1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirelyvoluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefro
2、m, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions.QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243TO PLACE A DOCUMENT
3、 ORDER; (724) 776-4970 FAX: (724) 776-0790SAE WEB ADDRESS http:/www.sae.orgCopyright 1970 Society of Automotive Engineers, Inc.All rights reserved. Printed in U.S.A.SURFACEVEHICLE400 Commonwealth Drive, Warrendale, PA 15096-0001INFORMATIONREPORTSubmitted for recognition as an American National Stand
4、ardJ836REV.OCT70Issued 1962-06Revised 1970-10Superseding HSJ 836aAUTOMOTIVE METALLURGICAL JOININGForewordThis Document has also changed to comply with the new SAE Technical Standards Board format.1. ScopeThis report is an abbreviated summary of metallurgical joining by welding, brazing, and solderin
5、g. Itis generally intended to reflect current usage in the automotive industry; however, it does include some of themore recently developed processes. More comprehensive coverage of materials, processing details, andequipment required may be found in the Welding Handbook, Soldering Manual, and other
6、 publications of theAmerican Welding Society and the American Society for Testing and Materials. AWS Automotive WeldingCommittee publications on Recommended Practices are particularly recommended for the design or productengineer.This report is not intended to cover mechanical joining such as rivets
7、 or screw fasteners, or chemical joiningprocesses such as adhesive joining.1.1 Classification of Welding ProcessesCurrent welding practices utilize a great variety of other weldingprocesses not covered in the scope of this report. The AWS has classified all these processes in their MasterChart of We
8、lding Processes (Figure 1).1.2 Standard Welding Symbols1.2.1 With the advancement of welding technology, more welding variables and controls are being continuouslyadded to the manufacturing requirements of weldments. These may include:1.2.1.1 Dimensional requirements of welds (size, length, pitch, n
9、umber of welds, etc.).1.2.1.2 Integrity requirements, such as shear strength for resistance welds, depth of penetration, etc.SAE J836 Revised OCT70-2-FIGURE 1AMERICAN WELDING SOCIETY MASTER CHART OF WELDING PROCESSES (REPRINTED BY PERMISSION OF AMERICAN WELDING SOCIETY)1.2.1.3 Performance requiremen
10、ts of welds and welded joints. These may include:1.2.1.3.1 Dimensional requirements (joint preparation, root opening, etc.).SAE J836 Revised OCT70-3-1.2.1.3.2 Process requirements (series, direct, indirect, over and under welding, and process designations).1.2.1.3.3 Other requirements such as weld a
11、ll around, field weld, etc.1.2.2 Symbols provide a universal means of communicating the above referenced information from the productdesigner to the process man without the risk of misinterpretation. Internationally accepted process andweldment symbols are shown in Figure 2.1.3 Automotive Welding Ap
12、plicationsCertain welding processes have made further inroads in the area ofautomotive welding than others. This fact is caused not only by their greater adaptability to perform automotivewelds, but also by keeping up with high production requirements at lower costs. At the present time thefollowing
13、 processes are being used extensively:a. Resistance welding processes.b. Arc welding processes.c. Brazing and soldering.d. Special process.2. References2.1 Applicable PublicationsThe following publications form a part of the specification to the extent specifiedherein. Unless otherwise indicated the
14、 lastest revision of SAE publications shall apply.2.1.1 AMERICAN WELDING SOCIETY PUBLICATIONSAvailable from?American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 30, p. 30.1.American Welding Society Welding Handbook, Fifth Edition, Section 5, Chapter 90, p. 90.18.Resistance We
15、lder Manufacturers Association Manual.American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapters 30 and 32.Resistance Welding Manual (RWMA), Third Edition, Chapter 4, p. 52.American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 30.Recommended Practices for Au
16、tomotive Welding Design D8.4-61.American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 31.Resistance Welding Manual (RWMA), Third Edition, Chapter 5, p. 67.American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 31.Resistance Welding Manual (RWMA), Third Ed
17、ition, Chapter 5, p. 67.American Welding Society Welding Handbook, Fifth Edition, Chapter 31.Resistance Welding Manual (RWMA), Chapter 9, p. 111.American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 35 (1964).W. C. Rudd, “High Frequency Resistance Welding.“ Welding Journal, Vo
18、l. 36, July 1957, pp. 703707.“Modern Joining Processes,“ Chapter 5, p. 51. American Welding Society (1966).American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 25.American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 28.American Welding Society Welding
