WORLDWIDE
Material Specification
ENGINEERING
Metals
STANDARDS
Weld Acceptance Criteria and Repair Procedures
Resistance Spot Welds – Steel
1 Scope
This standard applies to steels approved by GM for
Resistance Spot Welding (RSW).
1.1 Purpose. This standard provides the
acceptance criteria and repair procedures for
resistance spot welds in automotive products for
which GM is responsible for establishing or
approving product design.
1.2 Application. The criteria established in this
standard become mandatory when referenced on a
weld design document. Deviations from any weld
criteria provided in this standard must be identified
on a weld design document or other product
design document and be approved using the
Global Deviation Approval Process (GWS-8).
1.3 Usage. Welded structures are considered
satisfactory when they carry the intended service
loads for a required period. Service loads on
weldments in a vehicle are varied in both type and
magnitude and cannot be addressed by this
standard. Therefore, while the weld quality criteria
of this standard are consistent with service loading
requirements, they have been established
specifically for use in process and product
monitoring. Any attempted application of this
document to other uses, such as post-crash weld
quality assessment, may lead to an erroneous
result or conclusion. Discrepant welds by retaining
a portion of their engineering properties may still
contribute to the integrity of the assembly.
1.4 Process 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 applicable
Welding Process Control Procedures.
1.5 Clarification. For clarification of this
standard or editorial comments, email the
GMNA Weld Council at weld.council@gm.com.
Proposed changes to this standard must be
presented to the GMNA Weld Council. To suggest
a change to this standard, reference the
“Procedure for Weld Standard Changes” on the
GMNA Weld Council’s webpage.
© Copyright 2006 General Motors Corporation All Rights Reserved
January 2006 Originating Department: North American Engineering Standards
GMW14057
2 References
Note: Only the latest approved standards are
applicable unless otherwise specified.
2.1 External Standards/Specifications.
None
2.2 GM Standards/Specifications.
GMW3059 GMW3001
GMW14058
2.3 Additional References.
GWS-8
3 Requirements
3.1 Categories of Spot Welds. There are two
categories of spot welds: structural and process.
3.1.1 Structural Spot Welds. Structural spot
welds are installed for performance of the welded
product. All spot welds are structural unless
specifically noted as process welds on the weld
design document.
Structural spot welds shall be evaluated to the full
requirements of sections 3.2, 3.3 and 3.4 of this
standard.
3.1.2 Process Spot Welds. Process spot welds
are installed to facilitate in-process assembly, but
are not required for structural performance of the
product. Process spot welds must be approved by
Product and Manufacturing Engineering and
shown on the weld design document.
Process spot welds shall be evaluated to the
requirements of sections 3.2.1.2, 3.2.1.4 and
3.2.2.1 of this standard.
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GMW14057
3.2 Individual Spot Weld Criteria. There are 15
attributes used to evaluate spot weld quality.
These attributes are divided into two categories:
attributes that make the weld discrepant; and
attributes that do not make the weld discrepant, but
the attribute is undesirable for appearance or
processing.
3.2.1 Attributes – Discrepant Welds. Welds that
exhibit any of the following attributes are
discrepant welds. The welding process shall be
adjusted to its original qualified setup to eliminate
the discrepant condition.
3.2.1.1 Cracks. Spot welds with any surface
crack(s), that are visible without the aid of
magnification, are discrepant welds. See
Figure 3.
3.2.1.2 Holes. Spot welds that contain holes
extending through the weld are discrepant welds.
See Figure 7.
3.2.1.3 Edge Welds. Welds in which the spot weld
imprint, as defined by the impression left by the
electrodes, is not contained within all edges of the
sheet metal being welded are discrepant. See
Figure 5, welds E & F.
3.2.1.4 Missing Welds. When fewer welds exist
than are specified on the weld design document,
the omitted welds are discrepant.
3.2.1.5 Cold Welds. Weld locations that do not
produce a weld button after a chisel, pry or
destruct test or do not indicate a nugget when the
weld location is cross-sectioned are classified as
cold welds. Cold welds are discrepant welds.
© Copyright 2006 General Motors Corporation All Rights Reserved
Page 2 of 10
GM WORLDWIDE ENGINEERING STANDARDS
3.2.1.6 Weld Location. Spot welds must be
properly located relative to design location as
indicated on the weld template and to each other
as follows.
• In a pattern consisting of a single in-line row of
welds in which a distinct product feature
provides visual reference to the end weld, an
end weld installed greater than 10mm in radial
distance from the design location is a
discrepant weld. A distinct product feature
must be a visible trim edge or other
recognizable part feature that is perpendicular
or nearly perpendicular to the row of welds and
within 30mm of the end weld.
• For all other welds, a spot weld installed
greater than 20mm in a radial distance from
the design location is a discrepant weld.
• If the spacing between two adjacent welds in a
pattern consisting of a single in-line row of
welds exceeds the design spacing by greater
than 20mm, the weld furthest from the design
location is a discrepant weld.
January 2006
GM WORLDWIDE ENGINEERING STANDARDS GMW14057

