Esbm5a 1B310 S Aa

Engineering Specification
FRAME 2 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA
OUTLINE FRAME
I. GENERAL ……………………………………………………………..…………… 4
I.1 Scope of Engineering Specification, General Statement …………………… 4
I.2 Process Description …………………………………….…………………... 4
I.3 Design Guidelines ………………………………………………………..… 5
I.3.1 Material Gauge
I.3.2 Generic Joint Design Selection
I.3.3 Joint Design Recommendations
I.3.4 Flange Width
I.3.5 Joint Gap
I.3.6 Welding Position and Torch Access Requirements
I.3.7 Sheet Metal Gauge Ratio
I.4 Applicable Materials …………………………………………………….. 9

I.5 Control Welds …………………………………………………………… 10
I.6 GMA-Welded Seam Identification Symbols ………………………….... 11
II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS … 12
III. TEST PROCEDURES AND REQUIREMENTS …………………………………` 17

III.1 Applicability of Test Procedures for PV- and IP-Test Phases ………..….. 17
III.2 Welding Parameter Monitoring …………………………………….…….. 18
III.2.1 Introduction
III.2.2 Current [A]
III.2.3 Voltage [V]
III.2.4 Wire Feed [m/min]
III.2.5 Wire Feed Motor Current [A]
III.2.6 Welding Speed [m/min]
III.2.7 Flow of Shielding Gas [l/min]
III.2.8 Torch and Travel Angle [°]
III.2.9 Welding Direction
III.3 Inspection of the Visible Part of the Weld …..……………….……….... 19
III.3.2 Position of Weld
III.3.3 Weld Length
III.3.4 Weld Width
III.3.5 Weld Discontinuity
III.3.6 Undercut
III.3.7 Surface Cracks, End Crater Cracks
PD Nov 28, 2008 EBIW E 12173768 000 Gas-Shielded Metal Arc Welding ESBM5A-1B310-AA
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III.3.8 Surface Porosity

III.3.9 Open End Craters
III.3.10 Burn Through
III.3.11 Spatter
III.3.12 Slags and Oxides
III.3.13 Lack of Fusion
III.4 Inspection of Section Cut …..…………………………………………….. 22

III.4.2 Penetration
III.4.3 Porosity
III.4.4 Cracks
III.4.5 Undercut
III.4.7 Bead Geometry
III.4.8 Gap Condition
III.4.9 Bead Concavity and Convexity
III.4.10 Hardness
III.5 Destructive, Non-Destructive, and Functional Testing ………………... 24

III.5.2 Static Tensile Test
III.5.3 Peel Test
III.5.4 Impact Test
III.5.5 Chisel Test (Destructive)
III.5.6 Chisel Test (Non-Destructive)
III.5.7 Durability / Fatigue Test
III.6 Permissible Repair Methods ………………………………………..…… 26
IV. REVALIDATION REQUIREMENTS …………………………………………… 27
V. INSTRUCTIONS AND NOTES ……………………………………………….… 28
VI. COMPILATION OF REFERENCE DOCUMENTS …………………………... 28
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I. GENERAL
I.1 Scope of Engineering Specification, General Statement

This Engineering Specification is issued to define design factors and performance requirements applicable to the
joining of steel body components using the gas-shielded metal arc-welding (GMA-W) process in conjunction
with active gas (MAG–Welding). It covers manual and automated welding of two sheet steel stacks having
individual sheet thicknesses between 0.7 mm and 3.0 mm.
This Engineering Specification harmonizes the requirements globally for Ford Motor Company and is
applicable to new model programs.
This Engineering Specification is a supplement to the released drawing of a given part, and all requirements
herein must be met in addition to all other requirements of the part drawing. Each section specifies the
minimum measures necessary for documenting compliance to this specification.
The Engineering Specification is intended to evaluate specific characteristics as a supplement to normal material
inspections, dimensional checking, and in process controls and should in no way adversely influence other
inspection operations.
Preparation and submission of an acceptable Control Plan are the responsibility of the manufacturing source.
The manufacturing source will retain the original control plan and any later revisions per QS-9000 and provide a
copy to the design responsible Product Engineering activity.
I.2 Process Description

Gas Metal Arc-welding works with heat generated between a consumable electrode (filler metal wire) and the
work piece by an electric arc generated in a protective gas as shown in Figure 1.
1: Sheet Metal
2: Fillet
3: Filler Metal Wire Feed
4: Filler Metal Wire Coil
5: Gas Nozzle
6: Electrode Contact
7: Active Gas
8: Electric Arc
The characteristic parameters of the GMA-

Welding process are: Weld Current [A], Arc
Voltage [V], Wire feed [m/min], Welding Time,
Welding Speed [m/min], Filler Wire Stick Out as
well as Gas Flow [l/min].
Figure 1: Illustration of Gas Metal Arc-Welding Operation
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I.3 Design Guidelines
The following design guidelines describe the generic conditions for a proper GMA-Welded joint application.
Any deviation from these guidelines shall be analyzed jointly between the relevant Body and Manufacturing
Engineering Departments.
A GMA-Weld must be located at least 30 mm away from any previous adhesive or sealer application. This
distance should consider the edge of the material in a compressed state (not the "as applied" location"). A
minimum distance of 15 mm is required to any previous weld.
Part measuring devices may be required (e.g. touch sensing) for proper placement of the weld due to expected
part, tooling and equipment variation. Adequate clamping devices may be required for proper joint fit-up.
These conditions need to be verified during the design phase.
I.3.1 Material Gauge

The recommended individual sheet gauge range for the application of the GMA-Welding process is 1.2 mm to
3.0 mm. For applications with an individual gauge between 0.7 mm and 1.2 mm GMA-Welding can be
employed, but GMA-Brazing is the preferred joining process. Applications below 0.7mm require the approval
of the relevant Body and Manufacturing Engineering departments on the basis of weld trials.
I.3.2 Generic Joint Design Selection

This Engineering Specification covers two types of joint geometries: lap and butt joints.
Joint Type Advantage Disadvantage Recommendation

