GMW GMW15420-2012 Global Qualification Process for Aluminum Sheet Issue 3 English.pdf

1、 WORLDWIDE ENGINEERING STANDARDS General Specification GMW15420 Global Qualification Process for Aluminum Sheet Copyright 2012 General Motors Company All Rights Reserved November 2012 Originating Department: North American Engineering Standards Page 1 of 15 1 Introduction Note: Nothing in this stand

2、ard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. This procedure defines the requirements an aluminum producer or processor shall meet to qualify their aluminum products and processing

3、 lines at General Motors. This procedure applies to GMW material grades as specified in GMW15192. This includes GMW grades from new suppliers or grades that have undergone a significant change in process route. Aluminum sheet products supplied to GM production facilities must have Engineering and Ma

4、nufacturing approvals as defined in this procedure. 1.1 Scope. Release of specific parts and applications are not within the scope of this procedure. 1.2 Mission/Theme. The intent of this procedure is to create a common, global procedure for qualification of aluminum sheet materials that are used by

5、 GM worldwide. This procedure is intended to evaluate a suppliers ability to produce and supply aluminum sheet that meets GMs requirements. Emphasis is placed on the aluminum producers ability to supply a uniform and consistent product. Some material characteristics and attribute data are requested

6、for qualification purposes even though they are not requirements of GMW15192. In these instances, the data is required for informational purposes. While this procedure details the requirements for initiating global qualification, additional regional requirements may be requested by the Qualification

7、 Champion. The data required to be submitted for each shipment will be determined by the regional manufacturing location. 1.3 Classification. This procedure applies to GMW material grades as specified in GMW15192 for body and closure panel applications. 2 References Note: Only the latest approved st

8、andards are applicable unless otherwise specified. 2.1 External Standards/Specifications. ASTM E34 ASTM E517 ASTM E646 ISO 10113 ASTM E101 ASTM E606 ASTM E1251 ISO 10275 ASTM E112 ASTM E607 EN 573 ISO/TS16949 2.2 GM Standards/Specifications. GMW3011 GMW14700 GMW15192 GMW16170 GMW3059 GMW14704 GMW152

9、82 GMW16546 GMW3335 GMW14729 GMW15287 GMW16549 GMW14085 GMW14829 GMW15288 GMW14669 GMW14872 GMW15421 3 Test Preparation and Evaluation 3.1 Resources. 3.1.1 Calibration. The test facilities and equipment shall be in good working order and shall have a valid calibration label. 3.1.2 Alternatives. Alte

10、rnative test facilities and equipment may also be used. However, all testing must be performed at an International Laboratory Accreditation Cooperation (ILAC) member accredited laboratory, see Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo

11、reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15420 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 2 of 15 www.ilac.org for a list of national accreditation bodies. If the lab is not approved by a signatory of th

12、e ILAC mutual recognition agreement the laboratory must be approved for technical competence for the required testing as agreed upon by the Qualification Champion and supplier. 3.2 Test Conditions. Deviations from the requirements of this standard must be agreed upon by the Qualification Champion be

13、fore submission of the qualification package. Such requirements shall be specified on component drawings, test certificates, reports, etc. 3.3 Preparation. Suppliers are required to provide any test samples to General Motors or outside testing sources as required by this procedure and any referenced

14、 tests. Additional requirements for material may be identified at the start of testing or may be necessary if tests are repeated. The Qualification Champion shall inform the supplier if any additional samples are necessary as part of a re-test. 3.4 Safety. This standard may involve hazardous materia

15、ls, operations, and equipment. This standard does not propose to address all the safety problems associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

16、 3.5 Documentation. Documentation requirements are detailed in Section 7. Samples of components or material released to this standard shall be tested for conformity with the requirements of this standard and approved by the responsible GM department prior to the start of delivery of production level

17、 components or materials. Any change to the component or material, e.g., design, function, properties, manufacturing process and/or location of manufacture requires a new release of the product. It is the sole responsibility of the supplier to provide the customer, unsolicited, with documentation of

