1、 FORD LABORATORY TEST METHOD BA 017-01 Date Action Revisions Rev. 00 2018 03 06 Released D. Ruhno / T. Coon, NA Controlled document at www.MATS Copyright 2018, Ford Global Technologies, LLC Page 1 of 7 FASTENER PROJECTION WELDING ACCEPTANCE TEST FOR STEEL Application The procedure outlined herein is
2、 a standard fastener projection welding acceptance test for a given fastener (nut or bolt) to a given single sheet steel. This procedure is used to approve the capability of a Supplier or Ford activity to produce welds which meet active Fastener Projection Welding Engineering Specification (ES) requ
3、irements. If found acceptable, the fastener-to-sheet combination is recognized as fastener projection-weldable by Ford Motor Company. Therefore, this procedure shall constitute a method by which a Supplier or Ford activity may: become an approved provider of projection-welded fasteners, become an ap
4、proved provider of fastener projection-weldable sheet steel, or prove weldability of given fastener-to-sheet combination. Apparatus and Materials Required Resistance Projection Welder This test shall be conducted using a pedestal welder meeting the following requirements: The machine frame and elect
5、rode assembly are rigid enough to avoid flexing under load. The welder is capable of providing electrode forces to meet fastener-to-sheet combination requirements and has force actuation which provides fast follow up characteristics. The welder uses a Medium Frequency Direct Current (MFDC) inverter.
6、 The welder is equipped with a Ford-approved resistance weld controller. The weld controller shall have current and current rise-time capacities to meet the requirements of the range of fasteners and steel to be tested at a minimum rate of 5 welds per minute. These metrics shall be recorded and incl
7、uded in the test report. The welder is equipped with electrode holders capable of sufficient water flow capacity. In addition, other cooling circuits (e.g. transformer, secondary conductors, and control panel) must meet the minimum manufacturer-specified flow rates and temperature requirements at th
8、e requisite duty cycle. Welding Electrodes Geometries as required for the nut being tested. Material used shall be documented. Instrumentation A calibrated Miyachi Weld Tester MM-380A or equivalent, capable of simultaneous measurement of force, current, and voltage is recommended to set up and docum
9、ent weld schedules. Alternatively, separate meters may be used to accomplish the same purpose. Metallurgical Sample Preparation and Microstructural Feature Measurement Suitable equipment shall be available to cross section, polish, etch, and examine welded samples at up to 100X magnification. Note:
10、Chemicals, materials, parts, and equipment referenced in this document must be used and handled properly. Each party is responsible for determining proper use and handling in its facilities. FORD LABORATORY TEST METHOD BA 017-01 Copyright 2018, Ford Global Technologies, LLC Page 2 of 7 Procedure Pre
11、paration of Material A minimum of 200 weld nuts and 0.5 square meters of material shall be submitted per each fastener-to-sheet combination. The material shall be sheared in 50 mm x 50 mm pieces. Holes shall be added as specified in the most current release of ESBU5A-1294-AB, Global Generic Toleranc
12、es for Sheet Metal Components. All material must be welded in the as-received condition, with no modification to the surface condition. Welding Acceptance Test Equipment Setup The electrodes (reference the most current release of ESJU5A-1N265-AA, Projection Welding of Nuts and Bolts) shall be instal
13、led in the machine so that they are in precise alignment in the vertical plane and their welding faces are parallel under the electrode force requirement for the fastener-to-sheet combination being tested. Fracture Mode Definitions The following fracture modes are used when evaluating the performanc
14、e of a given projection upon fastener and sheet separation using the Push-Out Test as described in the active ES: Figure 1 Full Button Example Figure 2 Partial Button Example Figure 3 Interfacial Fracture Example Note: The fracture modes also apply to continuous ring projection fasteners. 100% of th
15、e ring circumference must be fused. Full Button (FB) Exceeds 70% of base projection diameter and leaves HOLE in mating sheet. Partial Button (PB) Exceeds 70% of base projection diameter and leaves CAVITY in mating sheet. Interfacial Fracture (IF) Exceeds 70% of base projection diameter and has EVIDE
16、NCE OF FUSION with crystalline fracture surface. Lack of Fusion (LF) Cannot be categorized in one of the three ways above, i.e. less than 70% of base projection diameter down to no weld created. FORD LABORATORY TEST METHOD BA 017-01 Copyright 2018, Ford Global Technologies, LLC Page 3 of 7 Test Proc
17、edure Screening for Optimized Parameters These steps shall be followed to find an optimized weld schedule (see also Figure 4 for reference): Develop a minimum nine-box weld lobe using the 50 mm x 50 mm coupons, See Figure 5. o Select a starting current, time, and force. o Keep force fixed. o Adjust
18、current in 750 A increments and time in 15 ms increments. Note: Heavy weld spatter shall be avoided as part of optimization. Perform Dimensional, Visual, and Thread Test Inspection as described in the active ES on each coupon. This inspection must pass to move on to the next step. Perform Non-Destru
19、ctive Torque Test as described in the active ES on each coupon. This inspection must pass to move on to the next step. Perform Push-Out or Pull-Out Test as described in the active ES on each coupon and evaluate the fracture mode of the projections. o Three of three projections or 100% of a ring proj
20、ection with fusion (Full Button, Partial Button, or Interfacial Fracture) shall be rated green with a “3” in the box. o Two of three projections or 70-99% of a ring projection with fusion shall be rated yellow with a “2” in the box. o Zero or one of three projections or less than 70% of a ring proje