Contact surface can easily be Lap joints result in increased Select Lap - instead of Butt
Fillet at Lap Joint increased. metal thickness at the joint Joint.
(craftsmanship!)
Lap compared to the Butt
joint provides a higher Lap joints show a potential to
strength (due to increased create stress concentration at
contact area), even when the edges of the lap where there
small discrepancies are is an abrupt change in material
present in the final weld. thickness.
Load transmission is
primarily shear (Desirable
Mode)
Lap Joints can easily be

designed to be self-aligning
Butt Joint Single sheet thickness Relatively small contact Butt joints should be chosen
surface, demanding that welded only when thickness of the
Relatively simple preparation joint be free of discrepancies in joint is a critical
order to maximize strength. consideration, strength
Sufficient strength for many requirements are secondary,
applications so that separation Load transmission is solely and where the strength of the
will occur in the base sheet tensile (undesirable mode) welded joint will
metal. satisfactorily meet
Requires smaller joint gaps performance requirements.
compared to lap joints and
precise fitting of panels to
avoid mismatch.
Table I.3.2: Basic Types of GMA-Welded Joints

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I.3.3 Joint Design Recommendations
NOT RECOMMENDED RECOMMENDED REMARKS
Overlap Lmin ≥ 8 mm
Details to be agreed between Body

Engineering and Manufacturing.
Lmin
Not OK OK
Overlap Lmin ≥ 8mm (trim edge to tangent of

fillet)
Details to be agreed between Body

Engineering and Manufacturing.
Lmin
Sheet metal bending radius at seam should be
as small as possible
Not OK OK
A1 min ≥ 8 mm,
A2 min ≥ 15 mm
A1
A1 Avoid 3-gauge joints and re-design to a 2-
gauge welded joint with application of an
alternative joining method like Resistance
Spot Welding to join the 3rd sheet member.
Spot welds and GMA-Welded seams should

A2 have a sufficient distance to each other.
Avoid variation in gap condition in vicinity

of welded seam to ensure constant heat
dissipation conditions.
Not OK OK
Figure 2: Fillet Joint Design Examples
Manufacturing Welds
GMA-welds executed as tack welds are considered manufacturing welds outside the regular weld pattern
supporting the Body Construction assembly process. These manufacturing welds do not need to comply with
the requirements of this specification and do not need to be repaired. However, they do need to be identified on
engineering drawings and agreed upon by Body Engineering. The minimum requirements need to be
determined during Production Validation (PV) phase testing.
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Welded Slot Holes – Recommended Dimensions and Weld Length
SINGLE-SIDED SLOT HOLES DOUBLE-SIDED SLOT HOLES PLUG DIMENSIONS
L1
L2 > 20 mm
L1
L2 > 20 mm ø Plug
B B Plug may be specific as a

fillet along the circumference
B > 8 mm (normal) or as completely filled.
B > 16 mm to support B > 16 mm NOT Recommended for
additional seam for repair robotic application.
on opposite side Plug diameter: ø > 10 mm
Figure 3: Contact Surface Optimized Welded Joint Design Examples
NOTE: Adequate clamping surfaces must be provided for pusher units used to aid joint fit-up. The
metal around slots/holes should be a minimum of 10 mm.
Weld Length
The weld length L2 is shown in the CAD-system and represents the min overall length on the BIW (inclusive of
start-stop). The effective weld length L1 is used for CAE-calculations only and should be the designed length L2
reduced by 5 mm.
The weld length of fillet joints in typical thin sheet metal applications should be as follows:
• Minimum weld length: 20 mm including start and end.
• Weld length exceeding 40 mm should be avoided due to heat-related panel distortion, but can be
obtained with the use of special cooling or clamping devices. The use of such a device must be
approved by the appropriate Manufacturing Engineer.
I.3.4 Flange Width

The flange width A, as shown in Figure 4, t1
should be at least 8 mm.
t2
Figure 4: Flange Width
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I.3.5 Joint Gap

The design gap G of the joint should be 0 mm (reference Figure 21 in Section III.4.8).
I.3.6 Welding Position and Torch Access Requirements

The GMA-Welding operation can be carried out in all positions. However, “overhead” welding operations
should be avoided.
Welding torch access as outlined in Figures 5 and 6 must be granted in design to support the following
recommended welding angles in longitudinal and transverse direction. A minimum of additional 5 mm clearance
around the torch diameter of 26 mm should be maintained.
5 mm
Figure 5: Longitudinal Angle Figure 6: Transverse Angle
I.3.7 Sheet Metal Gauge Ratio

In general, the gauge ratio of the base sheet metals should not exceed 1 : 3, with the thicker sheet on the bottom.
In thin sheet metal applications with the bottom sheet having 1.0 mm gauge or less, the gauge ratio should not
exceed 2 : 3.
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I.4 Applicable Materials
To achieve a properly welded joint, the filler and base materials should be metallurgically compatible.
Base Sheet Metal Specification
This Engineering Specification covers the use of the following steels categories:
FORD MATERIAL SPECIFICATION NO
CATEGORY TYPES OF STEEL Applicable to Applicable to
Ford of Europe, VCC Ford North America
MS Mild Steels, Hot and Cold WSS-M1A344-A1/A2 WSD-M1A333-A1/A2/A3/A4
Rolled, Low Carbon WSS-M1A345-A1/A2/A3/A4
DR Dent Resistant Steels WSS-M1A341-A1/A2/A3/A4/ WSS-M1A341-A1/A2/A3/A4/
including Bake Hardening, A5/A6/A7/A8/ A9/A10 A5/A6/ A7/A8/A9/A10
High Strength IF, Isotropic
and Rephosphorised Steels
HSLA High Strength Low Alloy WSS-M1A346-A1/A2/A3 WSB-M1A215-E1/F1
Steels WSS-M1A347-A1/A2/A3
DP 1) Dual Phase Steels WSS-M1A348-A1/A2/A3/A4/ WSS-M1A348-A1/A2/A3/A4/
A5/A6/A7/A8/A9 A5/A6/A7/A8/A9
TRIP 1) TRIP Steels WSS-M1A351-A1/A2/A3 WSS-M1A351-A1/A2/A3
MSW 1) Martensitic Steels TBD WSS-M1A183-D
BORON 1) Boron Steels WSS-M1A322-A3 WSB-M1A322-A1 (Uncoated)
WSS-M1A357-A1 (Coated) 2)
WSS-M1A358-A1 (Coated) 2)
1) DP, Trip and Boron steels are included in this Engineering Specification within a limited applicability. The use of these materials needs to be
verified with the relevant Body and Manufacturing Engineering Departments on a case-by-case basis.
2) WSS-M99P39-A1/A2/A3/A4 performance specification must be called out with these Boron steels.
Table I.4-1: Applicable Categories of Sheet Steel Covered By This Engineering Specification
Any other base sheet metal not listed needs the approval from the relevant Materials Engineering,
Manufacturing and Body Engineering Departments.
The text of the referenced Ford Material Specifications is available from the following weblink
http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html, Metals 1A-99A.
Standard Base Sheet Metal Coatings
GMA-Welding of coated sheet metal is possible as long as the individual thickness of zinc coating between overlapping
sheets surfaces does not exceed 20 µm, equal to 70 grams per square meter of sheet. Zinc coating between
overlapping sheets in excess of 20 µm has a critical influence on process stability resulting in porosity and overall joint
strength. It increases rework of such seams in the plant. Appropriate countermeasures (Design or Process related) shall
be determined individually for each GMA-Welding application during PV testing within the scope outlined in Sect. III.
GMA-Welding supports the following coatings in all combinations:
Specification Type Specification No. Coating Type
60G60G EL, 50G50G EL WSS-M1P94-A Electro-galvanized
55A55A HD WSS-M1P94-A Galvannealed
60G60G HD, 50G50G HD WSS-M1P94-A Hot Dip Galvanized
AlSi coating WSD-M1A295-A2 Hot Dip Aluminized
Table I.4-2: Standard Base Sheet Metal Coatings