18、 any change or modification to the product/process, and to apply for a new release. If not otherwise agreed to, the entire verification test shall be repeated and documented by the supplier prior to start of delivery of the modified or changed product. In some cases, a shorter test can be agreed to

19、between the responsible GM department and the supplier. 3.6 Supplier Quality Audit. General Motors, at its discretion, may perform a supplier assessment and review of its suppliers at any time prior to or following aluminum qualification. 4 Requirements and Procedure 4.1 Summary. This procedure outl

20、ines the testing requirements for sheet metal qualification to GMW15192. The first step consists of Global Engineering Requirements. Due to GM regional manufacturing differences and requirements, the second step consists of Regional Manufacturing Requirements, which is a regional qualification that

21、involves a separate approval in each GM region of manufacture. See 5.5 for a description of the qualification levels. All testing must be performed at an International Laboratory Accreditation Cooperation (ILAC) member accredited laboratory, see www.ilac.org for a list of national accreditation bodi

22、es. If the lab is not approved by a signatory of the ILAC mutual recognition agreement, the laboratory must be approved for technical competence for the required testing as agreed upon by the Qualification Champion and supplier. 4.1.1 Global Engineering Requirements. Global Engineering Requirements

23、are a set of GM Worldwide common, engineering-based requirements for all participating regions in the global qualification process. Some material characteristics and attribute data are requested for qualification purposes even though they are not requirements of GMW15192. Global Engineering Requirem

24、ents are summarized in Appendix A, Tables A1, A2, and A3. 4.1.2 Regional Manufacturing Requirements. Regional Manufacturing Requirements are a set of manufacturing requirements for the target GM production region. The target region is defined as the GM region where the supplier would like to provide

25、 material. The Regional Manufacturing requirements consist of additional laboratory testing and a plant try out to evaluate the ability of this sheet aluminum to be formed, hemmed, assembled, joined, bonded, cleaned, and painted in GM manufacturing and assembly operations. Regional Manufacturing Req

26、uirements are summarized in Appendix A, Tables A4 and A5. 4.2 Testing Requirements. Testing requirements in this procedure are determined by the aluminum grade, surface quality and the qualification status of the processing line. Copyright General Motors Company Provided by IHS under license with Ge

27、neral Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15420 Copyright 2012 General Motors Company All Rights Reserved November 2012 Page 3 of 15 GM also requires that all suppliers adhere to the fundamental qualit

28、y systems requirements of ISO/TS16949. Suppliers choosing other approaches must be able to show that their quality systems meet the intent of ISO/TS16949 as determined by GM Global Purchasing and Supply Chain (GPSC). 4.3 Qualification Requirements. Requirements for qualification are defined in this

29、procedure, including requirements for new suppliers, new process lines, and modified processes. Suppliers must also be capable of meeting the thickness tolerance requirements in GMW15192. Testing requirements are summarized in Appendix A, Tables A1 through A5. These tables define testing requirement

30、s for new suppliers, new process lines, or modified process routes. 5 Qualification Process 5.1 Qualification Initiation - GM. The global qualification process may be initiated by Global Purchasing and Supply Chain (GPSC) through establishment of a commercial need or by GM Engineering through establ

31、ishment of a technical need. 5.2 Qualification Initiation - Supplier. A currently approved aluminum producer or processor can initiate qualification by establishing a technical need. The aluminum producer or processor shall contact the Global Aluminum Sheet Team (GAST) to initiate qualification. 5.3

32、 Qualification Champions. When an appropriate request is received by the GAST, a team member will be assigned to coordinate the qualification and will be identified as the Qualification Champion. The Qualification Champion will generally be located in the region that identifies the need for the qual

33、ification. The Qualification Champion will also act as the interface between the aluminum producer and GM on all aluminum technical issues during the qualification process. Qualification Champions are required to make themselves available to attend Global Purchasing and Supply Chain meetings and pla

34、nt visits where technical issues and requirements are discussed. 5.4 Qualification Review Timing. The Qualification Champion will review and evaluate the test data submitted by the aluminum producer and determine whether it is ready for review by the GAST. Within six weeks of receiving all of the da

