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WHeel DEFECTS

CONTENTS
Wheel Zone Description. Inspection Conditions Types of Defects and Definition Acceptable Level of Defect & Pictures

Wheel Zones
Wheel is mainly divided into Four Zones based on the Specified Requirements particular to each Zone.
Sl.No 1 2 Zones Zone A Zone B Description The flat front surface of the wheel including visible surface called as Zone A Side surface of the Wheel Window including Spoke and area of stud Hole considered as Zone B

3
4

Zone C
Zone D

Inside the Wheel Rim excluding Nave seat area considered as a Zone C
Side Surface of the Wheel Covered by Tire including Tire flange called as Zone D

Wheel Zones- Pictures


Zone A Zone B

Zone C

Zone D

Wheel Inspection Condition


Sl.No 1 2 3 4 Particular Inspection Distance Illumination Inspection Time Inclination Angle Condition 0.9 ~ 1.0m 1000 100 Lux 10 ~ 30 Seconds 30 ~ 40

Types OF DEFECTSPainting

Sag
Description of the Defect A paint sag is a partial slipping down of the paint . Sagging appears as a thick uneven line on the surface. Major Causes
Due to Improper Painting; Due to Contamination / Foreign Particles

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOT OK Zone C Allowed Zone D Allowed

PAINT OVER FLOW


Description of the Defect
More paint qty. on surface .

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Allowed Zone D Allowed

AIR POCKET
Description of the Defect
On the surface paint not filled properly .

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

OVER PAINT
Description of the Defect
More paint qty. on wheel.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

PAINT NOT DONE PROPER


Description of the Defect
On the front side flange up to 10-15 mm silver paint required.

Acceptable Criteria Zone A NA Zone B NA Pictures OK NOK Zone C NA Zone D Not Allowed

HANGER CONTACT POINT


Description of the Defect
Hanger contact point on hub hole

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C NA Zone D NA

PAINT BLACKNESS
Description of the Defect
Paint not fill proper on the surface.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

Types OF DEFECTSassembly

Porosity
Description of the Defect
Gas entrapped in solidifying metal forms spherical or elongated pores in the weld, known as porosity. Porosity in the weld and

Major Causes
Weld Bead Too Small Poor Quality of Material being Welded

heat affected zone may lead to cracking.

Acceptable Criteria Zone A NA OK Zone B NA Pictures NOT OK Zone C Not Allowed Zone D NA

SPATTER
Description of the Defect Major Causes
severe electrode angles Small particles of weld metal expelled from Long arc length the welding operation which adhere to the

base metal surface

high amperages.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures Zone C Not Allowed Zone D Minor Level Allowed

OK

NOT OK

UNDERCUT
Description of the Defect
A groove cut at the toe of the weld and left unfilled

Major Causes improper welding parameters a)The travel speed and arc voltage Rust

Acceptable Criteria Zone A NA Zone B NA Pictures Zone C Not Allowed Zone D NA

OK

NOT OK

CRATER PIN HOLE


Description of the Defect A tiny or Small hole made by or as by a pin Major Causes The pinhole was located on the edge of the weld, close to the pipe base metal. ... Because all welds could have pitted Zone C Minor Level Allowed Pictures OK NOT OK Zone D NA

Acceptable Criteria Zone A NA Zone B NA

GRINDING MARK ON DISC


Description of the Defect
To remove the dent, wrong grinding on disc .

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

WRONG GRINDING ON WELDING


Description of the Defect
IN a all GM Wheel butt weld grinding not allowed

Acceptable Criteria Zone A NA Zone B NA Pictures OK NOK Zone C Not Allowed Zone D NA

BOLT HOLE CAPE DAMAGE IN ASSY.


Description of the Defect
IN Assembly if wheel not sit proper than bolt hole cap will damage.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C NA Zone D NA

PITTING MARK ON DISC


Description of the Defect
Material pitting mark on disc.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Allowed Zone D Allowed

BOLT HOLE DAMAGE IN DISC/CHAMFER UNEVEN


Description of the Defect
Bolt hole damage or uneven chamfer

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D NA

WELD SHIFT TO RIM


Description of the Defect
Weld shifted on rim & disc penetration zero.