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Any other coating not listed in Table I.4-2 needs the approval from the relevant Materials Engineering,
Manufacturing and Body Engineering Departments.
Filler Metal Wire Specification

• European Applications
The filler metal wire types released within the scope of this Engineering Specification must be covered by the
Material Specification WSS-M4A182-A. The use of filler wire not meeting the requirements of WSS-M4A182-
A needs the approval of the relevant Body, Manufacturing and Materials Engineering Departments.
• North American Applications

The filler metal wire types released within the scope of this Engineering Specification must be covered by the
Material Specification ESB-M4A170 (ANSI/AWS A5.18M:2001 Grade ER70S-3 or -6). The use of filler wire
not meeting the requirements of ESB-M4A170 needs the approval of the relevant Body, Manufacturing, and
Materials Engineering Departments.
GMA-Welding Of HSS/UHSS Sheet Metal

Joint strength in HSS/UHSS will be lower than base metal strength, regardless of filler wire strength (70 ksi
minimum = 480 in N/mm2). Since the heat-affected zone (HAZ) is the weak link in such joints, the same filler
wire as noted above will be sufficient.
Shielding Gases
• European Applications
The shielding gas used for the GMA-Welding process shall meet the requirements of EN 439. Any other gas
needs to be approved by the relevant Body, Manufacturing and Materials Engineering Departments.
• North American Applications

The shielding gas used for the GMA-Welding process should be blended Argon / Carbon Dioxide, with a
minimum content 75% Ar.
I.5 Control Welds

• Ford: Concept of “Control Welds”
"Control welds" for GMA-Welding are defined as welds that are important for structural integrity, safety, or
Federal compliance (North America). They shall be identified jointly between Body Engineering (Core and
Vehicle Program) and the Attribute Teams (Crash, Durability and, if applicable, NVH) on the basis of the
relevant Design-FMEAs, CAE-analysis and physical verification testing.
"Control welds" are identified by ’Control / ’. This designation is attached to specific welds in the
relevant CAD files. Welds not designated as "control welds" are considered "common welds".
• Volvo Car Corporation: Concept Of “Consequence Classes”

The weld classification shall be in accordance with Volvo Car Corporation Standard VCS 5060,39
Classification of Requirements - available at http://www.tech.volvo.se/standard/eng/stdnum.html. Due to
the situation with regard to production and inspection, consequence classes [3] or no consequence class are
normally used.
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I.6 GMA-Welded Seam Identification Symbols
The GMA-Welded joint symbols shall be in accordance with Ford Engineering CAD and Drafting Standard D-3
(Welding Symbols and Specifications).
Sizing of Fillet Weld, a- & z-value :

Two different concepts exist to specify the minimum
dimensions of a fillet weld. The a-value (throat) is
primarily used in Europe, whereas North America
uses the z-value (leg).
For global programs, both, the a- and the z-value

have to be indicated as shown exemplary in Figure 8.
Figure 7: Fillet Weld Dimensions
In the case of unequal thickness combinations, they
refer to the thinnest sheet in the joint as follows:
a = 0.7 *tmin, z = tmin
Please note that the throat and leg dimensions are
minimum dimensions. In practice, higher values are
often used, especially when welding thin sheet metal.
Figure 8: Identification of Fillet Weld
Figure 9a: Sketch of Intermittent Weld Figure 9b: Identification of Intermittent Fillet Weld
Intermittent seam welds shall be identified in accordance to ISO 2553 as shown in Figure 9b.
Sizing of Fillet Welds, s-value :
The s-value is the effective throat of the weld, as
shown in Figure 10, and describes the minimum
load-carrying portion of the joint.
s > 0.7*t min ; s > a

Figure 10: s-value
For control/delta welds, the s-value must be
indicated in the CAD-file.
Note: The process reference number according to ISO 4063 is 135 for the MAG-Welding process.
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II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS

