld pool. Shielding is obtained from decomposition of the electrode covering. This process is used
without the application of pressure.
Skewed T-Joint: A joint whose dihedral angle lies between that of a lap joint and a T-joint. A Joint whose obtuse
dihedral angle falls in the range of 120° and 150° is skewed T-joint. A joint whose obtuse dihedral angle is larger
than 150° is a lap joint. A joint whose obtuse dihedral angle is < 120° is a T-Joint.
Skip: Any portion within the weld bead that is missing. See Discontinuity for figure.
Spatter: The metal particles expelled during arc welding that do not form a part of the weld bead and remain
attached to the surface of the base metals.
Specified Weld/Braze Length (Lw): The weld/braze length stated on the weld design document.
Theoretical Braze Root: For a brazed joint a theoretical braze root exists when the braze root would cause the
throat to cross through either parent metal. In this situation the throat (which is always perpendicular to the
theoretical face) is translated (without changing its angle) until it is tangent with the edge of the parent material
that it had crossed through. The base of this throat projection is the Theoretical Braze Root. (See open squares
in Figures B1 through B10 and Appendix C.)
Toe: The junction of the weld/braze face and the base metal. See filled circles in Appendix A, Appendix B and
Appendix C. Refer also to Face; See Fillet Weld Figure.
Top Sheet: Regardless of part orientation in space, the top sheet is defined as:
a. The sheet whose edge is closest to the torch (for a lap joint; arc spot welding; and arc plug welding/brazing).
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
b. The sheet whose edge interests another sheet (T-Joint or Skewed T-Joint).
c. The thinner sheet/member (flare-v-groove joints; joints with rod, tube, or wire).
Theoretical Weld Face: A straight line drawn between the weld toes. See Weld Face; See Fillet Weld Figure.
Throat Thickness (a): The throat thickness is the minimum distance between any weld root and the weld face
minus any weld convexity. Throat thickness is indicated by “a” in the figures in Appendix A, Appendix B, and
Appendix C. See Fillet Weld Figure.
Transverse Crack: A crack that lies across the width of the weld.
Tungsten Inert Gas Welding (TIG): See Gas Tungsten Arc Welding (GTAW).
Twin-Plug Slot Brazes: A twin plug slot braze is a slot with an arc braze welded plug applied at both ends of
the slot. (The plug at each end of a slot is a separate discrete joint.)

Undercut: A groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld
metal.
Undercut
Under-fill: The distance from the surface of a plug weld/braze to the top of the hole being filled with weld/braze
filler wire.
Weld: A localized coalescence of metals produced by heating the metals to their melting temperature. In this
standard, weld is used interchangeably with Weld Bead.
Weld/Braze Bead: The solidified volume of molten metal from one continuous weld/braze pass. The term
weld/braze bead is used interchangeably with Weld/Braze.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Weld/Braze Centerline: An imaginary line drawn approximately equidistant from the weld toes extending from
the weld start to the weld end.
Weld Crater: See Crater.
Weld/Braze Design Document: A product document that describes welding requirements such as number of
welds, location of welds, applicable weld standards, weld patterns, weld notes, etc. This document is released
and approved by the appropriate Product Design Release Engineer.
Weld/Braze Direction: The direction of travel that the welding/brazing process is progressing from the start to
the end.
Weld/Braze End: A point along the weld/braze bead centerline where the arc is extinguished and the weld/braze
stops.
Weld/Braze Face: The surface of a weld/braze bead that is exposed to the torch. The width of the face on a
cross-section extends from the toe on one sheet to the toe on the other sheet. See Theoretical Weld Face; See
Fillet Weld Figure.
Weld/Braze Length Tolerance (Lt): The length that the effective weld/braze may be shorter that the length
specified on the weld/braze document. The weld/braze length tolerance (Lt) is subtracted from the specified
weld/braze length (Lw) to determine the minimum required weld/braze length (Lr). See Table 1.
Weld Pattern: See Pattern.
Weld Pool: The molten portion of a weld where the base metals (and filler if applicable) coalesce. For brazing,
the weld pool is the molten portion of the braze filler metal that wets the base metals being joined.
Weld Root: The portion of the joint to be welded where the members are in closest proximity to each other. In
a weld cross-section, the weld root(s) are the point(s) where penetration intersects each sheet metal surface at
the closest proximity between the sheets. When there is no gap there will only be one weld root. (See open
circles in Figures A1 through A18, and Appendix C).
Welding/Brazing Source: The manufacturing organization responsible for the welding of a product assembly.
Weld/Braze Start. A point along the weld/braze bead centerline where the arc is initiated.
Weld/Braze Template: An inspection overlay device used to evaluate weld location. Templates can be created
by plotting the weld location as defined by the weld design document on a transparent overlay for comparison
to the actual weld locations.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Weld Toe: See Toe.

