1、 WORLDWIDE ENGINEERING STANDARDS Material Specification GMW16536 Pumpable Sealer Between Flanges of Welded Structures - Steel Acceptance Criteria and Repair Procedures Copyright 2011 General Motors Company All Rights Reserved August 2011 Originating Department: North American Engineering Standards P
2、age 1 of 9 1 Scope Note: Nothing in this standard supercedes applicable laws and regulations. Note: In the event of conflict between the English and domestic language, the English language shall take precedence. 1.1 Purpose. This standard provides the acceptance criteria and repair procedures for we
3、ld-through sealer(s) in automotive products for which GM is responsible for establishing or approving product design. 1.2 Applicability. This standard applies to any application where a weld-through sealer(s) capable of being pumped at ambient temperatures and intended for use in the body shop is us
4、ed to seal body joints against water, dust and air intrusion. The criteria established in this standard become mandatory when referenced in product release information or an approved Product Quality Standard (PQS) document. Deviations from any sealer criteria provided in this standard must be identi
5、fied in product release information or an approved PQS document. 1.3 Usage. Weld-through sealed structures are considered satisfactory when they provide leak-free seams in identified water paths, and prohibit water intrusion to meet corrosion requirements for a required period. Corrosion requirement
6、s in structures containing “weld-through” sealer in a vehicle are varied in both type and magnitude and cannot be addressed by this standard. Therefore, while the sealer quality criteria of this standard are consistent with service requirements, they have been established specifically for use in pro
7、cess and product monitoring. Any attempted application of this document to other uses may lead to an erroneous result or conclusion. 1.4 Clarification. For clarification of this standard or editorial comments, email the GM Weld Council at: . Proposed changes to this standard must be presented to the
8、 Global Weld Council. To suggest a change to this standard, reference the “Procedure for Weld Standard Changes” on the Weld Councils web page. 2 References Note: Only the latest approved standards are applicable unless otherwise specified. 2.1 External Standards/Specifications. None 2.2 GM Standards
9、/Specifications. GMW15563 2.3 Additional References. GMS Operating Guidelines and Global Launch Manual, Section B4 Procedure for Weld Standard Changes available on Weld Councils web page. 3 Requirements 3.1 General Acceptance Criteria. 3.1.1 Correct Material. The weld-through sealer applied shall be
10、 the material specified in the design release documentation and/or the Process Data Sheet for Sealer Application (see Appendix A, Figures A1 and A2). The product is non-conforming if incorrect material is being applied. Copyright General Motors Company Provided by IHS under license with General Moto
11、rs CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16536 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 2 of 9 3.1.2 Substrate Condition. Cleaning of the faying surfaces is not required unless
12、 visibly contaminated by dirt, dust, corrosion, or other foreign matter. Preparation of the faying surfaces is not required unless specified in the material specifications. 3.2 Visual Acceptance Criteria. 3.2.1 Bead Location. The bead position along the flange, including the start and stop location
13、are to be in agreement with the design release and/or the Process Data Sheet for Sealer Application (see Figures A1 and A2). Beads not properly located require the process to be adjusted to the specified start and stop locations as well as bead position along the flange. Bead position across the fla
14、nge may be adjusted to achieve wet out and to minimize or eliminate excess material squeezed out of the joint (see Figures A4 and A5). Squeeze-out of weld-through sealant is not allowed in locating holes, fixing holes and tooling holes. For other types of holes, e.g., clearance holes, drain holes, e
15、tc., small amounts of squeeze-out can be accepted as long as functionality is not degraded and work environment and wash-off problems do not occur. Local squeeze-out towards the paint shop side of the flange shall be used to prevent pockets or undercuts where there is a risk of moisture intrusion be
16、tween a paint shop seal and a weld-through sealant. Missing or mislocated beads cause the product to be non-conforming. 3.2.2 Wet Out. Wet out is defined as the “footprint” of sealer surface area on each of the flanges in a joint the sealer covers. It is required that both flange surfaces exhibit ev
17、idence of sealer contact (flattening of the dispensed bead) after separation. Actual transfer of sealer during this separation may or may not occur (see Figure A5). On flange surfaces that do not exhibit some evidence of sealer “footprint” on both flanges, the process is to be adjusted to eliminate
18、the condition (see Figure A4). 3.2.3 Wet-Out Width. The wet-out width is to be a minimum 7 mm wide to a maximum of 100% of the flange width (see Figures A3 and A5). It is to be measured on the bead application flange surface at the narrowest place. If the wet-out width is less than 7 mm at the narro