Production Validation (PV) tests are used to obtain an initial estimate of the process potential to produce parts
that conform to engineering requirements, and to identify causal or predictive relationships between significant
design and process characteristics (to be used for process control). The tests must be completed successfully
using initial parts from production tooling and production process before Part Submission Warrant (PSW)
approval and authorization of production parts can be issued. Sampling plans for PV testing must be included in
the control plan.
In addition, tests can be done on prototype level parts or vehicles to the same extent as outlined for PV-testing.
This does not replace the necessity to run PV-phase testing as described above.
In-Process (IP) tests are used to further understand the relationship between significant design and process
characteristics and to establish a basis for continuing improvement. Tests must be completed with production
parts on an ongoing basis. Sampling plans for both IP testing and evaluation of the significant process
characteristics must be included in the control plan. When the process is found to be out of control or the test
acceptance criteria are not met, the reaction plan approved in the control plan shall be invoked.
Welded joints that do not meet the requirements outlined in Section II., Summary of Production Validation and
In-Process Tests, and Section III., Test Procedures and Requirements, of this Engineering Specification need to
be repaired following the reworking procedure as outlined in Section III.5.
The tables that follow summarize the various PV-and IP-tests and the acceptance parameters for each. They
form the basis on which to develop a complete control plan for these and their related significant process
characteristics. The control plan will include frequencies, sample sizes and reaction plans; see Ford Quality
System Requirements, QS-9000.
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II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cont.)
Welding Parameter Monitoring – for automated GMA-Welding applications only
Test Test Characteristic Low Tolerance Limit Target Value Upper Tolerance Minimum Minimum
Number Limit Sample Size Sample
Frequency
Controllable Parameters
III.2.2 Current [A] As determined in PV As determined in PV As determined in PV see 1) 100 %
testing testing testing
III.2.3 Voltage [V] As determined in PV As determined in PV As determined in PV see 1) 100 %
III.2.4 Wire Feed [m/min] As determined in PV As determined in PV As determined in PV see 1) 100 %
III.2.5 Wire Feed Motor Current Not Applicable As determined in PV As determined in PV see 1) 100 %
[A] (system dependent) testing testing
III.2.6 Welding Speed [m/min] As determined in PV As determined in PV As determined in PV see 1) 100 %
III.2.7 Flow of Shielding Gas Not Applicable Gas Flow Sensor Signals Not Applicable see 1) 100 %
[l/min] Gas Flow
Equipment Settings
III.2.8 Torch and Travel Angle [°] As determined in PV As determined in PV As determined in PV see 1) see 1)
III.2.9 Welding Direction As determined in PV As determined in PV As determined in PV see 1) see 1)
1)
Ford
Minimum Sample Size and Frequency to be determined by the manufacturing plant personnel responsible for the control plan in conjunction with the design responsible body-engineering activity and the
relevant quality departments as well as other appropriate functions. Reference:
Ford of Europe: Document VOPQUE-612, available at http://www.voqoeu.ford.com
Ford North America: Document VOPSSN-008, available at http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf
Volvo Car Corporation: Minimum Sample Size and Frequency to be defined by the relevant manufacturing unit.
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Inspection of the Visible Part of the Weld
Test Test Characteristic Lower Tolerance Target Value Upper Tolerance Minimum Minimum Sample
Number Limit Limit Sample Size Frequency
III.3.2 Position of Weld - 5 mm in longitudinal As outlined on assembly + 5 mm in longitudinal see 1) see 1)
direction drawing or in CAD- direction, in transverse
system direction: meet at least min.
a- or s-value
III.3.3 Weld Length Length shown on assembly Exceeding minimum 1.4 times the length shown see 1) see 1)
drawing or in CAD-system length on the assembly drawing or
is minimum length, see in CAD system
Section I.3.2 for the
definition of seam length
III.3.4 Weld Width 1.4 * t min Not applicable Not applicable see 1) see 1)
III.3.5 Weld Discontinuity Not applicable Not present Not applicable see 1) see 1)
III.3.6 Undercut Not applicable Not present 20% of tmin see 1) see 1)
III.3.7 Surface Cracks, End Not applicable Not present Not applicable see 1) see 1)
Crater Cracks
III.3.8 Surface Porosity Not applicable Not present Single pore diameter max see 1) see 1)
0.4*tmin, and max. 2 pores
per 10 mm weld length
III.3.9 Open End Craters Not applicable Not present Permitted, but not with see 1) see 1)
cracks
III.3.10 Burn Through Not applicable Not present Not applicable see 1) see 1)
III.3.11 Spatter Not applicable Not present See Section III.3.11 see 1) see 1)
III.3.12 Slags and Oxides Not applicable Not present prior to Not applicable see 1) see 1)
shipment to Paint
III.3.13 Lack of Fusion Not applicable Not present Not applicable see 1) see 1)
1)
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Inspection of Section Cut
Test Test Low Tolerance Limit Target Value Upper Tolerance Limit Minimum Minimum Sample
Number Characteristic Sample Size Frequency
III.4.2 Penetration 30% of bottom sheet Not applicable 100% of bottom sheet thickness see 1) see 1)
thickness
III.4.3 Porosity Not applicable Not present Single pore extension max see 1) see 1)
0.4* tmin and max. 20% of
projected section cut area for
multiple pores, pinholes not
permitted
III.4.4 Cracks Not applicable Not present Length of crack(s) ≤ 0.2 * tmin see 1) see 1)
and not extending to the surface
III.4.5 Undercut Not applicable Not present Max. 0.2 * tmin see 1) see 1)
III.4.6 Lack Of Fusion Not applicable Not present Max. 0.1 * t1 see 1) see 1)
III.4.7 Bead Geometry s > 0.7 * tmin s = tmin Not applicable see 1) see 1)
III.4.8 Gap Condition Not applicable 0 mm G < 0.5* tmin, not to exceed 1.0 mm. see 1) see 1)
III.4.9 Bead Concavity / Not applicable Not applicable Top bead convexity max 0.3* t1; see 1) see 1)
Convexity root concavity and convexity
max 0.3 *t2, unless otherwise
specified
III.4.10 Hardness Not applicable Not applicable As outlined in Section III.4.10 see 1) see 1)
1)
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Non-Destructive and Destructive Strength Testing
Test Test Low Tolerance Target Value Upper Minimum Minimum

Number Characteristic Limit Tolerance Sample Size Sample
Limit Frequency
III.5.2 Static Tensile Test Not applicable Sample to separate in base sheet metal or in Not applicable see 1) see 1)
HAZ but not in weld bead
III.5.3 Peel Test Tensile Strength Sample to separate in base sheet metal or in Not applicable see 1) see 1)
of lowest strength HAZ but not in weld bead
material in stack
III.5.4 Impact Test Not applicable Welded joint integrity in either component Not applicable see 1) see 1)
and/or subassembly testing; test set up and test
conditions to be agreed with responsible Safety
Attribute Team
III.5.5 Chisel Test Not applicable Base metal tears out with weld or weld fractures Not applicable see 1) see 1)
(Destructive) through throat with root fusion evident and
visible
III.5.6 Chisel Test Not applicable No partial or complete separation of welded Not applicable see 1) see 1)
(Non-Destructive) joint
III.5.7 Durability/ Fatigue Not applicable No fatigue cracks in welded seam and no lack Not applicable see 1) see 1)
Test of compliance following completion of full
vehicle PASCAR Phase 1 and 50% of PASCAR
Phase 2 testing according to CETP 00.00-R310
1)
Ford
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III. TEST PROCEDURES AND REQUIREMENTS
III. 1 Applicability of Test Procedures for Production Validation (PV) and In-Process (IP) Test Phases
Test Test PV-Test Phase IP-Test Phase

