1、 FORD LABORATORY TEST METHOD BV 062-01 Date Action Revisions Rev. 0 2014 04 08 Released E. Hetrick / W. Moision / K. Lazarz, NA Controlled document at www.MATS Copyright 2014, Ford Global Technologies, Inc. Page 1 of 4 ALUMINUM RESISTANCE SPOT WELDING ACCEPTANCE TEST FOR WELD THROUGH ADHESIVES AND S
2、EALERS Application This procedure is used as a welding qualification test for automobile body adhesives and sealers which are used in bead form. It does not apply to protective film spray sealers. The procedure outlined herein is specific to a given aluminum alloy + pretreatment + lubricant + heat t
3、reatment + adhesive system from a specific supplier(s). The aluminum alloy and gauge + pretreatment + lubricant + heat treatment system employed for this weldability assessment must have already been pre-qualified using FLTM BB 117-01. Chemicals, materials, parts, and equipment referenced in this do
4、cument must be used and handled properly. Each party is responsible for determining proper use and handling in its facilities. Equipment Required Resistance Spot Welder This test shall be conducted using a Medium Frequency Direct Current (MFDC) inverter combined with servo-actuated force including f
5、orce feedback and servo-inverter synchronization. The weld gun shall be capable of electrode forces up to 10 kN. It shall be equipped with a Ford approved aluminum resistance welding control and gun. The weld controller shall have current capacities to meet the requirements of the range of material
6、to be tested at a minimum rate of 10 welds per minute. The welder must be equipped with electrode holders capable of sufficient water flow capacity so that a minimum of 2.0 gal/min will flow through each electrode holder with a 20 psi pressure differential. In addition, other cooling circuits (e.g.
7、transformer, secondary conductors, and control panel) must meet the minimum manufacturer-specified flow rates and temperature requirements at the requisite duty cycle. Welding Electrodes Ford standard male, ”, “hi water flow“ electrode caps, with two inch radius face (Ford part number: WC11R263), as
8、 specified in WC1-002, will be used for all tests. The electrode caps must be made from RWMA Class 2 CuCr (ISO Type A2/1) material, unless otherwise specified by the Ford Vehicle Operations Joining Supervisor. The electrode caps, adapters and holders to be used will be found under the following stan
9、dards: Identification Ford Standard Designation Electrode Cap WC1-002 WC11R263-A2/1 Cap Adapter WB1 WB1S36-1XX Knife Edge Caliper Mitutoyo Absolute Digimatic Model No. CD-6”CSX or equivalent is required to measure weld button diameter. Instrumentation Calibrated Miyachi Weld Tester MM-380A or equiva
10、lent, capable of simultaneous measurement of force AND current and/or voltage, is required to set up and document weld schedule and test results. Test Panels Two sets of test panels shall be preparedone using 1.0 mm 5ST (5754-O) and one using 1.0 mm 6HS1 (6111-T4). The supplier + pretreatment + lubr
11、icant + heat treatment material system shall exactly match FORD LABORATORY TEST METHOD BV 062-01 Copyright 2014, Ford Global Technologies, Inc Page 2 of 4 that pre-qualified using FLTM BB 117-01. For each substrate, the material shall be sheared into 87 coupons measuring 25 mm x 76 mm and 15 panels
12、measuring 175 mm x 76 mm. All coupons shall be clean and free from burrs or ragged edges that might provide a shunt path for the welding current. Additional coupons shall be sheared to 25 mm x 76 mm for setup. Conditioning and Test Conditions All test values indicated herein are based on material co
13、nditioned in a controlled atmosphere of 23 C +/- 2 C and 50% +/- 5% relative humidity for not less than 24 hours prior to testing and tested under the same conditions unless otherwise specified. Procedure Equipment Setup The electrode caps shall be installed in the machine so that they are in precis