5.2 Acronyms, Abbreviations, and Symbols.
Weld/Braze root
Weld/Braze toe
Theoretical Braze root
a Throat thickness
ABW Arc Braze Welding
aw Adhesion Width
b Leg length
CTS Component Technical Specifications
dI Interface diameter for an arc-spot weld or arc-plug braze/weld
dI1 Interface diameter for interface 1 in a 3T arc-spot weld or arc-plug braze/weld
dI2 Interface diameter for interface 2 in a 3T arc-spot weld or arc-plug braze/weld
dn Nominal (original hole) diameter for an arc-plug braze/weld
dn1 Nominal (original hole) diameter in top sheet for a 3T arc-plug braze/weld
dn2 Nominal (original hole) diameter in second sheet for a 3T arc-plug braze/weld
dS Spot diameter for an arc-plug braze/weld
DT Determining Thickness
e Depth of fusion
f Weld face
FCAB Flux Cored Arc Brazing
FCAW Flux Core Arc Welding
fw Fusion width
GMAW Gas Metal Arc Welding
GMNA General Motors North America
GPS Global Propulsion Systems
GTAB Gas Tungsten Arc Brazing
GTAW Gas Tungsten Arc Welding
La Actual Weld/Braze Length
Ld Combined discontinuity lengths
Le Effective Weld/Braze Length
Lr Minimum Required Weld/Braze Length
Lt Length tolerance
Lw Specified Weld/Braze Length
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
MCAW Metal Cored Arc Welding


PAB Plasma Arc Brazing

PAW Plasma Arc Welding
PQRS Process Quality Requirements System
PQS Product Quality Standard
SMAW Shielded Metal Arc Welding
SME Subject Matter Expert
t Metal thickness
tmin Thickness of the thinner metal to be welded
VTS Vehicle Technical Specifications
6 Coding System
This standard shall be referenced in other documents, drawings, etc., as follows:
GMW14058
7 Release and Revisions

This standard was originated in August 2004. It was first approved by CCRW Global Council in December 2005.
It was first published in December 2005.
Issue Publication Date Description (Organization)
1 DEC 2005 Initial publication.
2 SEP 2009 Arc Braze and Slot Joints added. (Global Weld Council)
3 AUG 2018 Added processes, changed scope to join non-ferrous materials in addition to
steel, added tolerances and provisions for discrete welds evaluated in patterns,
added tolerance criteria needed for non-body welding, updated references.
(Welding - Manufacturing)
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Appendix A: Typical Arc Weld Cross-Sections

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure A1: Two Metal Stack-up Lap Joint Concave Fillet Weld
as Typically Displayed for Thick Metal Welding (> ca. 3 mm)
Figure A2: Two Metal Stack-up Lap Joint Concave Fillet Weld
as Typically Displayed for Thin Metal Welding (< ca. 3 mm)