Number Characteristic
III.2 Welding Parameter Mandatory Mandatory
Monitoring
Automated GMA-Welding Applications: Automated GMA-Welding Applications:
Definition of joint-specific welding process window Checks to verify compliance of running production with the
GMA-Welding process window determined during PV-Testing
Manual GMA-Welding Applications: Manual GMA-Welding Applications:
Definition of joint-specific set of "jobs" Checks to verify compliance of running production with these
"jobs" determined during PV-Testing
III.3 Inspection of the Mandatory Mandatory
Visible Part of the
Weld Dye Penetration Test recommended to further analyze the Dye Penetration Test recommended to further analyze the
occurrence of lack of penetration, surface cracks and occurrence of lack of penetration, surface cracks and porosity
porosity
III.4 Inspection of Section Mandatory Mandatory -- for control joints

Cuts Optional -- for normal welds
Recommended for
• root cause analysis in case of discrepancies and
• weld quality evaluation as part of the revalidation (Section
IV)
III.5 Destructive, Non- Mandatory: Destructive Chisel Test (III.5.5) Mandatory

Destructive and
Functional Testing Body and Manufacturing Engineering expert departments Non-destructive Chisel Test (III.5.6) for welds not tested in
to decide whether the following tests are required: Static Inspection of Section Cuts
Tensile Test (III.5.2), Peel Test (III.5.3), Impact Test
(III.5.4) , Durability /Fatigue Test (III.5.7) are required Destructive Chisel Test (III.5.5) as optional
(typically for unknown GMA-Welding applications only).
Table III.1: Applicability of Test Procedures and Requirements
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III.2 Welding Parameter Monitoring

Automated GMA-Welding Applications
Each automated welding application requires an individual set of fixed equipment settings as well as
controllable process parameters as outlined below - the so-called job characteristic curve. It consists of target
values as well as the upper and lower tolerance limits and shall be determined in Production Validation tests
individually for each GMA-Welded joint.
EQUIPMENT SETTINGS (Fixed) PROCESS PARAMETERS (Controllable)

Torch and Travel Angle [°] Current [A]
Welding Direction Voltage [V]
Filler Wire Speed [m/min]
Wire Feeder Motor Current (system dependent) [A]
Welding Speed [m/min]
Flow of Shielding Gas [l/min]
Table III.2.1: List of Fixed Equipment Settings and Controllable Process Parameters
GMA-Welding equipment used for the assembly of components according to this Engineering Specification
shall be equipped with a built-in memory unit capable of storing individual job characteristic curves for the
relevant welding jobs. This unit shall be capable of adjusting the parameters within the parameter window and
monitoring compliance of the welding operation with the job characteristic curve in order to ensure a weld of
high quality that meets the requirements outlined in this Engineering Specification.
The job characteristic curve shall be captured and maintained by the manufacturing source and applied on the
basis of a 100 % sampling rate in IP-conformance testing. Special provisions (e.g. robot issuing a failure
message) are required to identify those joints that were welded with parameters outside the tolerance limits of
the job-characteristic curve.
Manual GMA-Welding Applications
Manual GMA-Welding applications are defined on the basis of joint-specific "jobs" that shall be determined
individually for each application during the PV-test phase. These parameters shall be captured and maintained
by the manufacturing source, and be used during IP-phase for running production. The following parameters
define a manual "welding job":
• welding direction
• type of drawn-arc (short-arc, pulse, etc.)
• one lead dependent parameter; either welding current [A] or wire feed [m/min]
• shielding gas flow [l/min]
III.2.2 Current [A]

The welding current characteristic is a measure of the energy input into the welded joint. During IP-monitoring
(automated GMA-Welding application only), it shall stay within the process window of the job characteristic
curve as defined in PV-testing individually for each welded joint application.
III.2.3 Voltage [V]

The welding voltage is proportional to the length of the electric arc and thus controls the energy input into the
welded joint. During IP-monitoring (automated GMA-Welding application only), it shall stay within the process
window of the job characteristic curve as defined in PV-testing individually for each welded joint application.
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III.2.4 Wire Feed [m/min]

The filler metal wire feed determines the amount of filler material that is available for the actual welding
operation in conjunction with the speed of the gun (welding speed). Typically, the wire feed is proportional to
the welding current and voltage and is set during PV-Phase jointly with the welding speed as one element of the
job characteristic curve.
During IP-monitoring (automated GMA-Welding application only), the wire feed shall stay within the process
window of the job characteristic curve as defined in PV-testing individually for each welded joint application.
III.2.5 Wire Feed Motor Current (System Dependent) [A]

If possible, the wire motor current shall be monitored to ensure that a blocked wire in the wire guide can reliably
be detected during the welding operation. The wire feed signal is typically picked from the transporting wire
feed roll, which may slip while still sending o.k.-wire feed signals to the controller. During IP-monitoring
(automated GMA-Welding application only), the wire feed motor current shall not exceed the maximum value
as defined in PV-testing individually for each welded joint application.
III.2.6 Welding Speed [m/min]

Reference Section III.2.4. During IP-monitoring (automated GMA-Welding application only), the welding
speed shall stay within the process window of the job characteristic curve as defined in PV-testing individually
for each welded joint application.
III.2.7 Flow of Shielding Gas [l/min]

One of the main criteria for a quality-welded joint is the constant flow of shielding gas. Therefore, a gas sensor
shall continuously monitor whether or not a proper flow of gas is delivered to the welding torch.
III.2.8 Torch and Travel Angle [°]

During the IP-phase, the torch and the travel angle of the welding torch shall be equal to its range determined
during PV-testing individually for the relevant welded joint application.
III.2.9 Welding Direction

During the IP-phase, the welding direction of the gun (forehand, backhand) shall be as determined
during PV-testing individually for the relevant welded joint application.
III.3 Inspection of the Visible Part of the Weld

The visible part of the weld shall be inspected for discrepancies using the following two inspection methods.
The applicability of the relevant test methods is defined in Section III.1.
• Naked Eye Inspection
Visual inspections shall be performed (naked eye inspection) to detect those obvious discrepancies
outlined in this Section. Scales or calliper gauges are required to verify dimensional compliance.
• Dye Penetrant Testing
A dye penetrant test shall be performed to further analyze the following discrepancies:
¾ Surface Cracks, End Crater Cracks see Section III.3.7 and
¾ Surface Porosity, see Section III.3.8
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III.3.2 Position of Weld

The weld shall be positioned as outlined on the assembly drawing or in the CAD-system. The upper tolerance
limit is +/- 5 mm in longitudinal direction, while in transverse direction compliance with the minimum a-, z- or
s-value is mandatory.
III.3.3 Weld Length