3.2.1.7 Minimum Weld Size. The weld size may

be measured by either using the weld button
(Figure 10) or the weld nugget (Figure 13). The
minimum weld sizes shown in Table 1 are based
on the formula four times the square root of the
Determining Thickness (DT), with the DT
expressed in millimeters. A spot weld is discrepant
when the weld size is less than the minimum
acceptable weld size specified in
Table 1.

Table 1: Minimum Acceptable Weld Size

Determining Thickness Minimum Acceptable

(DT) Weld Size

0.65 - 1.29mm 4.0mm

1.30 - 1.89mm 5.0mm

1.90 - 2.59mm 6.0mm

2.60 - 3.25mm 7.0mm

With certain steels or types of loading, a weld

button may not always result from destructive
testing. In these cases metallurgical examination of
the fusion zone must be used to determine weld
size.
3.2.1.7.1 Selecting Determining Thickness (DT).
The DT of a two or three loose sheet welded
stackup is determined as follows:
• The thickness of the thinner sheet for a two
sheet stackup (Figure 1, stackup 2)
• The thickness of the second thinnest sheet for
a three unequal sheet stackup (Figure 1,
stackups 4, 5 & 6)
The thickness of one of the equal sheets for two or
three sheet stackup with two or more equal sheets
(Figure 1, stackups 1, 3, 7, 8, 9 & 10)
Figure 1: Determining Thickness
(2 & 3 Loose Welded Sheets)
3.2.1.7.2 Laminated Vibration Damping Steel.
The minimum weld size specified in Table 1 is
required only at the faying surface for laminated
steel. There are no minimum weld size
requirements for the interface between the layers
of the laminated steel.
For purposes of determining the minimum weld
size, the laminated steel shall be treated as one
sheet whose thickness is equal to the sum of the
two outer sheets and the inner visco-elastic layer
as shown in Figure 2.
Laminated Sheet Thickness