Figure A3: Two Metal Stack-up Lap Joint - Convex Fillet Weld
as Typically Displayed for Thick Metal Welding (> ca. 3 mm)
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure A4: Two Metal Stack-up Lap Joint - Convex Fillet Weld
as Typically Displayed for Thin Metal Welding (< ca. 3 mm)
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

x1
t1
a1
f b2
t2 a2
t3
b1
Figure A5: Three Metal Stack-up Lap Joint - Concave Fillet Weld
x1 a1
t1
f
a2 b2
t2
t3
b1
Figure A6: Three Metal Stack-up Lap Joint - Convex Fillet Weld
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure A7: T-Joint - Concave Fillet Weld
Figure A8: T-Joint - Convex Fillet Weld
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure A9: Flare-V-Groove Weld, Concave
Figure A10: Flare-V-Groove Weld, Convex

--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure A11: Flare-Bevel-Groove Weld, Concave
Figure A12: Flare-Bevel-Groove Weld, Convex

--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure A13: Flare-Edge-Groove Weld, Concave
Figure A14: Flare-Edge-Groove Weld, Convex
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure A15: Skewed T-Joint Weld
Figure A16: Edge Weld
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure A17: Sheet-to-Tube, Sheet-to-Rod, Sheet-to-Wire Weld

Figure A18: Welded Joints among Rods, Tubes, and Wires
Figure A19: Welded V-Groove Joint with Built-in Backing (Top) and
Joggle Joint (Bottom)
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Appendix B: Typical Arc Braze Cross-Sections
Figure B1a: Two Metal Stack-up: Lap Joint Fillet Braze
Figure B1b: Two Metal Stack-up: Lap Joint Fillet Braze
Figure B1: Two Metal Stack-up: Lap Joint Fillet Braze (both B1a and B1b)
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure B2: Three Metal Stack-up Lap Joint Fillet Braze
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure B3: T-Joint Fillet Braze

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure B4: Flare V-Groove Braze

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure B5: Flare Bevel-Groove Braze

Figure B6: Flare Edge-Groove Braze

--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure B7: Skewed T-Joint Braze
Figure B8: Edge Braze
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure B9: Sheet-to-Tube, Sheet-to-Rod, Sheet-to-Wire Braze
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure B10: Brazed Joints among Rods, Tubes, and Wires

--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Appendix C: Typical Cross-sections of Filled Slot Joints
tmin b b
a a
fw
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
-
Figure C1: Arc Welding Two-Metal Stack-up Filled Slot Joint

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure C2: Arc Brazing Two-Metal Stack-up Filled Slot Joint

Figure C3: Arc Brazing Two-Metal Stack-up Filled Slot Joint
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

GM WORLDWIDE ENGINEERING STANDARDS
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Template For ENG STDS GMW14058
Figure C4: Arc Brazing Three-Metal Stack-up Filled Slot Joint

--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Figure C5: Arc Brazing Three-Metal Stack-up Filled Slot Joint

Appendix D: Attributes, Criteria and Discontinuities for Arc Welds/Brazes
Table D1: Determining When an Arc Weld/Braze is Discrepant and must be Repaired Note1, Note 2
Discontinuities that make Discontinuity Discontinuities
a Weld/Braze Discrepant/ Length(s) not that do not
Criteria
Nonconforming to be Included Make the
Attribute (Section of Note1, Note 2
in Effective Weld/Braze
GMW14058) weld/braze Discrepant/
(See Appendix F and G
for Repair) length (Le) Nonconforming
Filler Metal 3.1.3 X Note 3