The length of the welded seam as outlined on the assembly drawing is the minimum length. See Section I.3.3 for
the definition of the seam length. It should not exceed 1.4 times the length shown on the assembly drawing or in
CAD system
III.3.4 Weld Width

The width of the weld depends on numerous joint criteria such as joint geometry, base sheet metal thickness and
gauge ratio, gap situation, etc. It also depends on process parameters such as wire feed and welding speed. It
should at least be 1.4 * t min..
III.3.5 Weld Discontinuity

Welds in which the continuity is broken are classified as discrepant. Seam discontinuity shall not be present and
is unacceptable.
III.3.6 Undercut
Undercut, as shown in Figure 18, shall not present. In case undercut is present, section cut analysis is required
to reveal compliance with the acceptance criteria outlined in Section III.4.5.
III.3.7 Surface Cracks, End Crater Cracks
Cracks are fracture type discontinuities characterized by a

sharp tip and high ratio of length to width. They typically
result from an inhomogeneous heat distribution in the joint
and a subsequent uncontrolled solidification of molten filler
metal. Surface cracks and end crater cracks as shown in
Figure 11 shall not be present and are unacceptable.
Figure 11: End Crater Cracks
III.3.8 Surface Porosity
The target is that surface porosity as shown in Fig. 12 shall

not be present. The upper tolerance for surface porosity is:
• Single pore extension maximum 0.4*t min and
• Max. 2 pores per 10 mm weld length.
Figure 12: Surface Porosity

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III.3.9 Open End Craters

The target is that open end craters shall be avoided. In those
cases, where open end craters cannot be avoided, they shall
not show any sign of end crater cracking. End crater cracks
are unacceptable (see Section III.3.7).
Figure 13: Open End Craters
III.3.10 Burn Through

Burn through in general is not permitted.
III.3.11 Spatter
Spatter is defined as filler metal particles that are expelled
during the welding operation and do not form a part of the
seam (illustrated in Figure 14). Spatter - to a certain degree -
is considered process typical and cannot be avoided entirely.
However, the occurrence of spatter shall be reduced to an
absolute minimum by adjusting the welding process
parameters during the definition of the job characteristic
Figure 14: Spatter curve in PV-testing.
The acceptance criteria for spatter depend on the class of surface finish as follows:
• Ford Class 1 Finish, VCC Classes 1 and 2 Finish:
Spatter shall not be detectable.
• Ford Class 2 Finish, VCC Classes 3 and 4 Finish:

Spatter shall not be detectable. Individual exemptions can be agreed between Manufacturing
Engineering and Craftsmanship.
• Ford Class 3 Finish, VCC Class 5 Finish:

The minimum occurrence of spatter – as determined during the definition of the job characteristic curve
in PV-testing - is acceptable unless the drawing indicates that spatter is prohibited.
Spatter on threads of weld nuts and bolts shall be avoided entirely, e.g. by using protection shields while
welding.
III.3.12 Slags and Oxides

Slags and oxides are considered to be a typical occurrence during the GMA- welding process. They should be
removed mechanically prior to the Body being sent to Paint.

A visible lack of fusion to one or both sheets in the joint shall not be present and is unacceptable.
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III.4 Inspection of Section Cut
The visual / dimensional inspection of a section cut gives the best insight into the seam properties and is
therefore used during the series of PV-testing performed to define the job characteristic curve for each
individual welding application. Its execution is mandatory for control/delta welds during PV and IP test phases.
In addition, section cut analysis is recommended for root cause analysis in case of discrepancies during IP-phase
for and bead quality evaluations as part of the revalidation (Section IV).
Section cuts shall be performed perpendicular to the seam. The location for the section cuts shall be determined
for each joint configuration during PV-testing.
III.4.2 Penetration
t1 Pd The target is that the weld penetration Pd into lower sheet, as

shown in Figure 15, shall be between:
t2
0.3*t2 ≤ Pd ≤ t2
Figure 15: Weld Penetration
Please see III.4.9 for weld penetration (root convexity) in
excess of t2.
III.4.3 Porosity
The target is that porosity as shown in Fig. 16 shall not be present.
The upper tolerance for porosity is:
• Single pore extension d max ≤ 0.4*t min, and
• Multiple pore extension max. 20 % of projected area.
• Pinholes are not permitted.
Figure 16: Porosity
III.4.4 Cracks
The target is that cracks shall not be present in the weld bead.
The upper tolerance value is defined as follows:
• Inner cracks with h ≤ 0.2* t min are permissible,
except for cracks that reach the surface.
Figure 17: Cracks
III.4.5 Undercut
The target is that undercut shall not be present in the weld
t1 h bead.
t2 The upper tolerance value is defined as follows:
• Undercut with h ≤ 0.2* t1 is permissible.
Figure 18: Undercut

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The lack of fusion along leg of top sheet, as shown in Figure 19,
t1
should not be present.
t2
The upper tolerance value is defined as follows:
• Lack of Fusion ≤ 0.1* t1 is permissible.
Figure 19: Lack of Fusion
III.4.7 Bead Geometry

The lower tolerance limit is that the bead geometry, as shown in Figures 20a and 20b, complies with at least the
minimum throat or leg requirements:
• a ≥ 0.7* t min , z ≥ t min or
• s ≥ a (Please see Section I.6 for the definition of s).
Figures 20a and 20b illustrate how to check compliance with the minimum a- and z-value in a section cut of a
lap joint.
t1 a t1
a
z
z
t2 t2
Figures 20a and 20b: Minimum measurement of a- and z-value in section cut
III.4.8 Gap Condition

The target is that the gap G between the sheets
t1 shall be 0 mm.
G
t2 The upper tolerance value is defined as follows:
• G < 0.5* tmin, not to exceed 1.0 mm.
Figure 21: Gap Condition
III.4.9 Bead Concavity and Convexity

