1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 1 of 18 NAVISTAR, INC. Material, Parts, and Process Specificati
2、ons (MPAPS) NUMBER: MPAPS P-9516 Former designation: TMS-9516 TITLE: Quality Requirements For Resistance Spot Welds CURRENT REV. No.: 1410 DATE: Oct. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-9516 - Feb. 2010 PRINTED COPIES OF THIS DOCUMENT MUST
3、 BE VERIFIED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determin
4、e the applicability of regulatory limits prior to use. Change Notice: Changed to new MPAPS format; updated reference documents; editorial changes. 1.0 APPLICATION This specification covers the quality requirements for resistance spot welds used in fabricating truck bodies and other truck components
5、made from bare or coated low carbon steel (Grade 1 or Grade 1GALV per MPAPS A-6), high-strength steel grades (Grade 6 or Grade 6GALV per MPAPS A-6), stainless steel per MPAPS A-37, and aluminum alloys per MPAPS C-10. The specification is applicable to spot welded assemblies produced in NAVISTAR plan
6、ts and/or produced by suppliers in supplier facilities and then shipped to NAVISTAR plants. 2.0 SCOPE This specification establishes three resistance spot weld classifications and defines the quality requirements for each class. Specific requirements for spot weld nugget/button size, weld spacing, o
7、verlap, test and inspection criteria, and repair options for each class of spot weld are detailed in this specification. Engineering will determine the required weld classification and designate the appropriate class by using the weld symbol for that class on the engineering drawing (see Figure 1).
8、Weld Classification Weld Symbol Weld Description Obsolete Weld Class Obsolete Symbol Compliance Critical Any weld contributing to structural integrity in such manner that compliance to FMVSS or to roof strength requirements could be compromised by a substandard weld. Class A or or Compliance Welds D
9、urability Critical Any weld contributing to structural integrity in such manner that cab durability requirements could be compromised by a substandard weld. - Commercial or Normal Spot welds subjected to moderate or low levels of stress, requiring only a commercial or normal level of quality. Class
10、B None Commercial Welds 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with the requirements of the MPAPS B-50 specification. 2NUMBER: MPAPS P-9516 TITLE: Quality Requirements For Resistance Spot Welds REVISION
11、: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 2 of 18 3.0 REFERENCE DOCUMENTS Unless otherwise specifie
12、d, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. 3.1 Definitions Welding terms used in this specification are defined below. 3.1.1 Minimum Weld Diameter The smallest diameter measured on a fused
13、 nugget or pulled button. 3.1.2 Average Weld Diameter The arithmetic average of the smallest and largest diameters measured on a fused nugget or pulled button. 3.1.3 Satisfactory Weld A tested spot weld which is properly located, shows positive evidence of metal coalescence, is complete, is not exce
14、ssively distorted (see Section 3.1.5) and with the fused nugget or pulled button having either a minimum diameter (see 3.1.3.1) or an average diameter (see 3.1.3.2) equal to or greater than the applicable value shown in Column 3 of Table 1 (for steel). 3.1.3.1 Compliance Critical and Durability Crit
15、ical Welds: Compliance and Durability critical welds will have a minimum diameter greater than or equal to the applicable value shown in Column 3 of Table 1. 3.1.3.2 Commercial/Normal Welds: Commercial/normal welds will have an average diameter equal to or greater than the applicable value shown in
