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. 2012 by Navistar, Inc. DECEMBER 2012 Page 1 of 5 NAVISTAR, INC. TMS (TRUCK MATERIAL SPECIFICATION) NUMBER
2、: TMS-9562 TITLE: Quality Requirements For Laser Welded Parts CURRENT REV. No.: 1212 DATE: December 2012 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: N/A PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REVISION This specification may involve ha
3、zardous 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 determine the applicability of regulatory limits prior to use. Change Notic
4、e: NEW Keywords: Welding, laser welding, sheet metal welding, tailor welded blanks. 1.0 APPLICATION This specification covers the quality requirements for laser welding used in fabricating truck parts, bodies, and other truck components made from uncoated low carbon or high-strength steel grades (CE
5、MS A-6 Part I), galvanized steel (CEMS A-6 Part II), stainless steel per CEMS A-37, and aluminum alloys per CEMS C-10. Laser welding may generally be considered for parts having material thicknesses in the range of 0.6 to 3.5 mm. A laser weld is expected to be at least as strong as the parent materi
6、al. 2.0 SCOPE This specification establishes quality requirements and defines test procedures used to assess quality and performance of laser welded parts. 2.1 Restricted Chemical Substances Effective January 1, 2007, all product supplied to the requirements of this specification must comply with th
7、e requirements of the CEMS B-50 specification. 3.0 REFERENCE DOCUMENTS Unless otherwise specified, the latest issue of all referenced standards shall apply. The following standards, specifications and regulations are referenced in this specification. 4.0 GENERAL REQUIREMENTS 4.1 Base Metal 4.1.1 Unc
8、oated Metal The type of uncoated metals covered in this spec would include: Quality System Standard ISO 9001 or TS-16949 NAVISTAR CEMS A-6, Part I NAVISTAR Manufacturing Standard MS-D-13 NAVISTAR CEMS A-6, Part II CFR Title 29, Part 1910 NAVISTAR CEMS A-37 NAVISTAR CEMS B-50 NAVISTAR CEMS C-10 AWS A
9、2.4 AWS C7.2M 2NUMBER: TMS-9562 TITLE: Quality Requirements For Laser Welded Parts REVISION: DECEMBER 2012 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
10、. 2012 by Navistar, Inc. DECEMBER 2012 Page 2 of 5 1) low carbon steel (Grade 1 per CEMS A-6, Part I) 2) structural steel (SS) (Grade 6, Types 205SS-380SS, per CEMS A-6, Part I) 3) high-strength low-alloy (HSLA) steel (Grade 6, Types 275X-550X per CEMS A-6, Part I) 4) stainless steel per CEMS A-37 5
11、) aluminum alloys per CEMS C-10 4.1.2 Metallic Coated Steel Carbon steel sheet to be laser welded may also be coated, on one or both sides, with zinc or zinc alloy coating (Grade 1GALV or Grade 6GALV) or aluminum (Grade 1A) per CEMS A-6, Part II. 4.2 Weld Requirements The type of welds required and
12、weld joint location will be specified on the engineering drawing using standard welding symbols per American Welding Society AWS A2.4. In addition, LBW (laser beam weld) will be placed in the weld symbol tail to indicate that laser welding is required. 4.2.1 Types of Joints 4.2.1.1 Butt Joint The bu
13、tt joint is a joint between two members lying approximately in the same plane, as shown below. Most laser welded butt joints are prepared as square groove welds (see weld symbol below). Example of butt joint: Square groove weld symbol: 4.2.1.2 Other Joints Other joints which are sometimes joined usi
14、ng laser welding include the T-joint and lap joint. The choice of weld symbols for these types of joints would depend on the desired weld requirements. See AWS A2.4 for weld symbols to use. 4.2.1.2.1 T-Joint A T-joint is the joint between two members located approximately at right angles to each oth
15、er to form a “T” (see below). Refer to AWS C7.2M, Figure 7.11, for common T-joint configurations related to laser welding. Example of T-joint: 4.2.1.2.2 Lap Joint A lap joint is a joint between two overlapping members as shown in the figure below. Refer to AWS C7.2M, Figure 7.12, for common lap join
16、t configurations related to laser welding. The applicable weld symbol would be shown on the engineering drawing, depending on the type of lap joint weld required. 3NUMBER: TMS-9562 TITLE: Quality Requirements For Laser Welded Parts REVISION: DECEMBER 2012 This document is restricted and may not be s
17、ent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2012 by Navistar, Inc. DECEMBER 2012 Page 3 of 5 Example of Lap Joint: 4.4 Pre-Weld Surface Condition The cleanliness and flatness of mating parts is
18、 a key factor in successful laser welding. The development of satisfactory interface contact of the mating parts, using production fixturing, requires clean conforming surfaces. The surfaces of parts to be welded should be free of contaminants that adversely affect weld quality, such as white or red
19、 rust, heavy scale, dirt, contaminated drawing oils, and drawing compounds hardened with age. Improper cleaning procedures are commonly found to be the cause of weld defects. 4.5 Weld Quality Two quality levels are defined for laser welds: 1) Class A laser welded joints with specific requirements fo
