1、 FORD LABORATORY TEST METHOD BB 113-07 Date Action Revisions 2002 08 30 Activated Formerly BA 113-07 R. Lord Printed copies are uncontrolled Page 1 of 6 Copyright 2002, Ford Global Technologies, Inc. WELDING ACCEPTANCE TEST FOR ALUMINUM Application The procedure outlined herein is a standard welding
2、 acceptance test for all aluminum alloys which are recognized or specified by the Ford Motor Company to be resistance weldable. Essentially, it is a procedure to approve the capability of a supplier or Company activity to obtain a spot weldable surface. This procedure shall constitute a method by wh
3、ich such a supplier or Company activity may become an approved supplier of spot weldable aluminum sheet and as a quality control procedure for checking consistency of weldability. Equipment Required Spot Welder This test shall be conducted on an air operated single point press type spot welder featu
4、ring a low inertia welding system and in general complying with the Resistance Welders Manufacturing Association specifications for the size of machine required. It shall be equipped with a Ford approved resistance welding control featuring 90 firing and phase shift heat control. It shall have elect
5、rode force capacities to meet the requirements of the range of material to be welded at a maximum of 550 kPa (80 psi) operating air supply line pressure. The transformer tap setting shall be selected to meet the secondary current requirements at phase heat control settings between 85 and 100 %. The
6、welder must be equipped with electrode holders conforming to Ford Drawing 2 ZU 265 and shall have furnished to it sufficient water flow capacity so that 7.6 L/min (2.0 gal/min) will flow through each electrode holder as isolated circuits from the water cooled transformer, secondary conductors, contr
7、ol panel, etc. Knife Edge Dial Caliper Brown and Sharpe Model 599-579-10 (metric model), or equivalent. Welding Electrodes Ford standard “increased water flow“ electrode caps with a radius welding face shown in Figure 1 will be used for all tests. The electrode caps must be made from Ford standard M
8、-2A107C (RWMA Class 1) material. The electrode caps, adapters and holder to be used will be found under the following identifications: Electrode Cap WC - modified as per Figure 1 Cap Adapter WB 1S Electrode Holder Assembly Drawing 2 ZU 265 FORD LABORATORY TEST METHOD BB 113-07 Page 2 of 6 Copyright
9、2002, Ford Global Technologies, Inc. Procedure Surface Preparation of Material The material submitted for approval shall be prepared according to the practice proposed to be used for production quantities. A letter shall accompany the material noting all pertinent data to identify completely the met
10、hod of preparation. A minimum of 7.5 square metres of material shall be submitted in a width equal to the maximum capability of the surface preparation equipment. The material shall be sheared in 25 x 300 mm and 100 x 300 mm pieces. Care shall be exercised to obtain pieces of each size from various
11、positions of its width. The Welding Acceptance Test shall be conducted as outlined herein. If failure occurs, the material is rejected. If the material passes the initial Welding Acceptance Test, the unused portion of the submitted material shall be stored on a rack permitting exposure of both surfa
12、ces of the sheets to normal shop atmosphere for 90 days. The Welding Acceptance Test is then repeated on the material after 90 days exposure. Approved Criteria Approval is granted when all of the following conditions are met: 1. Welding Acceptance Test on material before and after 90 days exposure t
13、o shop atmosphere produces a minimum of 2000 consecutive acceptable welds without failure. 2. Set up samples of 25 x 300 mm test strips to be free of expulsion (whiskers). 3. Indentation due to electrode pressure does not exceed 14 % of indented sheet thickness. 4. No sheet separation or buckling du
14、e to indentation. 5. Surface roughness meets applicable paintability specification requirements. Following approval, no changes in material or processing which could affect weldability may be made without prior written approval from the responsible Ford activity. Welding Acceptance Test Electrode Co
15、nditioning The electrode caps shall be installed 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 thickness of the material under test. Specimens for this setup are 100 x 300 mm coupons of th
16、e actual test material. This alignment shall be checked and face conditioned by making a series of 60 welds at welding current at least 10 % under that shown in the Weld Schedule Section of this specification. FORD LABORATORY TEST METHOD BB 113-07 Page 3 of 6 Copyright 2002, Ford Global Technologies
17、, Inc. Setting and Establishing Button Size Using 25 x 300 mm test strips and the appropriate weld schedule listed in Table 1 make six welds on the centerline approximately 50 mm apart. Discard the first weld on each test strip. Weld current shall be increased until a 12 +/- 2 % indentation occurs.
18、At this point no expulsion should occur and the measured weld button peeled from the test strip should be equal to or greater than the size listed in Table 1. (If expulsion should occur, reduce welding current.) It is expected that this condition shall be achieved in less than 19 welds and the welds
19、 made on the caps to date will not constitute part of the test count. The diameter of the weld button as determined by the method shown elsewhere in this test method shall be recorded on the companys data sheet. Also recorded at this time will be the secondary current, weld time, electrode force, an
20、d primary voltage. After establishing the proper weld button diameter, the test shall be made on 100 x 300 mm pieces of that material without any modification of the electrodes or adjustment of the weld schedule. The listed procedural details shall be followed during the test: (a) Rate of welding is
21、 the responsibility of the vendor but shall be at a minimum rate of 10 spot welds per minute. (b) To avoid welding on overheated panels, the panel shall be set aside and allowed to cool. Welding will be continued on a second set of panels. Additional welds may be made on the panel after cooling. (c)
22、 After every 250 welds, repeat the determination of button diameter through the use of 25 x 300 mm strips as described below. Under no circumstances shall the current level be raised above that established to provide initial spot welded button diameter. (d) The above steps shall be repeated until 2,
23、000 spot welds are obtained or the weld button on a coupon is below the minimum specified. When the first substandard button size is encountered, six additional test welds shall be made consecutively and measured. Failure shall be firmly established whenever the weld nuggets of any two of the additi
24、onal six measure below the specified minimum diameter or whenever any one produces a “no weld“ not assignable to welder malfunction. This latter situation is cause for failure even though the remaining 5 welds show adequate button size. (e) The above procedure of six additional welds shall also be m
25、ade at the 2,000 spot weld level even though no substandard nuggets have been encountered at that point. Determination of Spot Weld Diameter The spot weld specimen must be made so as to permit the weld button to be peeled perpendicular to the narrowest section. The buttons pulled from the spot weld
26、specimen shall be measured through their narrowest section when irregular shaped or through the minor diameter when elliptical in shape (see illustration following). FORD LABORATORY TEST METHOD BB 113-07 Page 4 of 6 Copyright 2002, Ford Global Technologies, Inc. Use knife edge dial caliper to measur
27、e button size 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 BB 113-07 Page 5 of 6 Copyright 2002, Ford Global Technologies, Inc. WELDING ACCEPTANCE TEST FOR ALUMINUM TABLE 1 RESISTANCE SPOT WELDING SCHEDULE STANDARDS ALUMINUM SHEET ABRADED TO FORD STANDARDS FORD LABORATORY TEST METHOD BB 113-07 Page 6 of 6 Copyright 2002, Ford Global Technologies, Inc. WELDING ACCEPTANCE TEST FOR ALUMINUM Procedure (Continued) Figure 1
