1 Purpose: Resistance Spot Welding Guideline

Resistance spot welding
Guideline
Proprietary and Confidential EGE-MOS-GL-09-07-01-E Rev 03 Page 1 of 45
Revision level Revision date Description of changes

03 01 Dec 2004 • Series monitoring, Weld class, Purpose, Torque for nuts,
Repair methods
02 01 Nov 2003 • Drawing description, weld class, weld nuts, series monitoring,
flange geometry
01 10 June 2002 • First edition
Prepared: Axel Geisler Checked: Bernd Engels Released: Ernst Pollak
Signature / Date Signature / Date Signature / Date
Electronic copies valid without signature
1 Purpose
As a basic principle for designing weld construction from customer has to use. If no
customer requirement exists, an agreement has to find which requirement is based for
designing. In every case it must consider about the place of production and the local
specifics.
This guideline serves the purpose of how resistance welding spots are to be executed and
represented.
This guideline determines the requirements for resistance spot weldings during the production of
assembly groups, consisting of two or several sheet metals of the same or different thicknesses.
This guideline is an extension of the welding drawing, which refers to it. The parts have to
correspond to this guideline in all points – as far as customized drawing requirements do not
exist.
This guideline is to be applied with uncoated as well as coated sheet metals and steel strip (zinc,
tin, nickel) with low carbon content. It is also to be applied with sheet metals with provisional rust
protection coatings and priming on the condition, that the coating does not obstruct the welding
process.
2 Area of validity
This guideline applies to all European locations of the Automotive Group (AG) of Johnson
Controls.
3 Responsibility
The Engineering Manager and the Launch Manager, who is responsible for respective project, is
responsible for the correct implementation of the guideline.
Master files are stored electronically and are available to all team members.
Printed copies of the master files are for reference only.
Guideline
1 PURPOSE ......................................................................................................1
2 AREA OF VALIDITY ......................................................................................1
3 RESPONSIBILITY ..........................................................................................1
4 DEFINITION....................................................................................................4
4.1 Resistance welding spot.....................................................................................................................4
4.2 Spot weld geometry ...........................................................................................................................4

4.2.1 Weld nugget diameter dL .............................................................................................................5
4.2.2 Weld nugget penetration depth t..................................................................................................5
4.2.3 Diameter of impression dE1, dE2 ...................................................................................................5
4.2.4 Depth of impression tE1, tE2 ..........................................................................................................6
4.2.5 Sheet thickness t1, t2 .....................................................................................................................6
4.2.6 Comparison sheet thickness tV .....................................................................................................7
4.2.7 Spot diameter dP (Figure 2) .........................................................................................................7
4.2.8 Welding cut-off............................................................................................................................8
4.2.9 Spot welding diameter as a function of the sheet thickness.........................................................8
4.3 Examination .......................................................................................................................................9

4.3.1 Fulfilled resistance welding spot .................................................................................................9
4.3.2 Faulty resistance welding spot.....................................................................................................9
4.3.3 Critical welding ...........................................................................................................................9
4.3.4 Welding classes .........................................................................................................................10
4.3.5 Spot welding position ................................................................................................................10
4.3.6 Sampling....................................................................................................................................11
4.4 Repair ...............................................................................................................................................12

4.4.1 Welding defect...........................................................................................................................12
4.4.2 Repair of faulty resistance spot weldings ..................................................................................13
4.4.2.1 Resistance spot welding.........................................................................................................13
4.4.2.2 Plug weld ...............................................................................................................................13
4.4.2.3 Plasma spot welding ..............................................................................................................13
4.4.2.4 Quality inspection..................................................................................................................13
Guideline
4.5 Constructional design resistance welding......................................................................................14

4.5.1 Principles ...................................................................................................................................14
4.5.2 Marking .....................................................................................................................................14
4.5.3 Drawing example.......................................................................................................................18
4.5.4 Spot welding connections ..........................................................................................................20
4.5.5 Welding joint .............................................................................................................................20
4.5.6 Three-sheet metal connection ....................................................................................................21
4.5.7 Spot arrangement.......................................................................................................................21
4.5.8 Spot size.....................................................................................................................................21
4.5.9 Spot position ..............................................................................................................................22
4.5.10 Spot distance..............................................................................................................................23
4.5.11 Design notes ..............................................................................................................................24
4.5.12 Construction measurements.......................................................................................................27
4.5.13 Overlapping b ............................................................................................................................28
4.5.14 Spot distance e, eNeb ...................................................................................................................28
4.5.15 Spot distance f ...........................................................................................................................28
4.5.16 Seam length l .............................................................................................................................28
4.5.17 Edge distance v..........................................................................................................................28
4.5.18 Flange width a ...........................................................................................................................29
4.5.19 Flange disalignment i.................................................................................................................29
4.5.20 Flange heights c1, c2 , h , g (Table 5) .........................................................................................29
4.5.21 Flange and overlap distance k....................................................................................................29
4.6 Projection welding ...........................................................................................................................34