Top bead concavity h, as shown in
t1 t1
Figure 22, is acceptable as long as the
bead geometry complies with the
t2 t2
h minimum a-, z- or s-value in III.4.7.
h
a a
The upper limit for top bead convexity
h is 0.3 * t1, as shown in Figure 23.
Figures 22 and 23: Top Bead Concavity and Convexity
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t1 t1
Root concavity d, as shown in Figure 24,
is acceptable up to 0.3* t2.
t2 t2
Root convexity, as shown in Figure 25,
d
d can be accepted up to d= 0.3* t2, unless
specified differently in the CAD system
Figures 24 and 25: Root Concavity and Convexity or on the drawing.
III.4.10 Hardness
Hardness testing shall be performed according to ISO 14271 on section cuts to determine the Vickers hardness
(low load range, HV 1) of the weld, the heat affected zone and the parent sheet metal.
Initial Parent Sheet Hardness In Table III.4.10 lists the permissible increase in
Metal Hardness Weld hardness based on the initial parent sheet metal
[HV 1] [HV 1] hardness.
< 120 < 350 The material used and the welding techniques
> 120… < 200 < 450 employed shall be such that the hardness of the
> 200 … < 300 < 550 weld and the heat-affected zone do not exceed
> 300 < 600 the limits listed in Table III.4.10.
Table III.4.10: Hardness Increase Limits
Note: The relevant expert department shall be consulted in case that these limits cannot be met.
III.5 Destructive, Non-Destructive, and Functional Testing
Welded bead strength tests are performed to ensure that the joint meets the individual performance requirements
in terms of static and dynamic loads. The applicability of the relevant test methods is defined in Section III.1.
The acceptance criteria are based on the theory that the application of the welding process shall not weaken the
integrity of the joint in any way.
III.5.2 Static Tensile Test

The static tensile test shall be performed in accordance with
• ISO 14273, Specimen Dimensions And Procedure For Shear Testing Resistance Spot, Seam And
Embossed Projection Welds or
• Volvo Cars Standard 5601,039, Static Testing of Line Joints.
• Auto/Steel Partnership Test Procedures for North America
The test specimen shall be manufactured using base sheet metal as well as filler metal wire identical to
production conditions in terms of material specification, gauge and base sheet metal coating. The length of the
seam shall be as indicated on the assembly drawing. The test specimen shall be loaded gradually and
continuously until separation occurs. Separation is acceptable in the base sheet metal or in the HAZ, but not in
the weld bead.
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III.5.3 Peel Test

The static peel test shall be performed in accordance with:
• ISO 14270, Specimen Dimensions And Procedure For Mechanized Peel Testing Resistance Spot, Seam
And Embossed Projection Welds or
• Volvo Cars Standard 5601,039, Static Testing of Line Joints.
• Auto/Steel Partnership Test Procedures for North America.
The test specimen shall be manufactured using base sheet metal as well as filler metal wire identical to
production conditions in terms of material specification, gauge and base sheet metal coating. The length of the
bead shall be as indicated on the assembly drawing. The test specimen shall be loaded gradually and
continuously until separation occurs. Separation is acceptable in the base sheet metal or in the HAZ, but not in
the weld bead.
III.5.4 Impact Test

Impact tests shall be performed with those welded joints that are subjected to loads at high speeds to verify
integrity of the welded joint.
The test set up and test conditions shall be agreed upon with the relevant Safety Attribute Team taking into
consideration the location and loading condition of the relevant joint on the vehicle. Testing can be performed
on either components or subassemblies (e.g. sled testing, drop testing) that contain the welded joint.
III.5.5 Chisel Test (Destructive)

Minimum acceptable conditions for the destructive chisel test are:
• the base metal tears out with weld or
• the weld separates through the throat (in metal thickness over 3mm) – root fusion must be evident and
visible.
The chisel test can be applied on subassembly or complete bodies. It is performed to validate the evidence of
fusion for the entire weld.
Destructive chisel testing requires separating the base sheet metal adjacent to the weld in the direction parallel to
the weld using a chisel. The chisel according to ISO 10447 is shown as an example in Figure 26 for Europe.
Figure 27 shows the chisel used in North America.
40
R 70
All edges to be
15 free of burrs
24 9 Ø 12.5
Figure 26: Chisel According to ISO 10447

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Figure 27: Spot Test Chisel Used in North America (ref. tool # 5ZF-15063)
III.5.6 Chisel Test (Non-Destructive)

The non-destructive chisel test shall be applied to exclude the risk of a lack of fusion. The operator - in contrast
to the destructive chisel test – should apply the load gradually and exercise care to avoid permanent damage to
the panels. There shall be no partial or complete joint separation.
The non-destructive chisel test can also be used to verify the integrity of joints that were welded with parameters
outside the job characteristic curve while showing no imperfections in a visual inspection (Section III.3).
III.5.7 Durability / Fatigue Test