19、Handbook, Fifth Edition, Section 2, Chapter 27.American Welding Society Recommended Practices for Automotive Welding Design D8.4-61.American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 29.American Welding Society Welding Handbook, Fifth Edition, Section 3, Chapter 54.American
20、 Welding Society Welding Handbook, Fifth Edition, Section 3, Chapter 52.American Welding Society Welding Handbook, Fifth Edition, Section 3, Chapter 56.American Welding Society Welding Handbook, Fifth Edition, Section 3, Chapter 49.American Welding Society Soldering Manual, First Edition, 1959.SAE J
21、836 Revised OCT70-4-2.1.2 SAE PUBLICATIONAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.SoldersSAE J473, Table 1.2.1.3 ASTM PUBLICATIONAvailable from ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.ASTM solder classifications are given in Tables 44.3 and 44.4 of
22、the Welding Handbook, AmericanWelding Society, Fifth Edition, Section 3.3. Resistance Welding ProcessesResistance welding is a group of welding processes wherein coalescenceis produced by the heat obtained from resistance of the work to the flow of electric current in a circuit of whichthe work is a
23、 part and by the application of pressure. It differs somewhat from other forms of welding in that noextraneous materials, such as filler rods, fluxes, etc., are utilized; thus the metallography of the weld is notcomplicated by the addition of materials and the cost of consumable material is nonexist
24、ent.The Master Chart of Welding Processes classifies six basic resistance welding processes; however, the greatmajority of metal joining is accomplished by the first three of the listed processes. These processes are:1. Resistance-spot welding.2. Resistance-seam and roll spot welding.3. Projection w
25、elding.4. Flash welding.5. Upset welding.6. Percussion welding.SAE J836 Revised OCT70-5-FIGURE 2AMERICAN WELDING SOCIETY STANDARD WELDING SYMBOLS (REPRINTED BY PERMISSION OF AMERICAN WELDING SOCIETY)SAE J836 Revised OCT70-6-Each of the processes described develops the heat of fusion by the resistanc
26、e offered to short time flow of low-voltage, high-density electric current. Force is always applied before, during, and after the application ofcurrent to assure a continuous electrical circuit and to forge the heated parts together.3.1 Resistance-Spot WeldingResistance-spot welding is a process whe
27、rein coalescence at the faying surfacesis produced in one spot by the heat obtained from the resistance to the flow of electric current through the workparts held together under pressure by electrodes. The size and shape of the individually formed welds arelimited primarily by the size and contour o
28、f the electrodes (see Figure 3).FIGURE 3RESISTANCE-SPOT WELDIn the majority of the commercial resistance-spot welding applications, the alternating current single-phasesystem is used. It is the least expensive and simplest form of resistance welding equipment comprised of:1. Welding transformer.2. F
29、orce applying system - air, hydraulic, or spring type.3. Timer and contactor.4. Associated cables and hoses.Figure 4 shows the resistance-spot weld setup.SAE J836 Revised OCT70-7-FIGURE 4RESISTANCE-SPOT WELD SETUPResistance welding equipment varies in form from a portable resistance-spot welding gun
30、, which makes asingle spot at a time and is taken to the work, to a multiple spot welding machine which will make as many as50 or more spot welds simultaneously on assemblies shuttled in and out of the machine at rates as high as600/h. See Figure 5Figure 7 for the respective types of equipment.FIGUR
31、E 5PORTABLE RESISTANCE WELD GUNSAE J836 Revised OCT70-8-FIGURE 6PORTABLE RESISTANCE-SPOT WELDING GUN APPLICATIONFIGURE 7MULTIPLE ELECTRODE PRESS WELDING MACHINEThe complexity of the spot welding equipment is predicated by the volume of production to support theequipment investment. The initial equip
32、ment cost is high compared to manual arc and gas equipment;however, the rate of welding is faster and the consumable material cost is nonexistent.High-quality fabrications can be produced consistently by use of proper designs and welding procedure.During the design of the product to be assembled by
33、resistance-spot welding, consideration must be given toprovide adequate flange widths and accessibility for welding equipment application. Difficulty in positioningand applying the welding equipment can materially affect production rate and quality.SAE J836 Revised OCT70-9-3.1.1 REFERENCES3.1.1.1 Am
34、erican Welding Society Welding Handbook, Fifth Edition, Section 2, Chapter 30, p. 30.1.3.1.1.2 American Welding Society Welding Handbook, Fifth Edition, Section 5, Chapter 90, p. 90.18.3.1.1.3 Resistance Welder Manufacturers Association Manual.3.2 Roll-Resistance Spot WeldingRoll-spot welding consis