4.6.1 Scope of application ..................................................................................................................34
4.6.2 General information...................................................................................................................34
4.6.3 Circular projection (Form A).....................................................................................................35
4.6.4 Elongated projection (Form B) ..................................................................................................36
4.6.5 Annular projections (Form C)....................................................................................................37
4.6.6 Projection special forms (S).......................................................................................................39
4.6.7 Tool measurements for circular projections ..............................................................................40
4.6.8 Tool measurements for elongated projections ...........................................................................40
4.6.9 Tool measurements for annular projections...............................................................................41
4.6.10 Tool measurements for projection special forms.......................................................................41
4.7 Weld nuts..........................................................................................................................................42

4.7.1 Inspection torque for weld nuts .................................................................................................43
4.8 Surface requirement........................................................................................................................44

4.8.1 Quality grade (surface) ..............................................................................................................44
4.8.1.1 Quality grade A .....................................................................................................................44
4.8.1.2 Quality grade B......................................................................................................................44
4.8.1.3 Quality grade C......................................................................................................................44
5 REPORTS / MINUTES..................................................................................45
6 REFERENCE LIST .......................................................................................45
Guideline
4 Definition
4.1 Resistance welding spot
When resistance spot welding, the welding zone of the parts to be connected is heated by electric
current until melted, with simultaneous effective electrode force. Size, form and position of the
melted base material depend on the temporal and spatial interaction of the amount of produced
and dissipated heat in the welding zone and its environment. Under the effect of the electrode
force the work pieces connect during the solidifying of the molten mass.
The resulting punctiform welded joint, more accurately lens-shaped "weld nugget", is called a
"spot weld" (figure 1), which unites the parts at the welding joint (figure 4).
4.2 Spot weld geometry
Figure 1 Definition of the spot weld geometry
Guideline
4.2.1 Weld nugget diameter dL
The weld nugget diameter is considered the diameter of the area in the parting plane (vertical to
the connecting plane) of the work piece parts that was liquid during the welding procedure and
stands out due to its different crystalline structure of the base material.
The smallest permitted measurement for dL is noted in Table 1. The measurement of the weld
nugget diameter dL and the evaluation of the weld nugget for welding defects take place by
means of metallographic examination (macro-etched slice).
4.2.2 Weld nugget penetration depth t

For weld class 1 (CC) the penetration depth of the weld nugget is to be 40 to 60 % of the
respective single sheet metal thickness.
For weld class 2 (SC) and 3 the penetration depth of the weld nugget is to be 20 to 80 % of every
single sheet metal thickness.
4.2.3 Diameter of impression dE1, dE2
The diameter of impression dE is considered in each case to be the medium diameter of the
impression caused by the electrode (Figure 1).
Guideline
4.2.4 Depth of impression tE1, tE2
The depth of impression tE is considered in each case to be the largest impression depth caused
by the electrode.
The maximum of depth of impression is at an two sheet joint 0.3 x thickness of the respective
single sheet tE1,2 ≤ 0,3 t1,2. At a three sheet joint the outer respective sheets are proper. During
welding of thin sheets (thickness ≤ 0,7mm) macroscopic deformation (Figure 2) are not appraised
as impression from electrode.
Figure 2 Real impression from electrode
Figure 3 Bending by electrode
4.2.5 Sheet thickness t1, t2
t1, t2 are sheet metal thicknesses of the spot welding connections. t1 is always the thinnest sheet
metal, t2 always the thickest sheet metal.
Differences of thickness > 1:3 are to prevent, see Figure 4 negative sample.
For the welding class 1 (CC) and 2 (SC) the relation should not exceed 1:2 for t1: t2.
Figure 4 Defects of weld points by an relationship 1 : 3
Guideline
4.2.6 Comparison sheet thickness tV
The comparison sheet thickness tV is relevant for the constructional design and for the
determination of the welding parameters with connections with different sheet metal thicknesses
(t1, t2) (Table 5).
4.2.7 Spot diameter dP (Figure 2)
The spot diameter dP is after shear fracture the medium diameter of the fracture surface in the
connecting plane of the work piece parts without occurring friction zone.
The medium diameter is calculated from the apparently minimum diameter and the additionally
measured right-angled diameter.
With a spot weld shear failure and mixed fracture dP is the medium diameter of the surface area
of the sheared cut-off (figure 2).
The spot diameter serves the set point adjustment of the weld nugget diameter dL (Table 1) and is
therefore not specified in the drawings. The standard value for uncoated sheet metal is:
dP ≥ 1,15 x dL
Figure 5 Point diameter dP
Guideline
4.2.8 Welding cut-off
A welding cut-off is a piece of metal, which is detached from one of the two welded parts during
the peeled test (see also Figure 2).
If no welding cut-off is ripped out, the fracture surface diameter can be considered equal to the
welding cut-off diameter under the condition that a good metal connection (crystalline fracture
surface and deformation of the base material) is present (Figure 2).
4.2.9 Spot welding diameter as a function of the sheet thickness
Parallel and overlapping splice St 12 , 13 , 14