Visco-Elastic Layer

Measure Weld Size at Faying Surface

Figure 2: Laminated Steel

© Copyright 2006 General Motors Corporation All Rights Reserved

January 2006 Page 3 of 10

GMW14057
3.2.2 Attributes – Appearance and Processing
Considerations. Welds that exhibit the following
attributes are undesirable either from an
appearance or processing viewpoint. However,
these attributes do not make the weld discrepant.
3.2.2.1 Extra Welds. The number of spot welds
installed shall not exceed the number specified on
the weld design document, except as required by
the repair procedures described in section 3.5 of
this standard. The welding process shall be
adjusted to eliminate extra welds.
3.2.2.2 Whiskers. Welds exhibiting whiskers
should have the welding process adjusted to
eliminate the condition. See Figure 14.
Note: Welds shall be free of whiskers when using
ultrasonic inspection equipment to avoid damage
to the transducer.
3.2.2.3 Distortion. Spot welds in which the sheet
surfaces are distorted more than 25° from the
normal plane shall have the welding process
adjusted to the original qualified setup in order to
reduce the distortion to less than 25°. See
Figure 4.
3.2.2.4 Thinning. Spot welds exhibiting thinning
greater than 30% of the total metal stackup should
have the welding process adjusted to the original
qualified setup in order to reduce the thinning
below 30%. See Figure 8.
3.2.2.5 Trim Edge Deformation. Welds in which
the original edge of the weld flange is deformed by
the electrodes but whose spot weld imprint is
contained within all edges of the sheet metal being
welded are not discrepant. The process shall be
adjusted to the original qualified setup to eliminate
the condition. See Figure 5, welds C and D.
3.2.2.6 Indentation. Indentation is a depression on
the sheet surface. See Figure 8. The appearance
criteria for indentation are listed in Appendix A.
3.2.2.7 Surface Eruption. Surface eruption is an
upsurge of the sheet surface adjacent to the
electrode cap imprint. See Figure 9. The
appearance criteria for surface eruption are listed
in Appendix A.
3.2.2.8 Spatter. Spatter is weld metal expulsion
that remains attached to surface(s) adjacent to the
weld. See Figure 14. The appearance criteria for
spatter are listed in Appendix A.
© Copyright 2006 General Motors Corporation All Rights Reserved
Page 4 of 10
GM WORLDWIDE ENGINEERING STANDARDS
3.3 Weld Surface Appearance Criteria.
3.3.1 Classification. The following classifications
are used to communicate the desired surface
appearance of spot welds and are in addition to
requirements specified in section 3.2.
Product and Manufacturing Engineering must
identify and approve the application of weld
appearance classifications IIB and IIC for those
welds where appearance is deemed necessary to
satisfy perceptual quality requirements. Class III
welds shall be considered the default weld
appearance classification when no other
classification is specified on the welding design
document.
Welds that do not meet the additional appearance
criteria contained in Appendix A for the designated
appearance classification are not discrepant but
shall have the welding process adjusted (to the
original qualified setup) to achieve the desired weld
surface appearance criteria.
3.3.1.1 Class IIB Welds. Class IIB welds are
intended for sheet metal surfaces that are visible
on secondary surfaces of completed vehicles.
Class IIB welds provide the least visible marking
on the sheet metal surface in comparison to Class
IIC or III welds.
3.3.1.2 Class IIC Welds. Class IIC welds are
intended for sheet metal surfaces that are visible to
the customer on secondary surfaces of completed
vehicles and applicable where the product design
enablers for a Class IIB weld cannot be met. Class
IIC welds can also be applied to sheet metal
surfaces not visible on completed vehicles, and
where either downstream processes require welds
to be free of jagged surface eruptions or where
weld spatter may create an appearance problem in
the immediate area adjacent to the weld. Class IIC
welds have more visible marking on the sheet
metal surface than attainable with a Class IIB weld,
but less visible marking than a Class III weld.
3.3.1.3 Class III Welds. Class III welds are
intended for general use on sheet metal surfaces
where there is no special requirement for surface
appearance. Class III welds have no additional
appearance criteria.
3.3.2 Other Procedures. Product or
Manufacturing Engineering may require Metal
Finishing or other procedures for those spot welds
not meeting the criteria for weld surface
appearance.
3.3.3 Confirmation. Confirmation of appearance
requirements specified in Appendix A shall be
verified using either visual comparison to boundary
samples or by direct measurement.
January 2006
GM WORLDWIDE ENGINEERING STANDARDS
3.4 Spot Weld Pattern Conformance Criteria. A
pattern is a collection of spot welds to which a
tolerance is applied to meet structural
requirements and for determining manufacturing
acceptance of the product. Spot weld patterns
must include all structural welds and be shown on
the weld design document. Process welds shall not
be included in any weld patterns.
The spot weld pattern is conforming when the
number of acceptable spot welds (not discrepant
per the requirements of section 3.2 of this
standard) within a pattern meets or exceeds the
pattern tolerance as stated on the weld design
document. Manufacturing acceptance of product is
based on all patterns conforming. Known and
suspect product with nonconforming patterns must
be repaired.
3.4.1 Missing Welds, Cold Welds, and Welds with
Holes. All known missing welds, cold welds or
welds with holes detected during in-process
inspection must be repaired.
3.4.2 Repair Exceptions. An exception to
specified product repair requirements may be
permitted provided there is documented review
and approval by the responsible Product Engineer
allowing the suspect product to deviate from
specification and pattern conformance criteria.
3.4.3 Surface Appearance. Spot weld surface
appearance criteria are not used in determining
weld pattern conformance.
3.4.4 Process Spot Welds. Process spot welds
are not to be used in determining weld pattern
conformance. Process welds containing holes
require product repair.
Process welds that do not meet the remaining
requirements of section 3.1.2 (missing and extra
welds) should have the welding process adjusted
to its original qualified setup and do not require
repair.
3.5 Spot Weld Repair Procedures.
3.5.1 Repair Procedures. When required, spot
welds shall be repaired according to the
procedures specifically authorized by the
appropriate Product Engineer. In the absence of
this repair procedure, the following repair methods
shall be used in the following order of preference.
© Copyright 2006 General Motors Corporation All Rights Reserved
January 2006
GMW14057
3.5.1.1 Resistance Spot Weld Repair. Spot weld
with a weld gun that is qualified for the metal types
and thicknesses to be welded. One repair spot
weld shall be added for each spot weld being
repaired. Repair spot welds must meet the
requirements of this standard. Locate repair spot
welds as close as possible to the original
designated weld location without overlapping the
existing spot weld.
3.5.1.2 Arc Weld Repair. Arc weld repair of
laminated steels is not permitted.
3.5.1.2.1 Arc Spot or Plug Weld Repair. For each
spot being repaired, weld using GMAW plug or
GMAW spot with steel filler wire. The GMAW spot
or GMAW plug weld shall conform to the applicable
arc spot and plug weld acceptance criteria
standard. All repair personnel using this method of
repair must be periodically qualified and approved
following local procedures.
3.5.1.2.2 Arc Fillet Weld Repair. A GMAW fillet
weld may be used for two metal thickness joints.
The GMAW repair weld must be located as close
as possible to the original designated weld location
and must be a minimum of 20mm in length. The
repair welds must conform to GMW14058. All
repair personnel using this method of repair must
be periodically qualified and approved following
local procedures.
4 Notes
4.1 Glossary. Terms are grouped by attributes
where applicable and not necessarily in
alphabetical order.
Boundary Sample. A reference used to evaluate
the appearance characteristics of a weld based on
visual comparison. Appearance characteristics are
surface attributes inherent in the manufacturing
process (i.e. indentation, surface eruptions,
distortion, etc.).
Cold Weld. A weld that does not produce a weld
button after a chisel, pry or destruct test. At the
faying surface of a cold weld there is no indication
of fusion. Cold welds do not indicate a nugget
when the weld is cross-sectioned.
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GMW14057 GM WORLDWIDE ENGINEERING STANDARDS

