1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW15563 Joining and Dispense Process Control Procedure Copyright 2013 General Motors Company All Rights Reserved December 2013 Page 1 of 17 1 Scope Note: Nothing in this standard supercedes applicable laws and regulations. Note: In the event o
2、f conflict between the English and domestic language, the English language shall take precedence. 1.1 Material Description. This standard defines equipment process control and product inspection requirements for producers of GM welded or mechanical clinched product. 1.2 Symbols. Not applicable. 1.3
3、Typical Applications. The requirements of this standard are applicable to joining and dispense processes utilized by a General Motors fabricating and/or assembly plant to manufacture automotive parts and assemblies (prior to paint operations). 1.4 Remarks. For clarification of this standard or edito
4、rial comments, email the GM Weld Council at . Proposed changes to this standard must be presented to the Global Weld Council. To suggest a change to this standard, reference the “Procedure for Weld Standard Changes” on the Global Weld Councils web page. 2 References Note: Only the latest approved st
5、andards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards/Specifications. None 2.3 Additional References. Body-in-White (BIW) Manufacturing Validation Standard (MV1) Dispense Tool Data Sheet Global Launch Manual GM Global Safety 21 Process Weld T
6、ool Data Sheet 3 Requirements 3.1 Requirements on Test Specimens. Not applicable. 3.2 Designation of Responsibility. 3.2.1 Product Engineering. The product engineering function is responsible for defining the structural requirements of the vehicle. These requirements include the joining method, quan
7、tity, location, and product tolerances. Product acceptance criteria are to be consistent with published GM Engineering Standards. 3.2.2 Manufacturing Engineering. The manufacturing engineering function is responsible for evaluating the product design for manufacturability. Manufacturing Engineering
8、defines the process, type of tooling, and operational sequences to manufacture the product in conformity to the released design. 3.2.3 Plant Responsibility. The plants must adhere to the product specifications approved by Product Engineering and the process requirements defined by Manufacturing Engi
9、neering. Product Engineering must Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15563 Copyright 2013 General Motors Company All Rights
10、Reserved December 2013 Page 2 of 17 approve any variance or deviation from product specifications. Variance from process requirements must be in agreement with written procedures. 3.3 Process Evaluation. 3.3.1 Tool Verification and System Qualification. The procuring manufacturing engineering functi
11、on must verify that new as built tooling agrees with the tool design and/or Tool and Equipment Statement of Requirements. The applicable sections of the Global Launch Manual and BIW Manufacturing Validation Procedure (MV1) are to be utilized to perform the verification and qualification activities.
12、Any tooling revisions necessitated by this procedure must be completed and tool design documents updated. Records of the verification and system qualification activity are to be maintained. Once qualified, the applicable Weld Tool Data or Dispense Tool Data Sheet and the associated robot program are
13、 to be placed under change control. 3.3.2 Tool Re-qualification. Each tool must be re-qualified whenever a change occurs in the product or process that was part of the original verification and qualification activity. Records of the re-qualification activity are to be maintained. 3.3.3 Equipment Pro
14、cess Monitoring. Equipment process monitoring, (i.e., predictive maintenance) consists of measuring process parameters established during tool qualification as well as visual evaluation of the equipment functional operation. Parameters identified outside prescribed limits require appropriate correct
15、ive action to restore the process to the qualified state. Equipment process monitoring requirements for the various joining and dispense processes are contained in Appendices A thru J of this standard. Tasks identified as Operator Maintenance (OM) should be considered for assignment to the productio
16、n organization if practical. Equipment process monitoring activities are to be described in written procedures or standardized work. 3.3.4 Equipment Scheduled Maintenance. Each location shall have documented plans for the preventative maintenance of equipment. The equipment maintenance schedule shou
17、ld be consistent with the tool or equipment manufacturers recommendations. 3.4 In-Process Inspection and Test. In-process inspection consists of evaluating the manufactured/welded product with the released design and the applicable GM Engineering Standards to identify, contain, and repair nonconform