Minimum Weld Spot Minimum shear
1)
Sheet thickness nugget diameter Diameter tension force
t1 dLmin. ≥ 3,5 √ t1 dP min. ≥ Fmin.
1,15 x dlmin.
in mm in mm in mm in kN
0,5 2,5 2,9 1,2
0,6 *) 2,7 3,1 1,5
0,7 2,9 3,3 1,9
0,8 3,1 3,6 2,3
0,9 *) 3,3 3,8 2,7
1,0 3,5 4,0 3,2
1,25 *) 3,9 4,5 4,2
1,5 4,3 4,9 5,1
1,75 *) 4,6 5,3 6,1
2,0 5,0 5,7 7,2
2,25 *) 5,3 6,0 8,3
2,5 5,5 6,4 10,6
2,75 *) 5,8 6,7 11,5
3,0 6,1 7,0 12,4
3,5 6,5 7,5 15,0
4,0 7,0 8,0 18,5
1) The thinner sheet metal t1 is relevant for the determination of the weld nugget and/or spot
diameter with different sheet metal thicknesses.
The Fmin. values were extrapolated for sheet metal thicknesses marked with *).
Table 1
Guideline
4.3 Examination
4.3.1 Fulfilled resistance welding spot

By means of destroying test determined welding cut-off diameter (average value of two under a
right angle measured diameter) or with a destroyed or none destroyed measured weld nugget
diameter which indicated to the spot diameter on the drawing.
d = dp ≥ (d1 + d2) / 2 or 1,15dL = dp ≥ (d1 + d2) / 2
The welding has to fit the requirements about the shearing force as shown in table 1.
4.3.2 Faulty resistance welding spot
A weld should be classified as defective if any indications were detected by burn through and
porous. Cuts are not allowed.
Exists in one row 10 or more weld spots than 10% of the weld spots could be insufficient (only for
weld class 2 and 3).
Insufficient weld points mustn’t be located together or at start and end of a row.
4.3.3 Critical welding
Faulty weldings, which are found in the following positions, are to be repaired without
consideration of grade or tolerance.
- Weldings for headrest fixtures.

- Weldings for Isofix bracket.
- Weldings for latches at backframes and cushions.
- Weldings which are in relation to allowed strain where the current strain is
0,75 σzul < σ < σzul . The calculation from the strain σ at the area of connection is done during
product development.
Guideline
4.3.4 Welding classes
The process requirements are divided into the classes [ 1 ] to [ 3 ]. This requirement must be
entered directly into the welding marking (4.5.2, Table 3).
The suitability as well as the quality must be confirmed by test weldings.
Welding classes:
1: Welding class 1 contains welded connections, which would cause endanger to human
life.
CC’s. (Critical Characteristic)
2: Welding class 2 contains welded connections, where their failure would cause
malfunctions unfit for using or a loss of property could occur.
SC’s (Significant Characteristic)
3: Welding class 3 contains welded connections, where their failure would cause a less loss
of property for the origin usability.
Welding class 1 may contain only spot welds in accordance with 4.3.1.
For a new product with welding class 1 the qualification and the quality must confirm by a report
about a work specimen or process check.
4.3.5 Spot welding position
Spot welds of the requirement class 1 may not be in the radius.

A deviation of < 10mm is to be achieved in each case with spot weldings with unclear position
indications e.g. corner spot welds or outline deviations from the coordinates.
Guideline
4.3.6 Sampling
The minimum test for the respective welding class is defined as follows:
Welding class To be conducted test
Destructive or non destructive

1
test 3 times per shift incl. “First
(CC)
part check”

2
test 2 times per shift incl. “First
(SC)
part check”

3
test for the “First part”
Table 2
The respective criteria of the examinations are to be taken from (Table 1).
Additional the criteria from 4.2.1 as well as 4.2.2 have to be achieved.
The verification of the process capability has to ensure the warranty of the weld points.
Deviations are to be co-ordinated with the responsible quality control and documented.
Guideline
4.4 Repair
4.4.1 Welding defect
• Spot welds broken open at edges are not regarded as fulfilled (Figure 3).
• Distorted edge spot welds should be reduced to a minimum. They are however permitted
under the following conditions:
• Measurement A > 80 % of D = > spot weld fulfilled (see 4.3.1)
• Not more than two spots lying next to each other may show distorted edges
Broken open edges Deformed edges
(Figure 6)
Guideline
4.4.2 Repair of faulty resistance spot weldings