Trim Edge Deformation. A condition in which the

Crack. A fracture type discontinuity characterized original edge of the weld flange is deformed by the
by a sharp tip and high ratio of length to width of electrodes but whose spot weld imprint is
opening displacement on the exterior surface. See contained within all edges of the sheet metal being
Figure 3. welded. See Figure 5, welds C and D.

F
Edge Weld
E
D Trim Edge
Deformation
C
B
Spot Weld
A
Figure 3: Surface Cracks
Weld Imprint
Distortion. Angle of displacement that the sheet B
surfaces are distorted from the normal plane. See Figure 5: Edge D
A E
Figure 4. Weld
C
Angle of Distortion
Extra Welds.
The number of
spot welds that
exceed the
number specified
on the weld % Thinning = 100 - E x 100
design document. B+D

Faying Surface.
The mating
Inden
surface of two
Figure 4: Distortion members to be welded. See Figure 6.
Faying
Edge Weld. A condition in which the spot weld Surface
imprint, as defined by the impression left by the
electrodes, is not contained within all edges of the
sheet metal being welded. See Figure 5, welds E
and F.

Figure 6: Faying Surface

GMAW. An acronym for Gas Metal Arc Welding.

© Copyright 2006 General Motors Corporation All Rights Reserved

Page 6 of 10 January 2006

GM WORLDWIDE ENGINEERING STANDARDS
Hole. A perforation in the spot weld that allows
light to travel through the material from one exterior
surface to the opposing exterior surface of the
weld. See Figure 7.
Figure 7: Hole
Indentation. The depression on the sheet surfaces
caused by the welding electrodes. See Figure 8.
Figure 8: Indentation & Thinning
Missing Welds. The number of spot welds not
installed as specified on the weld design
document.
Original Qualified Setup. The weld parameters
established and documented during Weld
Verification. Also referred to as Initial Qualified
Setup.
Pearls. See Weld Spatter.
Thinning. The amount of the original total metal
stackup thickness reduced by the welding process.
See Figure 8.
© Copyright 2006 General Motors Corporation All Rights Reserved
January 2006
GMW14057
Surface Eruption. Upsurge of the metal surface
adjacent to the weld imprint. See Figure 9.
Figure 9: Surface Eruption
Weld Button. That part of the weld that tears out
in a peel or chisel test. See Figure 10.
Figure 10: Weld Button
Weld Button Size. The weld button size of a
symmetrical (round) button is the diameter of the
button. The weld button size of an asymmetrical
(oval or oblong) button is calculated by adding the
measurement of the major axis to the
measurement of the minor axis and dividing by 2.
See Figure 11. The measurements are to be taken
at the faying surface. See Figure 12.
Weld Button Size = (d1+ d2)/ 2
d1
d2
Figure 11: Weld Button Size
Page 7 of 10
GMW14057 GM WORLDWIDE ENGINEERING STANDARDS