Surface Cracks 3.2.1 X X
Burn-through (Hole) 3.2.2 X Note 3
Meltback 3.2.3 X X
Melt-through > 2 x tmin Note 4 X
3.2.4 X
Melt-through < 2 x tmin 3.2.4 X Note 4
Missing Welds/Brazes 3.2.5 X
Extra Welds/Brazes 3.2.6 X
Crater 3.2.7 X
Direction of Weld/Braze 3.2.8 X
Wrapped Around Corners 3.2.9 X
Starts and Stops 3.2.10 X
Visual Appearance 3.2.11 X
Skip 3.2.12 X X
Rollover 3.2.13
(see 3.2.13) X
3.3.4.10
Notching 3.2.14 X X
Fill Requirements for Arc Spot
3.2.15 X Applies only to welds
Welds
Visual Requirements for Twin-Plug
3.2.16 X Applies only to brazes
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Slot Brazes
Spatter 3.2.17 X Note 4
Location 3.3.1 X
Insufficient Effective Weld/Braze
3.3.2 X
Length Le < Lr
Extra Length of Weld/Braze 3.3.2 X
Convexity 3.3.3 X
Leg Length 3.3.4.2 X Note 5
Throat Thickness 3.3.4.3 X Note 5
Fusion Width in Filled Slot Joints 3.3.4.4 X
Depth of Fusion < 10% X Applies only
3.3.4.5
to Welds
Depth of Fusion – No penetration 3.3.4.5 X Applies only to Welds

Discontinuities that make Discontinuity Discontinuities

a Weld/Braze Discrepant/ Length(s) not that do not
Criteria
Nonconforming to be Included Make the
Attribute (Section of Note1, Note 2
in Effective Weld/Braze
GMW14058) weld/braze Discrepant/
(See Appendix F and G
for Repair) length (Le) Nonconforming
Lack of Adhesion 3.3.4.5 X Applies only to Brazes

Excessive Undercut 3.3.4.6 X
Surface Porosity 3.3.4.7 X
Internal Porosity 3.3.4.8 X
Internal Cracks 3.3.4.9 X5
Fusion at Root 3.3.4.11 X
Arc Spot Weld Size 3.3.5 X Applies only to welds
Arc Plug Weld Size 3.3.6 X
Skewed T-Joint Weld Size 3.3.7 X X
Edge Weld Size 3.3.8 X X
Joints with Rods and Tubes 3.3.9 X X
Twin Plug Slot Braze Size 3.3.10.1 X Applies only to brazes
Note 1: Discrepant discrete welds need only be repaired if the pattern is nonconforming (See 3.4.1.2.)
Note 2: Welds/Brazes requiring repair can alternatively be dealt with by following the GM Global Quality Requirements for Nonconforming
Material.
Note 3: Welds/Brazes using the wrong filler metal or having holes burned through must be repaired – regardless of tolerance.
Note 4: Welds with melt-through or spatter only require repair if the melt-through/spatter interferes product performance or with subsequent
assembly operations.
Note 5: A single discrepant cross-section may not require repair. Refer to 3.4.1.3.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Appendix E: Surface Appearance in Special Areas of Vehicle
Table E1: Appearance Zones

Zone “A”
Exterior:
- 50 cm to 200 cm from ground height
- Roofs < 170 cm from ground height
- Including panel radii
Interior:
-Forward of rear seatback (visible from interior with panels closed)
Zone “B”
Exterior:
- Ground Level to 50 cm in height and >200 cm off ground level
- Roofs ≥ 170 cm from ground height
- Areas on front/rear closures that are only visible with panel open
Interior:
- Door inner panels (excluding Front door hinge area and other areas covered by the D zone.)
Includes rear door return flange
- Door openings (excluding hinge areas and other areas covered by the D zone)
- Rearward of rear seatback (visible from interior with panels closed)
- Entire surfaces of rear closures (including hinge areas)
- Cargo door inner panel and opening
- Decklid inner panel and opening
- Liftgate inner panel, opening
- Swing gate inner, opening
- Non Pick Up tailgate inner, opening
Zone “C”
- Pick Up Box inner (including enclosed)
- Pick Up Tailgate inner panel, opening
- Back panel on incomplete trucks (frame exposed)
- Trunk compartment (excluding areas covered by carpet, trim, etc.)
- Fuel door inner and opening
- Outside Rear View Mirror housing underside
- Other visible areas which are not defined as any other zone
Zone “D”
- Cargo van (cargo compartment) - B-pillar and behind (areas not covered)
- Engine compartment (only includes the fender rails, top surfaces of shock towers and
front end tie bar)
- Hood inner
- Hooks, tie-downs and trailer hitches
- Spare tire area
- Sun roof water channel
- Wheel arch
Interior:
- Door inner Lower area below door pad and hinge area
- Door opening hinge area
- Areas only visible when the seat is not in the mid position
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Figure E1: Appearance Zones
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Table E2: Additional Weld/Braze Surface Appearance Criteria by Surface Classification