Resistance spot weldings, which do not fulfill the requirements in accordance with 4.3.1, are to be
repaired according to the following methods.
4.4.2.1 Resistance spot welding
Additional, fully effective spot weldings, which should be placed with an distance of 3,5 dL from
the centre point of the incorrect spot weldings. They must have at least the dimensions specified
in the drawing.
4.4.2.2 Plug weld
Welding should be done as a MIG/MAG spot or MIG/MAG plug weld at middle position of flange.
Is their no access or the thickness to small a MIG/MAG seam can be placed at the end of the
flange with appr.15 mm length per each weld spot.
4.4.2.3 Plasma spot welding
Plasma spot should be placed in the middle of the defective spot weld.
4.4.2.4 Quality inspection
During rework a first and last destroying inspection is required. Additional a 100% visual
examination is required. Visual examination at the backside of the sheets can use as a quick
check. Quality inspection take place by a type related work instruction and quality control plan. It
is documented at an inspection chart defective weld spots.
Guideline
4.5 Constructional design resistance welding
4.5.1 Principles
The following principles, definitions are to be observed for the constructional and production-
correct design of spot welding connections.
4.5.2 Marking
The welding data are represented on the drawing by means of the following table:
Guideline
Define tolerance class

(current AE)
The description of the filler metal has to

be defined at the drawing in the table. In
general used filler metal is G-46.
Define welding process and

weld class
Table 3
Guideline
The diameter of the spot weld is to be indicated next to the labeling field. Or in a table, if several
welding methods are required (Table 4). The individual spots are to be separately numbered and
listed in the case of different spot weld diameters.
3 to 1 MIG001-004 a5 3 X 10 (20)
2, 4, 5 to 1 SPW005-008 ∅ 5 (4x40)
Verbindung von Teil * mit Teil * Schweißnummer Abmessung Bemerkung
Item * Welded to Item * Weld Number Dimension Comments
Table 4
Optional quantity and distance
Only for information
2- level melting spots are to be marked
with the symbol.
3- level melting spots are to be marked
with the symbol.
Projection welds has to be marked in the drawing with the text „projection weld" and the
identification letter according to the form (A, B, C).
Guideline
The weld points have to mark with an arrow line and the short symbol from the weld process.
In addition the marking of the weld class can be done if a standard mark for the hole drawing is
not possible.
SPW 104 [ 1 ]
That is also possible at same dimensions and unmistakable exposition shown at groups.
The dimensioning of the single weld points has to be done relatively or absolute together.
Guideline
4.5.3 Drawing example
Guideline
Guideline
4.5.4 Spot welding connections
Is an inseparable connection directly on the welding joint by means of a "spot weld" or "seam
weld", which is named ZSB (welding assembly) in drawings. Spot welding connections can
consist of one or several assemblies.
4.5.5 Welding joint
Is the form component, in which the parts are combined with one another by stop welding. The
respective joint type (Figure 4) is determined by the constructional given facts of the parts to each
other.
The parts are parallel to one

Parallel joint
another
The parts are parallel to one

Overlapping joint
another and overlap
Figure 7
Guideline
4.5.6 Three-sheet metal connection
Welded joints with 3 sheet metals are to be avoided constructionally if possible.
The following criteria are to be observed during the construction:
Sheet metal combination Condition
Connection with same plate thickness permissible
Symmetrical arrangement with thin sheet metal

permissible
inside
t inside
Symmetrical arrangement with thick sheet
-------- ≤ 2
metal inside
t outside
Connection with unequal sheet metal t inside t outside thick
thicknesses in ascending and/or descending ---------- ≤ 2 and -------------------- < 1
order t outside thin t inside + outside thin
Connection with unequal sheet metal t inside thick
thicknesses in mixed arrangement and thick ----------- ≤ 2
sheet metal inside t outside thin
Connection with unequal sheet metal t outside thick
thicknesses in mixed arrangement and thinnest --------------------- < 1
sheet metal inside t inside + t outside thin
4.5.7 Spot arrangement
The spot arrangement is to be selected in such a way that the force F applied from the outside is
symmetrically distributed if possible on all spots. If the force affects practically only one spot a
"zipper effect" develops, i.e. the spots tear out successively.
4.5.8 Spot size
The spot weld size, which is specified on drawings and the tables of this guideline, is to refer to
the weld cut-off or fracture surface diameter (see Table 1).
Guideline
4.5.9 Spot position
Spots, which cannot be perfectly welded due to accessibility difficulties, are to be avoided.
All spot welds should lie in a line.
Good Bad
Figure 8
Guideline
4.5.10 Spot distance
The effect of the shunt link cannot be neglected with spot distances below the spot distance eNeb.
(Table 5). In order to achieve the same weld nugget diameter with smaller spot distances, the
current must be increased starting from the second point. The current portion, which flows over
already given points of the seam, does not contribute to welding. Therefore a smaller nugget
diameter is achieved from the 2nd seam spot onwards with a too small spot distance and
constant adjustment data (Figure 9).
Bad Good
Figure 9
Different shunt link possibilities are shown in figure 10.
a) b) c)
Figure 10 a) Shunt link on the sheet metal by electrode unit

b) Shunt link by means of centering pin
c) Shunt link by means of bended sheet (not avoidable)
Guideline
4.5.11 Design notes
During the construction of components the following technical manufacturing aspects should be
considered:
- It must be determined in good time whether the given welding equipment is suitable and if the
constructions require equipment with large working and arm radius (Figure 11)
Figure 11 Example of to be avoided electrode arms
- Double sheared connections (3-sheet metal–welds) are to be avoided if possible.

