1、 FORD LABORATORY TEST METHOD BV 109-01 Date Action Revisions 2000 12 11 Revised Editorial no technical change A. Cockman 1992 02 14 Printed copies are uncontrolled Page 1 of 3 Copyright 2000, Ford Global Technologies, Inc. WELDING ACCEPTANCE TEST FOR WELD THROUGH SEALERS Application This procedure i
2、s used as a welding qualification test for automobile body sealers which are used in bead form. It does not apply to protective film spray sealers. Equipment and Instrumentation Required Spot Welder A single point spot welder having a low inertia head shall be used. At a transformer tap setting of 4
3、0 - 5.0 volts, open circuit, secondary voltage, adjustments shall be made to obtain the following weld schedule: Electrode Force 250 kg Weld Time 9 cycles Secondary Amperes 11,000 At the above current level, the secondary current trace shall be a full sine wave, starting at the zero degree point on
4、 the first half cycle. Electrodes Two WA1SA2510B spot welding electrodes, having a 6 mm diameter face and a 45 truncated cone. Instrumentation A galvanometer type oscillograph shall be used for recording the sine wave of the secondary current. Test Coupons Test coupons shall be 25 mm x 76 mm x 1 mm
5、cold rolled, low carbon steel. All coupons shall be clean and free from burrs or ragged edges that might provide a shunt path for the welding current. Tests for the weld through characteristics of the test material shall be conducted using 25 sets of coupons with sealer and two sets of bare coupons
6、to be run at the start and finish of the test. FORD LABORATORY TEST METHOD BV 109-01 Page 2 of 3 Copyright 2000, Ford Global Technologies, Inc. Conditioning and Test Conditions All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 %
7、relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. Procedure 1. Gun Application Prepare 50 coupon assemblies with 2.38 +/- 0.39 mm beads of sealer as shown in Figure 1. 2. Spray or Brush Application Prepare coupons as described
8、by applicable engineering specification. 3. Age 25 of the assemblies for 30 days at 23 +/- 2 C. 4. Verify the above specified weld schedule on a set of bare coupons. 5. Make 25 successive welds on the coupons, one weld for each set of coupons through a bead of sealer. The second bead of sealer on ea
9、ch set is to insure that there is no contact of bare metal. Initiate current flow when electrode force rises to 95 % of present level. After each weld, examine the sine wave trace. Acceptable materials must show 90 % of full welding current on or before the second half cycle of all welds. The height
10、 of the sine wave obtained in welding bare steel of the same thickness shall indicate full welding current. 6. Repeat the welding test on the 25 sets of coupons which were aged for 30 days at 23 +/- 2 C. 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 BV 109-01 Page 3 of 3 Copyright 2000, Ford Global Technologies, Inc. WELDING ACCEPTANCE TEST FOR WELD THROUGH SEALERS Figure 1