14、e alignment in the vertical plane and their welding faces are parallel under the electrode force requirement for the thickness of the material under test. Test Setup Procedure The following procedural details shall be followed during the test setup: (1) Initial weld schedules are determined during s
15、ubstrate material pre-qualification using FLTM BB 117-01 but must be confirmed on coupons prior to commencing this Welding Acceptance Test for Weld Through Adhesives and Sealers. (2) Steps (1) (8) in the Test Setup Procedure section of FLTM BB 117-01 are to be followed using the 25 mm x 76 mm setup
16、coupons without adhesive, as shown in Figure 1. (3) If the requisite setup button diameter is not achieved, weld current and / or weld time may be modified. Any significant weld schedule adjustments (i.e. 2 kA, 10 ms) must be approved by the Vehicle Operations Joining Supervisor. (4) The set points
17、as well as the actual delivered values of secondary current, weld time, and electrode force are to be documented. (5) After establishing the proper weld button diameter, electrode caps are to be changed and dressed and the test commenced without any additional modifications to the weld schedule. Pre
18、paration of Test Panels For each substrate, prepare 3 sets of 5 coupon assemblies with 4.0 mm +/- 0.8 mm beads of adhesive / sealer as shown in Figure 2. Test 1 set of 5 assemblies immediately. Age 1 set of 5 assemblies for 30 days at 23oC +/- 2oC. Age the final set of 5 assemblies for 30 days at 40
19、 C +/- 2 C. Note that the tape at the top and bottom edges of the panels is to ensure that there is no contact of bare metal to provide a shunt path. FORD LABORATORY TEST METHOD BV 062-01 Copyright 2014, Ford Global Technologies, Inc Page 3 of 4 X25WeldAll dimensions in mm3876Figure 1. Setup and con
20、firmation coupon geometry (Two completely overlapping coupons without adhesive) All dimensions in mmX253876X25X25X25X25175Tape to prevent shunt pathAdhesive / sealerUncompressed bead diameter = 4.0mm +/- 0.8mmWelds25mm x 76mm coupons 175mm x 76mm panelFigure 2. Weldability test panel geometry FORD L
21、ABORATORY TEST METHOD BV 062-01 Copyright 2014, Ford Global Technologies, Inc Page 4 of 4 Welding Test Test must be run a total of six times immediately, after 30 days aging at 23 C +/- 2 C, and after 30 days aging at 40 C +/- 2 C with both 1.0 mm 5ST (5754-O) and 1.0 mm 6HS1 (6111-T4). The followin
22、g procedural details shall be followed during each test: (1) Welding parameters are not to be altered throughout the duration of the test. Under no circumstances shall the current level be raised above that established during setup. (2) Make one weld at the center of a pair of completely overlapping
23、 25 mm x 76 mm coupons, without adhesive / sealer, as shown in Figure 1. (3) Make 25 successive welds on the 5 panel assemblies, prepared as shown in Figure 2. (4) Make one weld at the center of a pair of completely overlapping 25 mm x 76 mm coupons, without adhesive / sealer, as shown in Figure 1.
24、(5) Current traces shall be documented for each weld. Measure and record the welding current at 25ms (3rd half cycle) for all welds. (6) All welds are to be torn down via peel and the minimum and maximum diameter of the weld buttons measured and recorded using the method described in ESXXX-1B325-XX,
25、 Section III.5.4 Roll Peel Test. Approval Criteria Approval is achieved when all of the following conditions are met during all six tests (two substrates, 3 age conditions): (1) All 25 welds made through adhesive / sealer achieve 90% of full welding current on or before the 25 ms (3rd half cycle) me
26、asurement point. Full welding current is defined as the current achieved on the coupons welded without adhesive (Step (2) of Welding Test section) at the 25 ms measurement point. (2) All 25 welds made through adhesive / sealer, as well as the two welds made on coupons without adhesive / sealer immediately before and immediately after the 25 welds through adhesive / sealer, have a button diameter of 4t.