21、ction with fusion shall be rated red with a “0” or “1” as applicable in the box. Select an optimized schedule based on a matrix with at least a nine-green box window by choosing a setting in the center of the green. See Figure 5 for example. Note: The schedule used needs agreement from Ford. If a ni
22、ne-green box window cannot be found, Ford will determine whether yellow boxes may be included in the nine-box window. Select an initial set of weld parameters based upon similar materials.Develop a weld lobe based upon testing coupons welded in 750 A and 15 ms increments.Is the lobe atleast 1500 A b
23、y 30 ms? Select an optimized schedule and review with Ford for approval to proceed to Test Procedure Establishing Weldability.Can the parameters be further adjusted?Review the weld lobe with Ford to determine whether to end the test or proceed with selecting a sub-optimal schedule.Adjust the welding
24、 parameters to improve the welds.YesYesNoNoFigure 4 Weld Lobe Development Procedure FORD LABORATORY TEST METHOD BA 017-01 Copyright 2018, Ford Global Technologies, LLC Page 4 of 7 31,50030,75030,000 1 3 3 3 3 329,250 1 2 3 3 3 328,500 2 3 3 3 327,750 2 3 3 3 327,000 0 3 326,250 2 325,50024,75024,000
25、23,25022,50021,75021,00020,25019,50018,75018,00017,25016,50015,75015,00020 35 50 65 80 95 110 125 140WELD TIME (ms)WELD CURRENT (A)WELD SCHEDULE DEVELOPMENT MATRIXFigure 5 Weld Schedule Development Matrix Figure 6 Push-Out Test Illustration FORD LABORATORY TEST METHOD BA 017-01 Copyright 2018, Ford
26、Global Technologies, LLC Page 5 of 7 Test Procedure Establishing Weldability These steps shall be followed to determine the weldability of the fastener-to-sheet combination being tested. Using the 50 mm x 50 mm coupons, weld 63 samples with the optimized weld schedule established in the Screening. P
27、erform Dimensional, Visual, and Thread Test Inspection as described in the active ES on all 63 samples. Perform Section Cut Inspection as described in the active ES on samples 1, 32, and 63. o Take 100X magnification pictures at all three projections for each sample. o Measure and label: Gap between
28、 weld nut and sheet steel, Effective weld width, and Penetration into sheet steel, if evident. Note: Hardness testing is not required. Perform Push-Out or Pull-Out Test as described in the active ES on samples 2 through 31. o Record force at nut separation from material. o Evaluate each projection a
29、nd characterize the fracture mode as either: Full Button Partial Button Interfacial Fracture Lack of Fusion Perform Torque Test (Destructive) as described in ES on samples 33 through 62. o Record torque at nut separation from material. o Evaluate each projection and characterize the fracture mode as
30、 either: Full Button Partial Button Interfacial Fracture Lack of Fusion Note: Depending on the nut-sheet combination, Lack of Fusion in the Torque Test could be an indication of shear fracture. Test Reports At a minimum, reports are to include: Sheet metal material specification, grade, gauge, coati
31、ng, and weld nut/bolt part number. Information regarding equipment and parameter settings as noted in the Equipment Required section, Weld Schedule Development Matrices as shown in Figure 5, Metallographic images of the three section cut samples, labeled with gap, effective weld width, and penetrati
32、on (if applicable) measurements, and Matrices as shown in Figures 7 and 8. PD Recommended Approval Criteria Approval is granted when the following conditions are met: Section cut samples pass gap and effective weld width requirements. 27 of 30 samples (90%) in a given test o Pass Dimensional, Visual
33、, and Thread Test Inspection, o Show fusion (FB, PB, or IF fracture mode) on three out of three projections or 100% of a ring projection, and o Meet PD requirements for pull- or push-out and torque averages and standard deviations. Samples which do not meet the above criteria (up to three out of the
34、 set of thirty) o Pass Dimensional, Visual, and Thread Test Inspection, o Show fusion (FB, PB, or IF fracture mode) on two out of three projections or 70-99% of a ring projection, and o Meet PD requirements for pull- or push-out and torque averages and standard deviations. FORD LABORATORY TEST METHO
35、D BA 017-01 Copyright 2018, Ford Global Technologies, LLC Page 6 of 7 Reports shall be sent to the requesting Ford activity upon completion. Test Visual ObservationsP1 Diameter or Ring %P1 Description* P2 DiameterP2 Description* P3 DiameterP3 Description*Push- or Pull-OutForce (N)2345678910111213141
36、516171819202122232425262728293031Note: Projection diameters with fracture Average Push- or Pull-Outmodes except for lack of fusion are measured Standard Deviationusing calipers.*Button Descriptions: Post-Test Description: PercentageFB = Full Button 3/3 Projections with FB (or 100% Ring)PB = Partial
37、Button 2/3 Projections with FB (or 70-99% Ring)IF = Interfacial Fracture 1/3 Projections with FB (or 70% Ring)LF = Lack of Fusion 0/3 Projections with FB (or 0% Ring)Note: Rings are defined by percentage of circumference fused under P1. Total 100.0Figure 7 Push-Out or Pull-Out Test Data Form FORD LA
38、BORATORY TEST METHOD BA 017-01 Copyright 2018, Ford Global Technologies, LLC Page 7 of 7 Test Visual ObservationsP1 Diameter or Ring %P1 Description* P2 DiameterP2 Description* P3 DiameterP3 Description*Torque(N-m)333435363738394041424344454647484950515253545556575859606162Note: Projection diameters
39、 with fracture Average Torquemodes except for lack of fusion are measured Standard Deviationusing calipers.*Button Descriptions: Post-Test Description: PercentageFB = Full Button 3/3 Projections with FB (or 100% Ring)PB = Partial Button 2/3 Projections with FB (or 70-99% Ring)IF = Interfacial Fracture 1/3 Projections with FB (or 70% Ring)LF = Lack of Fusion 0/3 Projections with FB (or 0% Ring)Note: Rings are defined in terms of percentange of circumference fused. Total 100.0Figure 8 Torque Test Data Form