Weld Size. Resistance Spot Weld Size refers to

either the weld button size or the weld nugget size.
With certain steels or types of loading, a weld
button may not always result from a peel or tensile
test. In these cases metallurgical examination of
the weld must be used to determine weld nugget
size.
Weld Expulsion. Molten metal that is extruded
from between the sheets being welded or from the
interface between the outer sheet metal surface
and the electrode(s). See Figure 14.
Weld Imprint. The impression left in the metal
surface by the electrodes after welding. See Figure
5.
Weld Button Weld Spatter. Weld expulsion metal that remains
0.2 mm
attached to an adjacent metal surface away from
the electrodes. The visible weld spatter is
sometimes referred to as pearls. See Figure 14.
Whiskers. Sharp weld expulsion metal that
remains attached to the metal surface adjacent to
the weld imprint. See Figure 14.

Figure 12: Weld Button Size Measurement Weld Spatter

Weld Nugget. The weld nugget is that part of the Electrode

weld where fusion is evident at the faying surface
and extending into the parent metal resulting in a
metallurgical structure change. See Figure 13. Whiskers
Weld Nugget Size. The weld nugget size is the
dimension of the fusion zone measured from a
macro section examination or weld cross section.
See Figure 13.

Heat
Fusion Affected
Zone Zone Weld Expulsion
Figure 14: Weld Expulsion
Weld Design Document. A product document that
describes welding requirements such as number of
welds, location of welds, applicable weld
standards, weld patterns, surface appearance
Weld
classification, weld notes etc. This document is
Nugget
released and approved by the appropriate Design
Size
Release Engineer.

Figure 13: Weld Nugget Size

© Copyright 2006 General Motors Corporation All Rights Reserved

Page 8 of 10 January 2006

GM WORLDWIDE ENGINEERING STANDARDS
Weld Template. An inspection device used to
evaluate weld location. Templates are typically
created by plotting the weld spot location as
defined by the weld design document on a
transparent overlay for comparison to the actual
weld locations. See Figure 15.
Figure 15: Weld Template
© Copyright 2006 General Motors Corporation All Rights Reserved
January 2006
GMW14057
5 Rules and Regulations
5.1 All materials supplied to this specification must
comply with the requirements of GMW3001, Rules
and Regulations for Material Specifications.
5.2 All materials supplied to this specification must
comply with the requirements of GMW3059,
Restricted and Reportable Substances for
Parts.
6 Coding System
This welding standard shall be referenced in other
documents, drawings, Vehicle Technical
Specifications (VTS), Component Technical
Specifications (CTS), GME Specification Design
Mechanics (SKR, SKM) etc. as follows:
GMW14057.
7 Release and Revisions
7.1 Release. This standard was originated by the
Global Weld Standards Team in August 2004 and
approved in December 2005 by the CCRW Global
Council. This standard was first published in
January 2006.
Page 9 of 10
GMW14057 GM WORLDWIDE ENGINEERING STANDARDS

Appendix A

Table A1: Additional Spot Weld Surface Appearance Criteria by Weld Surface Classification

GMW14057
Attributes Class IIB Class IIC
Reference

Section 3.2.1.3 &

Edge Welds Not Permitted Not Permitted
Figure 5

Section 3.2.2.5 &

Trim Edge Deformation Not Permitted Not Permitted
Figure 5

Within 3mm of design Within 3mm of design

Weld Location Section 3.2.1.6
location location

Circular & Symmetrical Spot Weld

None Required Required
Imprint with Uniform Perimeter

Section 3.2.2.3 &

Distortion 4O Maximum 4O Maximum
Figure 4

Indentation Figure 8 0.20mm Maximum No Requirement

Surface Eruptions Figure 9 0.15mm Maximum No Requirement

Spatter (Pearls) Adjacent to

Figure 14 Not Permitted Not Permitted
the Weld

Whiskers Figure 14 Not Permitted Not Permitted

Note: Welds that do not meet the appearance requirements listed above must have the welding process adjusted to the original qualified
setup to achieve the appearance requirements. With the exception of edge welds, welds that do not meet the appearance requirements
listed above are not considered discrepant welds.

© Copyright 2006 General Motors Corporation All Rights Reserved

Page 10 of 10 January 2006