1、 FORD LABORATORY TEST METHOD BV 109-02 Date Action Revisions 2000 12 11 Revised Editorial no technical change A. Cockman 1995 03 23 Printed copies are uncontrolled Page 1 of 4 Copyright 2000, Ford Global Technologies, Inc. ELASTOMER SEALERS (TAPE-FORM) - WELDING ACCEPTANCE Application This procedure
2、 is a standard welding acceptance test for tape-form elastomer sealers. Apparatus Required Spot Welder Air operated, single point; low inertia welding system. Shall comply, in general, with the Resistance Welders Manufacturing Association specifications for the size machine required. “C“ frame type
3、test stands shall be equipped with Ford approved air cylinders, electrodes, electrode holders, and cables. All welding machines shall be equipped with a Ford approved resistance welding control. All machines shall have electrode force capacities to meet the range of materials to be tested at 550 kPa
4、 line pressure. All machines shall have sufficient water flow capacity to allow a minimum of 7.6 L/min to flow through each electrode holder as isolated circuits from the water cooled transformer, secondary conductors, control panels, etc. Secondary Weld Current/Weld Time Analyzer Equipped with prin
5、t-out capability to record welding current wave shape. Welding Force Gage Hydrostatic type (or equivalent). Knife Edge Caliper FORD LABORATORY TEST METHOD BV 109-02 Page 2 of 4 Copyright 2000, Ford Global Technologies, Inc. Materials Required Welding Electrodes Two WC1A25A 15.8 mm diameter; RWMA Cla
6、ss Two, 6.0 mm diameter face and a 45 truncated cone nose configuration. Test Coupons Cold rolled low carbon (SAE 1008) steel or equivalent; clean and free of burrs and/or ragged edges; 38 x 254 x 0.91 mm (nominal) (purchase as 0.78 mm minimum thickness). Test Panels Tape Form Sealer Nominal thickne
7、ss 1.6 mm unless otherwise specified by the applicable Engineering Material Specification; 152.4 mm long. 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 % relative humidity for not less than 24
8、 h prior to testing and tested under the same conditions unless otherwise specified. Procedure 1. Verify the following weld schedule for the shunt weld on a set of test coupons without sealer applied. Adjust transformer tap setting to obtain 4.0 - 5.0 V open circuit secondary voltage. Adjust the wel
9、ding controls and tip pressure to obtain the following weld schedule: Electrode force 2.5 kN Welding Time 9 cycles Secondary current 11,000 amp, nominal (set for a value that will just produce a 5.1 mm minimum button size). 2. Prepare 6 test panels as shown in Figure 1. 3. Using the weld schedule de
10、veloped for the shunt weld, make a shunt weld in each coupon, located as shown in Figure 1. FORD LABORATORY TEST METHOD BV 109-02 Page 3 of 4 Copyright 2000, Ford Global Technologies, Inc. 4. Using one of the test panels, make a series of test welds, through the sealer and adjust the welding machine
11、 controls to obtain the following weld schedule. Electrode force 2.9 kN Welding time 12 cycles (successful candidate material will require approximately 3 cycles of weld time to reach 90 % of full welding current.) Welding current 12,500 amp 5. Weld 5 additional test panels; refer to Figure 1. 6. Te
12、st welds by either the chisel test or the peel test per ES-E6DB-1N261-AA. The weld button size may be measured by a scale or knife edge caliper. The minimum button diameter: Shunt Weld 5.1 mm Sealer Test Weld 4.3 mm 7. If a 4.3 mm diameter weld button is not obtained with the weld schedule specified
13、 in Step 4, stop the test. 8. If the minimum button size is obtained, prepare 6 additional panels (shunt weld only) to be tested after 30 days using the sealer weld test. 9. The weld schedule specified in Step 4 shall be used for the 30 days weld test. The test coupons shall be aged for 30 days at 2
14、3 +/- 2 C. Note: During the above test, there shall be no constant or violent metal expulsion nor excessive smoke or fumes which are irritating to the operator. Occasional expulsion which is characteristic of most coated materials is acceptable. Chemicals, materials, parts, and equipment referenced
15、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 109-02 Page 4 of 4 Copyright 2000, Ford Global Technologies, Inc. ELASTOMER SEALERS (TAPE-FORM) - WELDING ACCEPTANCE Figure 1 TEST PANEL