16、Column 3 of Table 1. 3.1.4 Undersize Weld A tested spot weld which shows positive evidence of metal coalescence and with a fused nugget or pulled button having either minimum diameter (see 3.1.4.1) or average diameter (see 3.1.4.2) smaller than a satisfactory weld but greater than or equal to the va
17、lue in Column 4, Table 1 (for steel). 3.1.4.1 Compliance Critical and Durability Critical Welds: Compliance and Durability critical welds will have a minimum diameter greater than or equal to the applicable value shown in Column 4 of Table 1. 3.1.4.2 Commercial/Normal Welds: Commercial/normal welds
18、with an average diameter equal to or greater than the applicable value shown in Column 4 of Table 1. 3.1.5 Substandard Weld A visually inspected or tested spot weld that shows one or more of the conditions listed in this section is a substandard weld. (Refer to ANSI/AWS D8.7) 3.1.5.1 Nugget/Button D
19、iameter Too Small: A tested weld whose fused nugget or button has either a minimum diameter (for Compliance or Durability Welds) or an average diameter (for Commercial or Normal Welds) that is less than the applicable value shown in Column 4 of Table 1 (for steel). 3.1.5.2 Cold Weld: A tested weld t
20、hat shows no evidence of metal coalescence. 3.1.5.3 Missing Weld: A weld not present at, or missing from, its specified location. Quality System Standard ISO 9001 or TS-16949 NAVISTAR MPAPS A-6, Parts I spot welding of other stainless steel grades should be verified. *Material Thickness value is the
21、 thinnest piece of those being welded *Centerline to centerline *Minimum contacting overlap (L). TABLE 4 WELD BUTTON DIAMETER REQUIREMENTS FOR ALUMINUM ALLOYS Column 1 Column 2 Column 3 Material Thickness * SET-UP WELD BUTTON DIAMETER MINIMUM WELD BUTTON DIAMETER mm in mm in mm in 0.65 0.025 3.8 0.1
22、5 3.0 0.12 0.81 0.032 4.3 0.17 3.56 0.14 1.02 0.040 4.8 0.19 4.06 0.16 1.27 0.050 5.3 0.21 4.57 0.18 1.60 0.063 6.1 0.24 5.08 0.20 1.80 0.071 6.6 0.26 5.33 0.21 2.03 0.080 6.8 0.27 5.72 0.22 2.29 0.090 7.2 0.28 6.10 0.24 2.54 0.100 7.6 0.30 6.35 0.25 3.18 0.125 8.6 0.34 7.11 0.28 . * Material Thickn
23、ess value is the thinnest piece of those being welded 16NUMBER: MPAPS P-9516 TITLE: Quality Requirements For Resistance Spot Welds REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are
24、required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 16 of 18 TABLE 5 SPACING AND OVERLAP GUIDELINES FOR ALUMINUM ALLOYS Material Thickness * Minimum Spot Weld Spacing* Minimum Contact Overlap* Minimum Edge Distance mm in. mm in. mm in. mm in. 0.41 0.016 12.7 0.50 9.5 0.
25、37 4.8 0.19 0.51 0.020 12.7 0.50 9.5 0.37 4.8 0.19 0.64 0.025 15.9 0.63 11.1 0.44 5.6 0.22 0.81 0.032 15.9 0.63 12.7 0.50 6.4 0.25 1.02 0.040 19.0 0.75 12.7 0.50 6.4 0.25 1.27 0.050 19.0 0.75 15.9 0.63 7.9 0.31 1.60 0.063 25.4 1.00 15.9 0.63 7.9 0.31 1.80 0.071 28.6 1.13 19.0 0.75 9.5 0.37 2.03 0.08
26、0 28.6 1.13 19.0 0.75 9.5 0.37 2.29 0.090 31.8 1.25 19.0 0.75 9.5 0.37 2.54 0.100 34.9 1.37 22.2 0.87 11.1 0.44 3.18 0.125 38.1 1.25 25.4 1.00 12.7 0.50 *Material Thickness value is the thinnest piece of those being welded *Centerline to centerline *Minimum contacting overlap (L). Measured from weld
27、 center to edge of sheet. 7.0 SOURCE APPROVAL AND QUALITY CONTROL 7.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registration as long as the supplier can also fulfill all AIAG PPAP (Product
28、ion Part Approval Process) documentation and approval requirements. Suppliers must maintain their certification with an accredited registrar and must furnish copies of registration certificates to their Corporate Buyer upon request. 7.2 Approval Parts supplied against contracts or purchase orders ci