35、ts of making a series of separated spot welds in arow by means of one or two rotating, circular electrodes without retracting the electrodes or removing thewelding force between spots. The principles described for conventional spot welding apply also to thisprocess. The weld spacing is obtained and
36、accurately maintained by proper adjustment of electrode speedand current off-time using conventional seam welding equipment. In the case of roll-resistance spot weldingutilizing continuous motion, welding times are usually held to lower levels than that used for conventional spotwelding, thus requir
37、ing higher magnitudes of current. Due to the continuous electrode travel the welds tend tobe of an elongated nugget.Roll-spot welding is usually accomplished on thicknesses up to 1/8 in with continuous motion of the wheelelectrodes driven at a constant speed. For heavier thicknesses of 3/16 in and a
38、bove, an intermittent motion issuggested. In this method, the work stops during the time required to make each individual weld and isautomatically advanced the proper distance for the next weldment. This sequence is continued for the fulllength of the joint.3.3 Resistance-Seam WeldingSeam welding is
39、 a resistance welding process wherein coalescence is producedby the heat obtained from resistance to the flow of electric current through the work parts held together underpressure by circular electrodes. The resultant weld is a series of overlapping spot welds made progressivelyalong a joint by rot
40、ating the electrodes.Seam welding is usually applied to two types of joint designs - lap and flanged-lap. Variations of the standardseam weld principle are mash seam weld, foil-butt seam weld, and butt seam weld. For the respectivecharacteristics of each variety, see Section 3.3.1.Roll-spot welding
41、is used where precise spacing between welds is desired, as in welding the roof panel at thegutter area on an automobile body. Seam welding to produce a liquid and gas tight joint is used to fabricateautomobile gas tanks, buckets, mufflers, water tanks, thin wall piping, etc. Mash seam welding and fo
42、il-buttseam welds are used where surface finishing is required after the joining process as there is a minimum ofmaterial required to be removed - applied to refrigerator and appliance cabinets and limited automotive outerpanel fabrications. The butt seam weld is used for non-structural type joints,
43、 examples of which are found intoy and automobile horn fabrication.Figures 8 and 9 show equipment concepts of a standard seam welder and a schematic of a roll-spot welder,respectively.SAE J836 Revised OCT70-10-FIGURE 8RESISTANCE SEAM WELDING MACHINEFIGURE 9ROLL RESISTANCE-SPOT WELDING MACHINE3.3.1 A
44、dditional information can be found on seam-resistance and roll-resistance spot welding and the variation ofthe process in the following references:3.3.1.1 American Welding Society Welding Handbook, Fifth Edition, Section 2, Chapters 30 and 32.SAE J836 Revised OCT70-11-3.3.1.2 Resistance Welding Manu
45、al (RWMA), Third Edition, Chapter 4, p. 52.3.4 Projection WeldingProjection welding is a resistance welding process wherein coalescence is produced bythe heat obtained from resistance to the flow of electric current through the work parts held together underpressure by electrodes. The resulting weld
46、s are localized at predetermined points by the design of the parts tobe welded. The localization is usually accomplished by projections, embossments, or intersections.Projection welding is a modification of the spot welding process. The concentration of the welding current andforce is made by projec
47、tions prepared in the workpiece rather than by the size and shape of the weldingelectrode. Normally, the projections are formed in the heavier of the two light metal pieces to be joined and inthe case of dissimilar metal in the piece with higher electrical conductivity.Projections can be produced by
48、 means of drawing with a punch and die, cold heading, coining, machining,shearing, and using natural projections as is the case with cross wire welding.Advantages of projection welding which determine where the process can be best applied are:1. More welds per unit area.2. Improved surface marring c
49、ondition.3. Join difficult metal thickness combinations.4. Increase output.5. Less flange width requirement.6. Consistent location of weld spots.7. Longer electrode life.8. Surface conditions less critical.9. Allows joining components of irregular shapes (weld bolts, nuts, and tapping plates).There are also factors which can be considered disadvantages:1. Projections must be provided, which may mean an extra operation.2. Projection dimensions must be maintained, so die maintenance is required.3. Electrodes must be maintained although electrode life is longer.4. Nugge