Unexposed
GMW14058 Size/
Attributes Zone A Zone B Zone C Zone D Secondary
Reference Description
Surfaces
Aesthetic
No Additional No Additional No Additional No Additional
Cracks 3.2.1 Visible Repair
Requirement Requirement Requirement Requirement
Required
Aesthetic Aesthetic Aesthetic
Burn- Normal Normal
3.2.2 Any Size Repair Repair Repair
Repair Repair
through Required Required Required
Melt-through 3.2.4 Any Size Repair Repair Repair -- --
Required Required Required
> 1 mm to No Additional No Additional No Additional
-- --
< 2 mm Requirement Requirement Requirement
Aesthetic
≥ 2 mm to No Additional No Additional
Crater 3.2.7 Repair -- --
< 4 mm Requirement Requirement
Required
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
≥ 4 mm Repair Repair Repair -- --

Required Required Required
More than More than
1/100 mm 5/100 mm
No Additional No Additional No Additional
Any size Aesthetic Aesthetic
Requirement Requirement Requirement
Repair Repair
Required Required
More than More than
Small 1/100 mm 5/100 mm
Spatter > 1 mm to Aesthetic Aesthetic
3.2.17 < 2 mm Repair Repair
(Pearls)
Required Required
Medium Aesthetic Aesthetic
≥ 2 mm to Repair Repair
< 4 mm Required Required
Large No Additional No Additional
Repair Repair Repair
≥ 4 mm Required Required Required
Requirement Requirement
Distortion No Additional No Additional

3.2.11 Visible -- -- --
Requirement Requirement
(Waviness)

Appendix F
Table F1: Repair Procedures for Discontinuities in Arc Welds Note 1

GMW14058
Discontinuities Description Repair Method
Reference
Incorrect Filler Filler Metal used not Filler Metal Grind to remove weld bead and re-
3.1.3
Metal Used specified. weld. Note 2
Surface Cracks Cracks occurring in weld bead or crater. 3.2.1 Re-weld to eliminate crack. Note 2
Use sealer released by responsible
product engineer (e.g., Midwest
Thermal Spray CBF100 conductive
body filler for repairs before paint;
Burn-through Hole in the weld bead - Hole < 2 mm. 3.2.2 9984532 for repairs after paint).A
Product Engineering approved
Product Quality Standard (PQS) is
required to identify welds/brazes that
do not require hole repair.
Burn-through Hole in the weld bead - Hole ≥ 2 mm. 3.2.2 Arc weld to repair hole. Note 2
One of the base metals to be welded is Re-Weld to eliminate meltback

Meltback 3.2.3
melted back away from its edge. condition. Note 2
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Weld melt-through extends more than

Melt-through 2x tmin or interferes with product 3.2.4 Metal finish to correct surface. Note 2
performance or subsequent assembly.
Arc weld at correct location to the
Missing Weld Weld not installed or omitted. 3.2.5
specified weld/braze length. Note 2
Add weld to achieve required weld
Crater Crater causes insufficient length 3.2.7
length. Note 2
Incorrect Direction Grind to remove weld and re-weld
Specified Weld Start Location incorrect 3.2.8
of Weld with correct start position. Note 2
Corners not Weld not wrapping corner of part when
3.2.9 Re-weld to eliminate condition. Note 2
Wrapped so indicated on documentation.
Grind and re-weld without cold
Additional starts and stops in a weld
Un-authorized starts/stops in bead or TIG weld
bead not called out in product 3.2.10
Starts and Stops additional starts/stops to ensure
documentation.
fusion. Note 2
Surface Appearance does not meet
Visual Appearance 3.2.11 Follow procedures in Appendix E
requirements in Table E1.
Section of Weld Bead contains a length
Re-weld to eliminate Skip condition.
Skip of Skip that is greater than allowable 3.2.12 Note 2
discontinuity length shown in Table 1.
Section of weld bead contains a length
of Rollover at toe of weld indicating lack
3.2.13 Grind and re-weld to eliminate
Rollover of fusion. Length is greater than
3.3.4.10 rollover condition. Note 2
allowable discontinuity length shown in
Table 1.
Notching is located in Re-weld and metal finish as required
Notching 3.2.14
Zones A, B, C, or D. Note 2 for special area of vehicle. Note 2
Under-filled Arc
Arc Spot Weld is Under-filled. 3.2.15 Re-weld to correct condition Note 2
Spot Welds