Acceptable Criteria Zone A NA Zone B NA Pictures OK NOK Zone C Not Allowed Zone D NA

WELD SHIFT TO DISC


Description of the Defect
Weld shift on disc & rim penetration is zero.

Acceptable Criteria Zone A NA Zone B NA Pictures OK NOK Zone C Not Allowed Zone D NA

ASSY NAVE TOOL MARK


Description of the Defect
Assy nave tool mark on wheel.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D NA

Types OF DEFECTSRIM

Crack
Description of the Defect Cracks are brittle separations in the weld and base metal. Major Causes Weld Bead Too Small Poor Quality of Material being Welded

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOT OK Zone C Not Allowed Zone D Not Allowed

Incomplete Fusion
Description of the Defect
Incomplete fusion occurs when the base metal and weld metal fail to combine

Major Causes unclean base metal, Improper welding techniques

across all boundaries. OR


Where weld metal does not form a Consistent bond with the base metal.

Improper joint design


Insufficient welding heat

Acceptable Criteria
Zone A NA Zone B NA Pictures OK NOT OK Zone C Not Allowed Zone D Not Allowed

OVERLAP
Description of the Defect Major Causes
When the face of the weld extends beyond Improper Welding Techniques
the toe of the weld Improper Griper Block

Acceptable Criteria Zone A NA Zone B NA Pictures OK NOT OK Zone C NA Zone D Not Allowed

DEEP DENT MARK


Description of the Defect
A depression in a surface made by dust,
Tool Damage ..

Major Causes
Due to Dust /Foreign Particles, Tool Damage.
Improper Handling

Acceptable Criteria Zone A Zone B Zone C 1.5mmX 1.0mm Deep(Max.5Nos allowed) Zone D

Not Allowed

Not Allowed

Not Allowed

Pictures OK NOT OK

Grinding Mark
Description of the Defect
Marks made event of a paint repair or
Polishing Operation.

Major Causes
While doing the Rework Operation

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Zone C 15mmX 0.25 mm Allowed Zone D Allowed

Pictures OK NOT OK

BUTT WELD CRACK


Description of the Defect
Cracks are brittle separations in the weld and base metal.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Zone C NA Zone D Not Allowed

Pictures OK NOK

MATERIAL DENT MARK


Description of the Defect
A depression in a surface made by dust, Tool Damage ..

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

BUTT JOINT HEELING


Description of the Defect
Mismatch of two butting edges

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C NA Zone D Not Allowed

BUTT WELD OVERLAP


Description of the Defect
When the face of the weld extends beyond the toe of the weld

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

MATERIAL CRACK
Description of the Defect
Cracks are brittle separations in the weld and base metal

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

CRACK ON BUTT WELD


Description of the Defect
Cracks are brittle separations in the weld and base metal.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

MARKING SHIFT AT POSITION


Description of the Defect
Not meeting as per drawing

Acceptable Criteria Zone A NA Zone B NA Pictures OK NOK Zone C Not Allowed Zone D NA

PITTING MARK ON BUTT WELD


Description of the Defect
Pitting mark on butt weld

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

MATERIAL LAMINATION CRACK


Description of the Defect
Material lamination crack

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

LINE MARK
Description of the Defect
Deep & long line mark

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

NECKING ON BUTT WELD


Description of the Defect
One type of thinning only on butt weld.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C NA Zone D NA

SHALLOW FLASH CUTTING ON BUTT WELD


Description of the Defect
Improper removal of excessive welding

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C NA Zone D Not Allowed

MATERIAL PITTING MARK


Description of the Defect
Material; pitting mark due to on the raw material pitting mark .

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Not Allowed Zone D Not Allowed

TWO VALVE HOLE


Description of the Defect
Both side valve hole not allowed in any wheel.

Acceptable Criteria Zone A NA Zone B NA Pictures OK NOK Zone C NA Zone D Not Allowed

WRONG SIDE MARKING


Description of the Defect
In M-300 (WCC047) Wheel rear side marking required.

Acceptable Criteria Zone A Not Allowed Zone B Not Allowed Pictures OK NOK Zone C Allowed Zone D NA

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