- Projection welding is to be preferred with parts with flat point flanges with very small spot
distances.
- The distance between electrode outside diameter and/or – holder and sheet metal inner edge
should be at least 2 mm (Figure 12).
- The construction is to be executed in such a way that short, straight and form-rigid arms,
electrode holders and electrodes can be used (Figure 12).
Figure 12 Springy and pushing electrodes cause defective welding quality
Guideline
- When welding seam welds the welding sequence must be selected in such a way that no
cavities can form between the metal sheets (Figure 13).
Bad Good
Bad Good
Figure 13
- The electrode shaft should be vertical to the sheet metal surface (90° ±1°) (Figure 14, left).
Asymmetrical electrode caps are not permissible (Figure 14, right).
Bad Good Bad Good
Figure 14 Examples of bad and good contact surfaces for the welding electrodes
Guideline
- Constructions with bad accessibility are to be avoided, because particularly formed

electrodes and/or electrode arms are required (Figure 15).
Bad Good Bad Good
Bad Good
Bad Good
Figure 15 Examples of bad and good accessibility for the welding electrodes
at the welding flanges
Guideline
4.5.12 Construction measurements
Figure 16 Seam weld Figure 17 Seam weld

single-row single sheared double-row single sheared
Figure 18 Seam weld Figure 19 Seam weld

double-row shifted single sheared double-row double sheared
Guideline
4.5.13 Overlapping b
The overlap b is the width of the contact surface of the welding flange of the sections. The levels
of the contact surfaces must run parallel and completely contact each other (Figures 16 – 27).
Border lines of the contact surfaces are either sheet edges or points of application of radii. Thus b
is the shortest distance of the border lines.
Therefore the following applies: b ≥ 2v
4.5.14 Spot distance e, eNeb
The spot distance e is the distance in the middle of two neighboring spot welds (Figures 16 -19).
The spot distance eNeb marks the distance, when – if fallen short of - the shunt link cannot be
neglected during the welding procedure any more.
Therefore the following applies: e ≥ eNeb.
4.5.15 Spot distance f
With several seam welds the seam distance f is the shortest distance of neighboring seams,
related to the spot weld centre (Figure 17 – 19).
Therefore the following applies: f ≥ e
4.5.16 Seam length l
The seam length l is the distance of the spot weld center of the first and last spot weld of a seam
weld (Figure 16 – 19).
4.5.17 Edge distance v
The edge distance v is the distance of the spot weld center to the nearest border line of the
contact surface (Figure 16 – 27). In the case of a double sheared spot weld connection, v is
increased in relation to the values in (Table 5) by approx. 50%.
Guideline
4.5.18 Flange width a
The flange width a is measured from the flange end up to the radius application of the further
sheet metal. With multi-rowed seam welds the flange width a is to be increased according to the
seam distance f (Figure 21 and 22).
If in a later operation sequence a further sheet metal is added to a single sheared connection, the
sheet metal t3 must be considered during the design of the flange geometry of the single sheared
connection. This arrangement is not considered a double sheared connection.
The flange width a is distinguished according to
Guide flange width aF

The guide flange is the flange that due to the constructional design is of higher
importance during the assembly and forms the limit of the assembled part.
Adaptation flange width aA

The adaptation flange is the flange that due to the constructional design is of lesser
importance during the assembly and is to be adapted in such a way to the guide flange
that it does not tower above it.
4.5.19 Flange disalignment i
The flange disalignment I is the maximum projection from the guide flange to the adaptation
flange, e.g. for the mounting of gaskets (Figure 22 and 23).
4.5.20 Flange heights c1, c2 , h , g (Table 5)
The measurements c1 , c2 and h consider the dimensions of the spot welding units, the electrode
space requirement and the work piece accessibility in production (Figure 22 and 23). The
measurement g indicates the maximally permissible disalignment (Figure 21).
4.5.21 Flange and overlap distance k