GMW14058
Reference
Spatter exists on Class A, B, C or D
Spatter Surface or spatter interferes with product 3.2.17 Metal finish to correct surface. Note 2
Weld not located within 6mm of the
Improperly Located
location shown on weld design 3.3.1 Arc weld at correct location. Note 2
Weld
document.
Insufficient Weld A weld whose effective weld length is Add weld to achieve required weld
3.3.2
Bead Length less than the required weld length. length. Note 2
Convexity weld bead interferes with
Convexity product performance or subsequent 3.3.3 Metal finish to correct surface. Note 2
assembly.
Insufficient Leg Grind and re-weld to the specified leg
Leg length is less than specified. 3.3.4.2
Length length. Note 2
Insufficient Throat Grind and re-weld to the specified
Throat thickness is less than specified. 3.3.4.3
Thickness throat. Note 2
Insufficient Fusion
Width in a Filled Fusion Width is less than Slot Width. 3.3.4.4 Grind and re-weld. Note 2
Slot Joint
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Insufficient Depth
No Penetration. 3.3.4.5 Grind and re-weld. Note 2
of Fusion
Excessive Measured length and/or depth of Re-weld to eliminate undercut
3.3.4.6
Undercut undercut is not acceptable. condition. Note 2
Excessive Surface Grind to eliminate porosity and re-
Porosity exceeds stated limits. 3.3.4.7
Porosity weld. Note 2
Excessive Internal Grind to eliminate porosity and re-
Porosity weld. Note 2
Visible cracks in the weld metal or base Grind to remove cracks and re-weld.
Internal Cracks 3.3.4.9 Note 2
metal.
Re-Weld next to undersized spot; or
Insufficient Arc
Arc Spot Weld undersized. 3.3.5 Re-weld with TIG to increase spot
Spot Weld Size
size, or Grind and re-weld. Note 2
Insufficient Arc Re-weld with TIG to increase spot
Arc Plug Weld undersized. 3.3.6
Plug Weld Size size, or Grind and re-weld. Note 2
Insufficient Weld
Grind and re-weld to the specified
Size for Skewed-T Fillet weld undersized. 3.3.7
leg/throat size. Note 2
Joint
Insufficient Weld
Grind and re-weld to the specified
Size for Edge Edge weld undersized. 3.3.8
Welded Joint
Insufficient Weld
Size for Joints Grind and re-weld to the specified
Fillet/Flare-V Groove weld undersized. 3.3.9
involving tube or leg/throat size. Note 2
rod
Note 1: The repair filler metal used for “re-weld” must be the filler metal specified for the original weld.
Note 2: Repairs on Special areas of the vehicle shall follow procedure in tables.