29、ting this specification shall be equivalent in all respects to those samples that were approved by the purchaser. No changes in formulation or processing practices are permitted without approval. In the event that changes in material, properties, processing practices, construction, color, or labelin
30、g of the product are required, the supplier shall notify NAVISTAR Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samples, and new or amended or updated Material Safety Data Shee
31、ts (MSDS), in accordance with CFR Title 29, Part 1910, shall be submitted with the request for change. 17NUMBER: MPAPS P-9516 TITLE: Quality Requirements For Resistance Spot Welds REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission f
32、rom Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 17 of 18 7.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS-16949 guidelines, or p
33、rovide statistical evidence of the lot having been produced in a state of statistical control and with a process capable of providing all required properties. The part supplier and the quality control manager of the using NAVISTAR plant may determine testing and reporting requirements on specific pr
34、oducts. 8.0 SHIPPING, PACKING, IDENTIFICATION, AND PRESERVATION Loading, packing, identification, and preservation of parts supplied to this specification shall be in accordance with Manufacturing Std. MS-D-13. 9.0 TECHNICAL INFORMATION For further information related to the technical content of thi
35、s specification, contact: Suppliers may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. 10400 W. North Ave. Melrose Park, IL 60160 E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7
36、179 E-mail: AutomotiveIHS.com Website: http:/ A.0 GENERAL INFORMATION (Not a Requirement of the Specification) A.1 WELD REPAIR The weld repair procedure used to repair substandard welds must fully restore the joint to the quality level required by the original weld classification specified. A flowch
37、art showing the various weld procedures for steel in general order of preference is shown in Section A.2. A.1.1 Preferred Parts for Weld Repairs using Fasteners Contact the NAVISTAR Fastener Engineering group for guidance in selecting the appropriate fastener (part number) to be used in repair proce
38、dures. A.2 WELD REPAIR FLOW CHART (see chart on next page) 18NUMBER: MPAPS P-9516 TITLE: Quality Requirements For Resistance Spot Welds REVISION: 1410 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers
39、 are required to assume all patent liability. 2014 by Navistar, Inc. OCTOBER 2014 Page 18 of 18 STA R T C - f ra m e sp o t w e ld e r a c c e s s th e j o i n t? P a rts p a in te d o r e - c o a te d ? G re a te r t h a n 2 T sta c k u p ? MIG sp o t w e ld e q u ip . a v a il .? Se a le r o r a d
40、 h e s iv e p re s e n t? T rie d ri v e t re p a ir? 4 .4 . 1 Re - s p o t w e ld 4 .4 . 2 MIG sp o t w e ld Y e s No No Y e s No No Y e s 4 .4 . 3 Plu g / p u d d le w e ld No Y e s A c c e s s t o b o th s id e s o f j o in t? R iv e t h e a d o b je c ti o n a b le ? * Stru c tu ra l r iv e t o
41、b je c ti o n a b le ? * No No Y e s No Y e s Y e s 4 .4 . 6 Stru c tu ra l r iv e t P i n & c o l la r lo c k b o lt o b je c -ti o n a b le ? * No 4 .4 . 4 Pin & c o ll a r l o c k b o lt Y e s No C - f ra m e p ie rc e ri v e t m a c h in e re a c h th e w e ld ? Flu s h h e a d o f p ie rc e riv
42、 e t o b je c -ti o n a b le ? * No No Y e s 4 .4 . 5 Se lf - p ie rc in g ri v e ts Y e s Y e s R e m o v e p a in t o r e - c o a t Y e s T rie d we ld re p a ir? No Y e s Y e s P a i n t re m o v a b le ? No Sc ra p p a rts Sc ra p p a rts Sc ra p p a rts * objectionable = cosmetic appearance of repaired part is adjudged to be unacceptable.