The flange and overlap distance k is the minimum distance between overlap b and radius
application (Figure 21).
Guideline
Table 5 Welding flange geometry as a function of the comparison sheet thickness tV and the
welding-technical conditions
Comparison Spot Flange Diameter Free size

sheet measurements
thickness distance
TV eNeb v b I c1 c2 g k ED SD FM
h =< 100 h > 100
min. min. min. min. max. max. min. min.
0.5 to 0.6 10 3.3 6.6 15 1.0-1.0 20 16 1.1 2 13 13 8.5
>0.6 to 0.8 12 3.9 7.8 17 25 20 1.3 16 18 11
>0.8 to 1.0 15 4.3 8.6 20 1.5-1.5 1.5
>1.0 to 1.1 18 4.8 9.6 21 30 24 1.7
>1.1 to 1.2
>1.2 to 1.5 24 5.3 10.6 24 2.0
>1.5 to 1.6 27 5.6 11.2 27 2.0-2.0 40 32 2.5
>1.6 to 2.0 6.3 12.6 20 20 12
>2.0 to 2.5 36 6.8 13.6 30 3.0
>2.5 to 3.0 45 7.6 15.2 33 3.5 24 24 14
>3.0 to 3.5 54 8.1 16.2 36 2.5-2.5 50 40 4.7 5
>3.5 to 3.8 63 8.8 17.5 39
>3.8 to 4.0
Guideline
Addition to table 5:
Explanation
tV = 0,8 x t1 + 0,2 x t2
b≥2v
FM ≥ SD/2 + 2 *
h = Flange height
t1 = thinnest sheet metal of the
welding joint
t2 = thickest sheet metal of the
welding joint
ED = electrode caps - ∅
SD = electrode shank - ∅
FM = Free size
* With unequal sheet metal thicknesses
of a welding joint is the free size FM
always refers to the thicker sheet metal.
.
Tolerances are ±5 % up to 20mm and

≤1.5 mm over 20mm .
Guideline
Figure 20 Figure 21
Figure 22 Figure 23
Guideline
Figure 24 Figure 25
Figure 26 Figure 27
Guideline
4.6 Projection welding
4.6.1 Scope of application
The scope of application applies to the production of circular projections, elongated projections,
annular projections and projection special forms in steel sheet 0.3 mm to 4 mm. The surface must
be free of scale, rust, oil, water and color arrears. The emulsion must be reduced to a minimum
with drawn parts.
4.6.2 General information
The projection is to be manufactured in the thicker sheet metal with the measurements of the
lighter sheet metal in the case of different sheet metal thicknesses. A sheet thickness ratio of
1 : 2,5 should not be exceeded.
Circular projections to be preferably applied with sheet metal thicknesses ≥1 mm. Annular
projections are more favorable due to their larger rigidity with sheet metal thicknesses ≤1 mm,
especially if these are to be welded on heavier sheet metals.
Elongated projections are predominantly used, if single welded connections are stressed on
twisting and/or if there is no possibility of at least two circular and/or annular projections due to
space reasons.
Elongated projections can also be executed arc-shaped. The projection length is then to be
regarded as radian measure.
At the drawing the short symbol PJW (Project welding) has to be used in addition with the
projection form and size.
Guideline
4.6.3 Circular projection (Form A)
Figure 28 Form of a circular projection
Table 6 Measurements of the circular projection Measurements in mm
Projection Projection height

Die Distance
Projection Sheet Diameter A
Dia- L1
Identification thickness d1 +0,1
1) meter 2)
letter t +0,1 = 0,05
D2 Min.
0 0
A1 ≤ 0,50 ∅ 2,3 0,6 ( ∅ 0,8 ) 10
A2 >0,50 ≤ 0,75 ∅ 2,8 0,9 ( ∅ 0,9 ) 10
A3 >0,75 ≤ 1,00 ∅ 2,8 0,9 ( ∅ 0,9 ) 12
A4 >1,00 ≤ 1,50 ∅ 3,8 1,1 ( ∅ 1,3 ) 16
A5 >1,50 ≤ 2,00 ∅ 4,6 1,2 ( ∅ 1,5 ) 24
A6 >2,00 ≤ 2,50 ∅ 5,8 1,3 ( ∅ 1,9 ) 30
A7 >2,50 ≤ 3,00 ∅ 6,8 1,4 ( ∅ 2,3 ) 36
A8 >3,00 ≤ 3,50 ∅ 7,9 1,5 ( ∅ 2,6 ) 40
A9 >3,50 ≤ 4,00 ∅ 9,0 1,7 ( ∅ 3,0 ) 40
1) The equal space tolerance applies to groups of projections welded in one operation.
2) Measurements must be confirmed by findings.
Guideline
Figure 29 Projection distances
The following applies for the projection distance l2 : l2 ≥ d1 (Figure 29)
4.6.4 Elongated projection (Form B)
Figure 30 Form of an elongated projection
Guideline
Table 7 Measurements of the elongated projection Measurements in mm
Projection Projection Projection height