Appendix G
Table G1: Repair Procedures for Discrepant Arc Brazes Note 1

GMW14058
Reference
Incorrect Filler Grind to remove braze bead and re-
Filler Metal used not Filler Metal specified. 3.1.3
Metal Used braze. Note 2
Surface Cracks Cracks occurring in braze bead or crater. 3.2.1 Re-braze to eliminate crack. Note 2
Use sealer released by responsible
product engineer (e.g., Midwest
Burn-through Hole in the braze bead - Hole < 2 mm. 3.2.2 Thermal Spray CBF100 conductive
body filler for repairs before paint;
9984532 for repairs after paint)
Burn-through Hole in the braze bead - Hole ≥ 2 mm. 3.2.2 Arc braze to repair hole. Note 2
One of the base metals to be brazed is Re-Braze to eliminate meltback
Meltback 3.2.3
melted back away from its edge. condition. Note 2
Braze melt-through extends more than 2x
Melt-through tmin or interferes with product performance 3.2.4 Metal finish to correct surface. Note 2
or subsequent assembly.
Arc weld/braze at correct location to
Missing Braze Braze not installed or omitted. 3.2.5
the specified weld/braze length. Note 2
Add weld/braze to achieve required
Crater Crater causes insufficient length. 3.2.7
weld/braze length. Note 2
Incorrect Direction Grind to remove weld and re-weld
Specified Weld Start Location incorrect. 3.2.8
of Weld with correct start position. Note 2
Corners not Braze not wrapping corner of part when
3.2.9 Re-braze to eliminate condition. Note 2
Wrapped so indicated on documentation.
Grind and re-braze without cold
Additional starts and stops in a braze
Un-authorized starts/stops in bead or TIG braze
bead not called out in product 3.2.10
Starts and Stops additional starts/stops to ensure
documentation.
fusion. Note 2
Surface Appearance does not meet
Visual Appearance 3.2.11 Follow procedures in Appendix E
requirements in Table E1.
Section of Braze Bead contains a length
Re-braze to eliminate Skip condition.
Skip of Skip that is greater than allowable 3.2.12 Note 2
Section of braze bead contains a length of
Rollover at toe of weld indicating lack of 3.2.13 Grind and re-braze to eliminate
Rollover
fusion. Length is greater than allowable 3.3.4.10 rollover condition. Note 2
Re-braze and metal finish as
Notching is located in
Notching 3.2.14 required for special area of vehicle.
Zones A, B, C, or D. Note 2 Note 2
Twin Plug Slot

Twin Plug Slot Braze does not fill the end Fillet braze repair along free edges of
Braze End not 3.2.16.1
of the slot. slot. Note 2
Filled
Twin Plug Slot Twin Plug Slot Braze is not centered in Fillet braze repair along free edges of
3.2.6.2
Braze not centered end of the slot. slot. Note 2
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

GMW14058
Reference
Spatter exists on Class A, B, C or D
Spatter Surface or spatter interferes with product 3.2.17 Metal finish to correct surface. Note 2
Braze not located within 6mm of the
Improperly Located
location shown on braze design 3.3.1 Arc braze at correct location. Note 2
Braze
document.
Insufficient Braze A braze whose effective braze length is Add braze to achieve required braze
3.3.2
Bead Length less than the required braze length. length. Note 2
Convexity braze bead interferes with
Convexity product performance or subsequent 3.3.3 Metal finish to correct surface. Note 2
assembly.
Insufficient Leg Grind and re-braze to the specified
Leg length is less than specified. 3.3.4.2
Length leg length. Note 2
Insufficient Throat Grind and re-braze to the specified
Throat thickness is less than specified. 3.3.4.3
Thickness throat. Note 2
Insufficient Fusion
Width in a Filled Fusion Width is less than Slot Width. 3.3.4.4 Grind and re-braze. Note 2
Slot Joint
Insufficient Depth
No Adhesion. 3.3.4.5 Grind and re-braze. Note 2
of Fusion
Excessive Measured length and/or depth of undercut Re-braze to eliminate undercut
3.3.4.6
Undercut is not acceptable. condition. Note 2
Excessive Surface Grind to eliminate porosity and re-
Porosity braze. Note 2
Excessive Internal Grind to eliminate porosity and re-
Porosity braze. Note 2
--`,,,,,`,,,,,``,```````-`-``,```,,,`---
Visible cracks in the braze metal or base Grind to remove cracks and re-braze.
Internal Cracks 3.3.4.9 Note 2
metal.
Re-Braze next to undersized spot; or
Insufficient Arc
Arc Spot Braze undersized. 3.3.5 Re-braze with TIG to increase spot
Spot Braze Size
size, or Grind and re-braze. Note 2
Insufficient Arc Re-braze with TIG to increase spot
Arc Plug Braze undersized. 3.3.6
Plug Braze Size size, or Grind and re-braze. Note 2
Insufficient Braze
Grind and re-braze to the specified
Size for Skewed-T Fillet braze undersized. 3.3.7
Joint
Insufficient Braze
Grind and re-braze to the specified
Size for Edge Edge braze undersized. 3.3.8
Brazed Joint
Insufficient Braze
Size for Joints Grind and re-braze to the specified
Fillet/Flare-V Groove braze undersized. 3.3.9
involving tube or leg/throat size. Note 2
rod
Twin Plug Slot Fillet braze repair along free edges of
Twin Plug Slot Braze undersized. 3.3.10.3
Braze undersized slot. Note 2
Note 1: The repair filler metal used for “re-weld” must be the filler metal specified for the original weld.
Note 2: Repairs on special areas of the vehicle shall follow procedure in tables.