18、ing product. In-process inspection and tests are to occur as close as practical to the point of operation. The in-process inspection and test activity for all welded parts and dispense applications must be described in written procedures or standardized work. Unless stated elsewhere, inspection and
19、testing is to occur at evenly spaced intervals throughout the shift, (i.e., a frequency of four times per shift would equate to one check approximately every 2 h of an 8 h shift, a frequency of two times per shift would equate to one check in the first half of the shift and one check in the second h
20、alf of the shift). The purpose of the in-process inspection is to periodically verify specific quality attributes and detect deficiencies prior to product leaving the weld shop. In-process inspection is not a substitute for the required equipment maintenance or equipment process monitoring. Nonconfo
21、rming product identified during in-process inspection and test requires suspect product to be contained and repaired or an authorization allowing the product to deviate from specification. Documented corrective actions are required for nonconforming product. 3.4.1 In-Process Inspection and Test (Res
22、istance Spot Welds and Sheet Metal Projection Welds). A deformation check of all spot welds (for all styles and all cells) is recommended to occur four times per shift at evenly spaced intervals. The minimum required frequency is one check per weld gun, metal stack-up, and weld schedule combination,
23、 sampled two times per shift. When a weld gun installs more than one weld on the same metal stack-up or on different body styles, rotate the in-process inspection (where practical) to include the other welds and body styles. Concurrent with the deformation checks, visually inspect the adjoining weld
24、s for conformance to the applicable product drawing and GM Engineering Standard. This visual inspection is to identify welds containing holes or cracks, welds not installed, edge welds, welds with excessive indentation, distortion, or surface eruptions, and extra welds. In instances where a deformat
25、ion check of spot welds is not possible or the spot welds are inaccessible due to being closed out, the alternative methods of verifying or assuring weld fusion may be utilized: Ultrasonic weld inspection (refer to 3.6). Increased equipment process monitoring. Increased weld destruct test frequency.
26、 Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15563 Copyright 2013 General Motors Company All Rights Reserved December 2013 Page 3 of
27、17 Witness coupons. The frequency and use of an alternative method must be documented as described in 3.4. 3.4.2 In-Process Inspection and Tests (Welded Fasteners). Welded fasteners shall be verified for conformance to the visual acceptance criteria of the applicable standard a minimum of two times
28、per shift. Threaded welded fasteners are to be tested with a chisel notch test, click wrench procedure or portable nut retention tester. Retention of non-threaded welded fasteners is to be tested with a chisel notch test. The minimum required frequency is one fastener per weld gun and metal stack-up
29、, sampled two times per shift. When a weld gun welds more than one fastener on the same metal stack-up or on multiple body styles, rotate the in-process inspection (where practical) to include the other fasteners. 3.4.3 In-Process Inspection and Tests (Welded Studs). Welded studs shall be verified f
30、or conformance to the visual acceptance criteria of the applicable standard a minimum of two times per shift. Drawn arc weld studs are to be proof tested utilizing a nondestructive bend test or click wrench style stud testing tool. The minimum required frequency is one stud per weld gun and metal st
31、ack-up, sampled two times per shift. When a weld gun installs more than one stud on the same metal stack-up or on multiple body styles, rotate the in-process inspection (where practical) to include the other studs. 3.4.4 In-Process Inspection and Tests (Mechanical Clinches). Mechanical clinches shal
32、l be verified for conformance to the visual acceptance criteria of the applicable standard a minimum of two times per shift. Mechanical clinches are to be tested according to the manufacturers recommendation using a Go/No Go gauge, calipers or a scissors gauge (7.1, Glossary). The minimum required f
33、requency is one clinch for each operation and metal stack-up, sampled two times per shift. When one tool installs more than one clinch on the same metal stack-up or on multiple body styles, rotate the in-process inspection (where practical) to include the other clinch locations. 3.4.5 In-Process Ins