Projection Sheet length width a
Identification thickness l b +0,1
letter t +0,1 +0,1 = 0,05 1)
0 0 0
B1 ≤ 0,50 4,6 2,3 0,6
B2 >0,50 ≤ 0,75 5,6 2,8 0,9
B3 >0,75 ≤ 1,00 5,6 2,8 0,9
B4 >1,00 ≤ 1,50 7,6 3,8 1,1
B5 >1,50 ≤ 2,00 9,2 4,6 1,2
B6 >2,00 ≤ 2,50 11,6 5,8 1,3
B7 >2,50 ≤ 3,00 13,6 6,8 1,4
B8 >3,00 ≤ 3,50 15,8 7,9 1,5
B9 >3,50 ≤ 4,00 18,0 9,0 1,7
.
4.6.5 Annular projections (Form C)
Figure 31 Form of an annular projection
Guideline
Table 8 Measurements of the annular projection Measurements in mm
Projection
Projection Projection height
Sheet
Dia- a
thickness d2 d3 d4 r
Identification meter 0
t
letter d1 = 0,05 1)
-0,1
C1 0,5 ≤ 0,8 ∅ 3,0 ∅ 1,6 ∅ 1,7 ∅ 2,3 R 0,3 0,4
C2 > 0,8 < 1,0 ∅ 4,0 ∅ 2,0 ∅ 2,2 ∅ 3,0 R 0,4 0,5
C3 1,0 ∅ 4,5 ∅ 2,0 ∅ 2,25 ∅ 3,25 R 0,5 0,5
.
Guideline
4.6.6 Projection special forms (S)
Projection special forms are to be dimensioned in the appropriate drawing.
The final form and the measures must be determined by suitable tests for the respective
application.
Depending upon application a collecting gutter is to be foreseen, in order to take up displaced,

liquid material around the projection. The collecting gutter must be sufficiently large, in order to be
able to take up unilaterally flowing material.
Figure 32 Examples of projection special forms
Guideline
4.6.7 Tool measurements for circular projections

Nominal diameter in the die plate and the projection are alike. The die diameter d3 is alike or
larger than the hole diameter d1 of the die plate. Figure 33 shows a tool for the production of
circular projections. For measurements see Figure 33 and table 6.
/ Die
/ Sheet metal
/ Die plate
Figure 33
4.6.8 Tool measurements for elongated projections
The nominal dimensions l and b of the projection as well as the die plate and the die are alike.
The measurements for the die have negative tolerances; the measurements for the die plate have
positive tolerances. For measurements see Figure 31 and table 7.
Die /
Sheet metal /
/ Die plate
Figure 34
Guideline
4.6.9 Tool measurements for annular projections
Nominal diameter in the die plate and the annular projection are alike. The die diameter d5 is
larger than the hole diameter d1 of the die plate.
Figure 35 shows a suitable tool for the production of annular projections.
For measurements see Figure 35 and table 8.
/ Die
/ Sheet metal
/ Die plate
/ Counter-die
Figure 35 Production of an annular projection
4.6.10 Tool measurements for projection special forms
The tool measurements of projection special forms for resistance welding must be defined
according to respective application.
Guideline
4.7 Weld nuts
The processing of weld nuts is an special kind of resistance welding. This connection is placed at
project welding. Basically there are two different types of weld nuts. Heaxagon weld nut DIN 929
and Square weld nut DIN 928.
Notice: DIN 929 must be used till grade < 8.8. For higher grades > = 8.8 EN ISO 21670 must be
used.
The exposition at the drawing has to be done as shown in Figure 36 and 37:
PJW XXX
PJW XXX
Figure 36 Square weld nut DIN 929
PJW XXX
PJW XXX
Figure 37 Heaxagon weld nut DIN 928
The correct description has to be done as shown in Table 4. For an example see Table 9.
2 to 5 PJW 001 Weldnut DIN 929 M8