Appendix H: Weld Acceptability Flow Chart
Figure H1: Weld Bead Length Acceptability Flow Chart
--`,,,,,`,,,,,``,```````-`-``,```,,,`---

Deviations
GM Manufacturing Plants: For the GMT6XX Programs (where XX is a place holder for any digits).
Continue to Follow GMN3903.
--`,,,,,`,,,,,``,```````-`-``,```,,,`---


GMW14058 - August 2018

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

GMW14058 - August 2018

Uploaded by

Copyright:

Available Formats

Template For ENG STDS

Weld Acceptance Criteria and Repair Methods:

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 1 of 59

Copyright General Motors Company Order Number: W2130815

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 2 of 59

Copyright General Motors Company Order Number: W2130815

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 3 of 59

Copyright General Motors Company Order Number: W2130815

3.3 Measurable Acceptance Criteria.

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 4 of 59

Copyright General Motors Company Order Number: W2130815

Table 1: Weld/Braze Length Requirements Note 1

Maximum Allowable Length Minimum Required

Note 1: Effective weld/braze length = Le = La - Ld

Table 2: Cross-Section Quantity and Location Requirements

August 2018 Page 5 of 59

Copyright General Motors Company Order Number: W2130815

Parts being Throat Thickness (a) Throat Thickness (a)

-to-Tube/Rod ≥ 1.0 Z ≥ 0.7 Z

≥ 0.9 Z ≥ 0.7 Z ≥ 0.7 Z

Tube/Rod See Note 4 See Note 4 See Note 4

-to-Tube/Rod ≥ 1.0 Z ≥ 0.7 Z

Arc Weld ≥ 0.9 tmin ≥ 0.7 tmin ≥ 0.7 tmin

See Figure A17, Figure A18, Figure B9 and Figure B10.

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 6 of 59

Copyright General Motors Company Order Number: W2130815

Table 4: Maximum Undercut

Table 5: Maximum Surface Porosity

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 7 of 59

Copyright General Motors Company Order Number: W2130815

Table 6: Maximum Surface Porosity

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 8 of 59

Copyright General Motors Company Order Number: W2130815

Table 7: Minimum Acceptable Size for Arc Spot Welds

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 9 of 59

Copyright General Motors Company Order Number: W2130815

550 MPa or Lower?

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 10 of 59

Copyright General Motors Company Order Number: W2130815

Table 9: Maximum Under-fill for Arc Plug Welds/Brazes

August 2018 Page 11 of 59

Copyright General Motors Company Order Number: W2130815

Figure 6. Cross-sectioning Twin-Plug Slot Welds

visual, and measurable criteria described in this standard).

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 12 of 59

Copyright General Motors Company Order Number: W2130815

3.4.1.3 Cross-Section Conformance.

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 13 of 59

Copyright General Motors Company Order Number: W2130815

© Copyright 2018 General Motors Company All Rights Reserved

August 2018 Page 14 of 59

Copyright General Motors Company Order Number: W2130815

Actual Weld Face