34、pection and Tests (Arc and Laser Welds). Manually installed arc welds shall be verified for conformance to the visual criteria of the applicable GM Engineering Standard and product design release information on all jobs. Automated or robotically installed arc welds, arc braze, plasma braze, laser an
35、d laser braze joints shall be verified for conformance to the visual acceptance criteria of the applicable standard a minimum of two times per shift on each body style produced. In-process physical testing of arc welds, arc braze and laser braze joints is not required. 3.4.6 In-Process Inspection an
36、d Tests (Sealer and Adhesives). Manually applied sealer and adhesive shall be verified for conformance to the visual acceptance criteria of the product release document or the approved Product Quality Standards (PQS) on all jobs. Note: Bead diameters when shown are reference values only to aid in th
37、e initial set up and qualification of the process to achieve wet out. Automated dispense operations equipped with vision monitoring require inspection of a single 25 mm portion of the bead. Automated dispense operations not equipped with vision monitoring are to be visually verified for conformance
38、to requirements once per shift on each body style produced. 3.4.7 In-Process Inspection and Tests (Self Pierce Rivets). Self Pierce Rivets (SPR) shall be verified for conformance to the visual acceptance criteria of the applicable standard a minimum of two times per shift. 3.4.8 In-Process Inspectio
39、n and Tests (Clinch Studs). Clinch studs shall be verified for presence and correct part a minimum of two times per shift. Clinch stud torsional resistance is to be verified per the sample size and frequency specified for standard care fasteners in the GM Global Quality Requirements (GQR) Manual. 3.
40、4.9 In-Process Inspection and Tests (Clinch Nuts). Clinch nuts shall be verified for presence and correct part a minimum of two times per shift. Clinch nut torsional resistance is to be verified per the sample size and frequency specified for standard care fasteners in the GM Global Quality Requirem
41、ents (GQR) Manual. 3.4.10 In-Process Inspection and Tests (Fasteners). Torque controlled fasteners (including Self Piercing and Extruding Screws) inspection and process control requirements are specified in the GM Global Quality Requirements (GQR) Manual. 3.5 Weld Destruct Test - General. The purpos
42、e of the weld destruct is to verify the effectiveness of the joining and dispense related process controls, (i.e., equipment process monitoring, equipment maintenance, and in-process inspection) implemented. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNo
43、t for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW15563 Copyright 2013 General Motors Company All Rights Reserved December 2013 Page 4 of 17 Nonconforming product identified during a destruct test requires suspect product to be han
44、dled in accord with the Global Quality Requirements for Nonconforming Material. Documented corrective actions are required for nonconforming product. 3.5.1 Weld Destruct Test Frequency - Assembly Plants. At the Start of System Fill, the frequency of full body destruct is one of each new body style p
45、er month. Once the system is running at a steady state, the weld system process capability can be assessed. Once acceptable process capability has been demonstrated and documented, the weld destruct frequency can then be reduced to a quarterly destruct test of each body style. An acceptable process
46、capability demonstration consists of completing three consecutive monthly destruct tests that meet requirements (all patterns conforming). 3.5.2 Weld Destruct Test Frequency - Fabricating Plants. At Start of Production, the frequency of destruct tests is to be one of each assembly per month until pr
47、ocess capability is demonstrated and documented. Process capability consists of completing three consecutive destruct tests that meet requirements (all patterns conforming). The frequency can then be reduced to a quarterly destruct test of each assembly. 3.5.3 Weld Destruct (Resistance Spot Welds).
48、Prior to conducting each weld destruct and as part of a re-qualification activity, weld quantity and location are to be verified. Visual acceptance criteria including applicable appearance standards are also to be verified. The weld destruct test is an evaluation of welded product that uses any of t
49、he various methodologies (i.e., destructive hammer and chisel, peel test, mechanical spreader, cross sectioning) to measure and evaluate various product quality characteristics for conformance to requirements. Destructively tested product results in irreversible metal separation, and this product cannot be reworked or repaired. Note: Peel testing is the preferred method of inspection for aluminum spot welds. Hammer and chisel testing is not an acceptable met