35、ta for Global Engineering requirements, a decision will be rendered on granting Level 1 Approval as defined in 5.5. Within six weeks of receiving all of the data for Regional Manufacturing Requirements, a decision will be rendered on granting Level 2 Approval as defined in 5.5. 5.5 Supplier Qualific

36、ation Levels. The GAST shall review the data submitted by the supplier. The Qualification Champion shall act as the lead in this review and work with the GAST to identify any discrepancies with the material in relation to the appropriate specifications and expectations. The GAST can issue one of the

37、 following qualification levels: Level 1 Approval: Granted to a supplier after the Global Engineering Requirements (Appendix A, Tables A1, A2, and A3) have been met for the specified GMW15192 aluminum grade. The supplier may then initiate the process for qualification to the Regional Manufacturing R

38、equirements (Appendix A, Tables A4 and A5) as described in a Level 2 Approval. The outline of a Level 1 Approval is as follows: Show conformance to Global Engineering Requirements (Appendix A, Tables A1, A2, and A3). Level 2 Approval: Granted to a supplier after demonstrating that the Regional Manuf

39、acturing requirements have been met in the target GM region. Once these requirements have been met, the supplier will then be approved to supply product in that region. The supplier may not supply outside of the approved region(s). The outline of a Level 2 Approval is as follows: Level 1 Approval an

40、d show conformance to Regional Manufacturing requirements (Appendix A, Tables A4 and A5) for a selected region or regions. Level 3 Approval: Granted to a supplier that has completed the Level 1 Approval and has Level 2 Approval in all regions. The regions requiring approval to be granted a Level 3 A

41、pproval include: GMNA, GME, GMLAAM and GMAP. For the GMAP region, qualification is required at GM Holden, GM Korea and GM China before a Level 3 Approval can be granted. Outline of a Level 3 Approval is as follows: Level 1 Approval + Level 2 Approval in all regions (GMNA, GME, GMLAAM, GM Holden, GM

42、Korea and GM China). 5.5.1 Rejection. The GAST may determine that the material does not meet specification requirements (Level 1 or Level 2) and/or there is sufficient missing information to warrant rejection of the qualification. The supplier must resubmit a qualification package in order to be con

43、sidered for approval. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15420 Copyright 2012 General Motors Company All Rights Reserved Nov

44、ember 2012 Page 4 of 15 5.6 Required Testing. Data from the test requirements shown in Appendix A, Tables A1, A2 A3, A4, and A5 and defined here must be received from the aluminum producer to satisfy the requirements of this procedure. See Section 4.1 for laboratory accreditation requirements. Befor

45、e testing, the responsible Qualification Champion has to agree on the test plan and the test lab. Additional testing may be conducted in GM laboratories. In some instances, A/B comparison testing of a new material to an already approved material may be required. 6 Test Content 6.1 Global Engineering

46、 Requirements. Global Engineering Requirements are summarized in Appendix A, Tables A1, A2, and A3. A material cannot be approved for use in any region until the regional manufacturing requirements have also been met (see Appendix A, Tables A4 and A5). 6.1.1 All materials supplied to this procedure

47、must comply with the requirements of GMW3059, Restricted and Reportable Substances for Parts. Compliance with the requirements of GMW3059 must be documented in the International Material Data System (IMDS). The IMDS web site address is: https:/ 6.1.2 Chemical Analysis of Base Aluminum. Base metal co

48、mposition based on product (ingot, coil or sheet/blanks) analysis determined per ASTM E34, ASTM E101, ASTM E607, ASTM E1251 or EN 573 shall conform to the requirements in GMW15192. Chemical analysis samples should be based on statistical sampling of multiple ingots or coils. Additional demands and r

49、estrictions may be given by the GAST. In addition, the melt specification from the qualifying mill shall be reported, including the maximum and minimum allowable for each alloy element and any residual elements. 6.1.3 Mechanical Properties. Products approved by this procedure shall be tested to and conform to the mechanical properties as specified in GMW15192. The required mechanical standards are defined in GMW3335. The appropriate tensile test sample geometry req