19、west place, then the bead is to be adjusted to eliminate the condition. 3.2.4 Voids, Skips or Interruptions. Any voids, skips or interruptions in sealer bead applications cause the product to be non-conforming. 3.3 Measurable Acceptance Criteria. Not applicable. 3.4 Disposition/Repair Procedure. 3.4
20、.1 Disposition. All known and suspect product with non-conforming sealer applications must be repaired. Refer to Appendix B - Table B1 to determine when a weld-through sealer application is non-conforming. When required, sealer applications shall be repaired according to the procedures specifically
21、authorized by the appropriate Product Engineer. 3.4.2 Repair Procedure. Beads that are non-conforming with this standard can be repaired with suitable methods, e.g., placement of a new bead of sealer conforming to this standard, and/or application of paint shop seal. 4 Manufacturing Process 4.1 Proc
22、ess Control. The welding source is responsible for establishing practices and test methods to assure that the criteria of this standard are met and are consistent with the GM Joining and Dispense Process Control Procedure, GMW15563. 4.2 Sealer Bake Control. The painting source is responsible for est
23、ablishing practices and test methods to ensure that the cure and/or post-cure cycle criteria are met and are consistent with the applicable material specifications. 5 Notes 5.1 Glossary. Faying Surfaces: Pre-bonded pair of close-fitting surfaces that are to be connected. Product Quality Standard (PQ
24、S): Measurable requirements for product characteristics which, when satisfied, ensure the product meets internal and external customer requirements. (Refer to GMS Operating Guidelines and Global Launch Manual, Section B4.) Copyright General Motors Company Provided by IHS under license with General M
25、otors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16536 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 3 of 9 5.2 Acronyms, Abbreviations, and Symbols. BFO Bill of Material Family Owner BO
26、M Bill of Material MPD Master Process Document PQS Product Quality Standard 6 Coding System This standard shall be referenced in other documents, drawings, etc., as follows: GMW16536 7 Release and Revisions This standard was originated in February 2011. It was first approved by the Global Weld Counc
27、il in July 2011. It was first published in August 2011. Issue Publication Date Description (Organization) 1 AUG 2011 Initial publication. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license fr
28、om IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16536 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 4 of 9 Appendix A Figure A1: Process Data Sheet for Sealer Application Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for R
29、esaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16536 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 5 of 9 Figure A2: Visual Aid for Sealer Application Copyright General Motors Company Provided by IHS under
30、license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16536 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 6 of 9 Figure A3: Wet Out Test Measurement Copyright General Mo
31、tors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-GM WORLDWIDE ENGINEERING STANDARDS GMW16536 Copyright 2011 General Motors Company All Rights Reserved August 2011 Page 7 of 9 Figure A4: Bead Locat
32、ion and Appearance 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 GMW16536 Copyright 2011 General Motors Company All Rights Reserved August
33、 2011 Page 8 of 9 Figure A5: Wet Out 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 GMW16536 Copyright 2011 General Motors Company All Righ
34、ts Reserved August 2011 Page 9 of 9 Appendix B Table B1: Determining When a Weld-Through Sealer Application is Discrepant Attribute Criteria Does Non-conformance Make the Bond Discrepant? Corrective Action(s) Required Disposition Wrong Material Refer to section 3.1 Yes Replace with Correct Material
35、and Purge System Refer to section 3.4 Contaminated Substrate Refer to section 3.1 No Clean Substrate N/A Missing Bead Refer to section 3.2 Yes Adjust Process Refer to section 3.4 Mislocated Bead Refer to section 3.2 Yes Adjust Process Refer to section 3.4 Wet Out Refer to section 3.2 No Adjust Proce
36、ss N/A Voids, Skips or Interruptions Refer to section 3.2 Yes Adjust Process Refer to section 3.4 Note 1, Note 2, Note 3, Note 4 Note 1: Non-conforming Body shop applications in closed joints that are secondary seals where paint shop application is the primary seal shall be considered remediated by
37、definition. Note 2: Voids, skips or interruptions which may be closed-out during the wet-out process or by material expansion during cure do not require repair. During qualification, evaluate and document according to local procedures and maintain a representative boundary sample. Note 3: Localized
38、disruptions resulting from the welding process (or other mechanical fastening) do not require repair. During qualification, evaluate and document according to local procedures and maintain a representative boundary sample. Note 4: Localized thinning and/or minor interruptions at sheet metal transiti
39、ons and sharp corners/radii do not require repair. During qualification, evaluate and document according to local procedures and maintain a representative boundary sample. Copyright General Motors Company Provided by IHS under license with General Motors CompanyNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-