Full vehicle durability testing according to CETP 00.00-R310 (PASCAR test) shall be performed on a test
vehicle equipped with the relevant welded joints. These joints shall be welded to meet all requirements of this
specification.
No fatigue cracks in the welded seam and no lack of compliance to full vehicle PASCAR Phase 1 and
completion of half of PASCAR Phase 2 - testing.
III.6 Permissible Repair Methods
A program specific repair procedure must be defined for each GMA-Weld joint within the body structure during
the design process. Repair procedures must be inline with design guidelines as defined in Section I.3, and must
be approved by both Body and Manufacturing Engineering.
In the case of a discrepant weld, when reworking becomes necessary, the following rules apply, unless specified
differently on the assembly drawing or in the CAD-file:
• Any welds that are missing, below specified length, contain discontinuities, or insufficient throat
thickness may be brought within specification by additional welding, using the same welding process
and filler wire applied to make the original weld.
• In the case of burn through, repair shall be started by grinding off any excess material. Potentially with
the help of a chill block, repair shall be executed as puddle weld using the same process that was made
to make the original weld. Localized areas that indicate in visual inspection areas of under-filled weld
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condition shall be built up. Any excessive penetration shall be removed by grinding. The gauge of the
base sheet metal should not be reduced by more than 10 % of its nominal gauge as a result of the
grinding operation.
• Any other condition of non-compliance with this Eng Spec requires grinding off the discrepant weld and
re-welding it.
• In the case of GMA-Welds on high or ultra high strength steels (Cat. DP, TRIP, MSW, BORON in
Table I.4, Section I.4), both repair steps, additional welding and re-welding after grinding, require
specific care and shall not be executed without the prior approval of the relevant Body and
Manufacturing Engineering Departments.
• If additional welding at the initial location or grinding off an re-welding are not possible, place an
additional weld next to the discrepant one after getting approval from Body Engineering.
IV. REVALIDATION REQUIREMENTS
Any of the following conditions that affect the welding operation require a re-run of Production Validation (PV)
tests as agreed upon by the relevant Body and Manufacturing Engineering Departments.
• Process Change - Any change in the process which could alter its capability to meet the design
requirements or durability of the product. This includes:
¾ New, different, relocated, or rehabilitated production machinery or equipment (does not include
portable manual GMA-Welding equipment)
¾ Any change in subcontracted products or services including the use of engineering-approved
alternate materials
¾ Changes to rework methods
¾ Changes in the sequence of operations
¾ Changes in chemical compounds such as lubricants, which are part of the product
¾ Changes to filler metal or gas shielding type
• Engineering Change - Any change in the part(s) initiated by Ford Motor Company.
• Material and Coating Change - Any change in the material properties, or a change in sheet metal
coating when the new/revised coating is not listed in Section I.4. A change in steel supplier for steels
having a yield strength equal to or exceeding 310 MPa (representing DP600) in the "as received
condition" is also considered a material change.
• Sub-Supplier Change - Any change in the source of subcontracted components.
• Adopting Optional Design - Any change where the supplier incorporates optional designs specified on
the released engineering drawing or relevant CAD model.
NOTE: See QS-9000, Control of Subcontracted Suppliers; Retention of Inspection and Test Samples;
Notification of Completion of Inspection and Testing; Changes in Manufacturing Process; Change Approval
Certain process parameters will have a significant influence on the Welded joint quality. The control plan, as
defined in Ford QS 9000, is an essential part of a quality product. Some recommended process variables to
include in the control plan are:
• Job Characteristic Curve defined by: Current [A], Voltage [V], and Wire Feed [m/min]
• Wire Feed Motor Current [A]
• Welding Speed [m/min]
• Flow of Shielding Gas [l/min]
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V. INSTRUCTION AND NOTES
Control Plans address all significant design and process characteristics, which include all ES tests and Control
Item characteristics. They describe the process potential studies that will be performed for product validation
(including PV tests) and the ongoing product and process evaluation for continuing improvement (including IP
tests). They include acceptance criteria, sample size, frequencies, data analysis methods and reaction plans.
The control plan is developed, and updated as necessary by the manufacturing source in conjunction with the
design responsible Product Engineering activity and other appropriate functions such as Supplier Technical
Assistance (STA). The control plan defines the management of the upstream production process and part
variables (significant process characteristics) that affect the outcome of the ES tests or other significant design
characteristics. The control plan also identifies the specific ES tests, with their sample sizes and frequencies
which will be performed in order to:
• Confirm whether the process is being managed effectively.
• Further identify significant process characteristics.
• Evaluate performance of marginal processes.
• Better anticipate the customer effect of proposed process improvements.
For any part on which ES tests have been specified, the manufacturing source must present the control plan and
any revisions to the design-responsible Product Design activity for review. This Product Engineering activity
has flexibility to honour business relationships with suppliers having proprietary processes.
Examples of formats for control plans are shown in Quality System Requirements, QS-9000. Internal reference
documents can also be found in procedure VOPQUG-051 (Control Plans – Vehicle Operations Procedure –
Global).
VI. COMPILATION OF REFERENCE DOCUMENTS

A. QS-9000, Quality System Requirements
B. ISO 10447, Welding – Peel and Chisel testing of Resistance Spot, Projection and Seam Welds
C. ISO 14270, Specimen Dimensions and Procedure for Mechanized Peel Testing Resistance Spot, Seam and
Embossed Projection Welds
D. ISO 14271, Vickers Hardness Testing Of Resistance Spot, Projection and Seam Welds (Low Load And
Microhardness)
E. ISO 14273, Specimen Dimensions and Procedure for Shear Testing Resistance Spot, Seam and Embossed
Projection Welds, Edition 2000-11-01
F. Volvo Cars Standard 5601,039, Static Testing of Line Joints
G. Standard for Testing Line Welds, Auto/Steel Partnership
H. Ford Corporate Engineering Test Procedure 00.00-R-310, North Atlantic Durability Test for Passenger Cars
I. FNA Weld Quality Program Procedure VOPSSN-008 available at
http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf
J. FoE Vehicle Operations Operating procedure VOP QUE-612, Uniform Test and Evaluation Program For
Welding and other joining Operations; available at http://www.voqoeu.ford.com
May92
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Engineering Specification

FRAME 2 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

I.4 Applicable Materials …………………………………………………….. 9

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS … 12

III. TEST PROCEDURES AND REQUIREMENTS …………………………………` 17

FRAME 3 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

III.3.8 Surface Porosity

III.4 Inspection of Section Cut …..…………………………………………….. 22

III.5 Destructive, Non-Destructive, and Functional Testing ………………... 24

III.6 Permissible Repair Methods ………………………………………..…… 26

IV. REVALIDATION REQUIREMENTS …………………………………………… 27

V. INSTRUCTIONS AND NOTES ……………………………………………….… 28

VI. COMPILATION OF REFERENCE DOCUMENTS …………………………... 28

FRAME 4 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

I.1 Scope of Engineering Specification, General Statement

I.2 Process Description

The characteristic parameters of the GMA-

Figure 1: Illustration of Gas Metal Arc-Welding Operation

FRAME 5 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

I.3 Design Guidelines

I.3.1 Material Gauge

I.3.2 Generic Joint Design Selection

Joint Type Advantage Disadvantage Recommendation

Lap Joints can easily be

Table I.3.2: Basic Types of GMA-Welded Joints

FRAME 6 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

I.3.3 Joint Design Recommendations

NOT RECOMMENDED RECOMMENDED REMARKS

Details to be agreed between Body

Overlap Lmin ≥ 8mm (trim edge to tangent of

Details to be agreed between Body

Spot welds and GMA-Welded seams should

Avoid variation in gap condition in vicinity

Figure 2: Fillet Joint Design Examples

FRAME 7 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

Welded Slot Holes – Recommended Dimensions and Weld Length

SINGLE-SIDED SLOT HOLES DOUBLE-SIDED SLOT HOLES PLUG DIMENSIONS

B B Plug may be specific as a

Figure 3: Contact Surface Optimized Welded Joint Design Examples

I.3.4 Flange Width

Figure 4: Flange Width

FRAME 8 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

I.3.5 Joint Gap

I.3.6 Welding Position and Torch Access Requirements

Figure 5: Longitudinal Angle Figure 6: Transverse Angle

I.3.7 Sheet Metal Gauge Ratio

FRAME 9 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

I.4 Applicable Materials

Table I.4-2: Standard Base Sheet Metal Coatings

FRAME 10 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA

Filler Metal Wire Specification

• North American Applications

GMA-Welding Of HSS/UHSS Sheet Metal

• North American Applications

I.5 Control Welds

• Volvo Car Corporation: Concept Of “Consequence Classes”

FRAME 11 OF 28 REV. LET. PART NO. ESBM5A-1B310-AA