Verbindung von Teil * mit Teil * Schweißnummer Abmessung Bemerkung
Item * Welded to Item * Weld Number Dimension Comments
Table 9
Guideline
4.7.1 Inspection torque for weld nuts
Inspection torque for weld joints nut / sheet were followed numbers based (Table 10 Hexagon,
Table 11 Square nut).
These numbers must be confirmed with trials at the related materials.
Inspection torque
Thread
[Nm]
M4 6,8
M5 11
M6 15
M8 28
M10 44
M12 65
7/16 UNF 43
Table 10 Recommended inspection torque for Hexagon weld nuts DIN 929
Inspection torque
Thread
[Nm]
M4 11
M5 20
M6 30
M8 60
M10 80
7/16 UNF 80
Table 11 Recommended inspection torque for Square weld nuts DIN 928
Guideline
4.8 Surface requirement
4.8.1 Quality grade (surface)
The surface quality after spot welding is divided into the following grades. The quality grade as
well as the critical areas is to be entered into the drawing and apply in each case only to the
designated page, if not differently indicated.
Grade C is applies for surfaces, where no grade is prescribed.
4.8.1.1 Quality grade A
This welding classification refers to sheet metal surfaces, which must be so free of markings and
impurities after the "Metal finish“ that they are invisible after painting or can be eliminated by the
"Metal finish". Not more than 10% of the sheet thickness may be removed by "Metal finish".
Markings of more than 10% of the sheet thickness must be filled out before the "Metal finish".
4.8.1.2 Quality grade B
This welding classification includes a minimum of welding marks on the surface (max. 10% over
and max. 15% underneath the normal surface). Welding splashes are not permissible.
4.8.1.3 Quality grade C
The surface mark of each sheet metal may not exceed 25% of the respective sheet thickness.
Guideline
5 Reports / Minutes
Not available
6 Reference list
Ford S91 AG 1K251 AA
Saab SDT 3492
Saab SDT 811
VW 011 05 Part 1
BMW GS 9600 : 2000-12
GM Common Welding Principles WS-1 Section A: Resistance Spot Welding 04/02/00
GM Automotive Welding Handbook 15/11/96
JCI Resistance Welding Design Guideline US 7/6/1999 Rev 0
JCI Resistance Welding Process Guideline US 11/24/1999 Rev 0
DVS 0939 Toleranzen beim Schweißen mit Industrieroboter
DVS 2915-1 Gütesicherung beim Punkt-, Buckel- und Rollnahtschweißen;
Grundlagen
DVS 2915-2 Gütesicherung beim Punkt-, Buckel- und Rollnahtschweißen;
Prozeßkontrolleinrichtungen
DVS 2915-3 Qualitätsicherung beim Punkt-, Buckel- und Rollnahtschweißen;
Qualitätsregelkarte
DVS 2916 Prüfen von Punktschweißungen
DVS 2937 Widerstandsschweißen mit Industrieroboter
DVS 2902-1 Widerstandspunktschweißen von Stählen bis 3mm Einzeldicke;
Übersicht
Punktschweißeignung
Konstruktion und Berechnung
Grundlagen, Vorbereitung und Durchführung
DIN 8524-3 Fehler an Schweißverbindungen aus metallischen Werkstoffen
DIN 5184 Gerade Punktschweißelektroden
DIN EN 22553 Schweiß und Lötnähte; Symbolische Darstellung in Zeichnung

1 Purpose: Resistance Spot Welding Guideline

Uploaded by

Copyright:

Available Formats

You might also like

1 Purpose: Resistance Spot Welding Guideline

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1 Purpose: Resistance Spot Welding Guideline

Uploaded by

Copyright:

Available Formats

Resistance spot welding

Revision level Revision date Description of changes

Signature / Date Signature / Date Signature / Date

Electronic copies valid without signature

2 AREA OF VALIDITY ......................................................................................1

4.2 Spot weld geometry ...........................................................................................................................4

4.3 Examination .......................................................................................................................................9

4.4 Repair ...............................................................................................................................................12

4.5 Constructional design resistance welding......................................................................................14

4.6 Projection welding ...........................................................................................................................34

4.7 Weld nuts..........................................................................................................................................42

4.8 Surface requirement........................................................................................................................44

6 REFERENCE LIST .......................................................................................45

4.1 Resistance welding spot

4.2 Spot weld geometry

Figure 1 Definition of the spot weld geometry

4.2.1 Weld nugget diameter dL

4.2.2 Weld nugget penetration depth t

4.2.3 Diameter of impression dE1, dE2

4.2.4 Depth of impression tE1, tE2

Figure 2 Real impression from electrode

Figure 3 Bending by electrode

4.2.5 Sheet thickness t1, t2

Figure 4 Defects of weld points by an relationship 1 : 3

4.2.6 Comparison sheet thickness tV

4.2.7 Spot diameter dP (Figure 2)

Figure 5 Point diameter dP

4.2.8 Welding cut-off

4.2.9 Spot welding diameter as a function of the sheet thickness

Parallel and overlapping splice St 12 , 13 , 14

4.3.1 Fulfilled resistance welding spot

d = dp ≥ (d1 + d2) / 2 or 1,15dL = dp ≥ (d1 + d2) / 2

4.3.2 Faulty resistance welding spot

4.3.3 Critical welding

- Weldings for headrest fixtures.

4.3.4 Welding classes

The suitability as well as the quality must be confirmed by test weldings.

CC’s. (Critical Characteristic)

SC’s (Significant Characteristic)

4.3.5 Spot welding position

Spot welds of the requirement class 1 may not be in the radius.

Welding class To be conducted test

Destructive or non destructive

Destructive or non destructive

Destructive or non destructive

4.4.1 Welding defect

• Measurement A > 80 % of D = > spot weld fulfilled (see 4.3.1)

Broken open edges Deformed edges

4.4.2 Repair of faulty resistance spot weldings

4.4.2.1 Resistance spot welding

4.4.2.2 Plug weld

4.4.2.3 Plasma spot welding

4.4.2.4 Quality inspection

4.5 Constructional design resistance welding

Define tolerance class

The description of the filler metal has to

Define welding process and

2- level melting spots are to be marked