20、r strength, reliability, or safety. 2) Class B laser welded joints having non-critical requirements for strength, reliability, or safety. Applies to all welds not designated as Class A. Refer to Table I for allowable weld defects for both Class A and Class B welds. The required weld class for a give
21、n part or weld location should be specified on the engineering drawing. If none is specified, Class A will be assumed. 4.6 Requirements for Inspection and Test Methods 4.6.1 Visual Examination After laser welding, joints should be examined for external imperfections as described in Table I. 4.6.2 Ra
22、diography X-ray radiography may be used to identify presence of internal imperfections such as cracking, porosity, lack of penetration, lack of fusion, etc. Refer to Table I. 4.6.3 Computerized Weld Inspection Inspection and documentation of laser welding may be accomplished through use of online co
23、mputer monitoring of weld profiles for process control and control limits. Attributes for computer monitoring might include types of weld defects, number and severity of defects, weld reject data, process variables, etc. Documentation obtained from this type of inspection/monitoring should be includ
24、ed as part of the Quality Control Plan, and be available to purchaser on request. 4.6.4 Tensile Testing Pull testing to failure of laser welds will be performed on a regular basis and included in the Quality Control Plan. Failure should not occur in the weld in order to be acceptable. 5.0 QUALITY CO
25、NTROL PLAN A Quality Control Plan will be developed in conjunction with the Manufacturing Weld Process Control plan to assure compliance with the requirements of the Engineering drawing and of this specification. The Quality Control Plan will cover inspection procedures, including laser weld testing
26、 methods. The weld inspection results will be documented. 4NUMBER: TMS-9562 TITLE: Quality Requirements For Laser Welded Parts REVISION: DECEMBER 2012 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers
27、 are required to assume all patent liability. 2012 by Navistar, Inc. DECEMBER 2012 Page 4 of 5 6.0 SOURCE APPROVAL AND QUALITY CONTROL 6.1 Supplier Requirements All suppliers to NAVISTAR are required to be registered to ISO 9001 Quality System Requirements. NAVISTAR will also accept TS-16949 registr
28、ation as long as the supplier can also fulfill all AIAG PPAP (Production 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
29、. 6.2 Approval Parts supplied against contracts or purchase orders citing 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 materi
30、al, properties, processing practices, construction, color, or labeling of the product are required, the supplier shall notify Materials Engineering and Purchasing and Supplier Development of the proposed change(s). Test data indicating conformance to all requirements of this specification, test samp
31、les, and new or amended or updated Material Safety Data Sheets (MSDS), in accordance with CFR Title 29, Part 1910, shall be submitted with the request for change. 6.3 Process Control The supplier shall either perform and report results of tests on specific lots of parts produced using ISO 9001 or TS
32、-16949 guidelines, or provide 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 requ
33、irements on specific products. 7.0 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. 8.0 DESIGNATION ON DRAWINGS Drawings requiring laser welding will
34、include weld symbol and weld location on the engineering drawing. A note should be added to the drawing: “Must meet requirements of TMS-9562, Class A” (or Class B if applicable) 9.0 TECHNICAL INFORMATION For further information related to the technical content of this specification, contact: Supplie
35、rs may purchase controlled copies of this specification by contacting: Materials Engineering and Technology Dept. E-mail: MaterialsEngineeringN IHS Global Inc. 15 Inverness Way East Englewood CO 80112-5776 Phone: 1-800-854-7179 E-mail: AutomotiveIHS.com Website: http:/ 5NUMBER: TMS-9562 TITLE: Quali
36、ty Requirements For Laser Welded Parts REVISION: DECEMBER 2012 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. 2012 by Navistar, Inc. DECEMBER 2012 Page
37、5 of 5 TABLE I. WELD IMPERFECTION LIMITS Type of Imperfection Remarks Limits for Imperfections* Class A Class B Cracks A break or gap in the surface of a weld. None permitted None permitted Crater cracks A gap or break in the surface of a weld that occurs at the crater of the weld due to improper we
38、ld termination. None permitted None permitted Porosity Discontinuity in the weld which appears as tiny bubbles or voids, which can weaken the weld area. Size of pore 0.3t Size of pore 0.4t Clustered porosity Max. dimension of single pore same as for porosity above. Combined porosity permitted, as lo
39、ng as the affected weld length (L) (distance from edge to edge of pore) is as shown: L t L t Undercut A groove melted into the base metal at the weld toe which is left unfilled by weld metal. Gap depth 0.05t Gap depth 0.1t Lack of fusion or incomplete penetration Lack of complete integration between
40、 the weld and the base metal None permitted None permitted Linear misalignment The limits apply to deviations from the correct position. Centerlines should coincide. h 0.1t h 0.15t Weld spatter Small particles of material expelled on the part surface during welding. None permitted None permitted * t = material thickness
