GMW14057

Template For ENG STDS
WORLDWIDE
ENGINEERING Material Specification GMW14057
STANDARDS
Weld Acceptance Criteria and Repair Methods

Resistance Spot Welds - Steel
1 Introduction
Note: Nothing in this standard supercedes applicable laws and regulations.
Note: In the event of conflict between the English and domestic language, the English language shall take
precedence.
Note: For the stainless steel resistance spot welding in powertrain/propulsion systems applications, see
Deviation Section.
1.1 Purpose. This standard provides the acceptance criteria and repair methods for resistance spot welds in
automotive products for which GM is responsible for establishing or approving product design.
Note: This standard applies to steels approved by GM for Resistance Spot Welding (RSW).
1.2 Applicability. The criteria established in this standard become mandatory when referenced on a weld design
document. Deviations from any weld criteria provided in this standard must be identified on a weld design
document or other product design document.
1.3 Remarks.
1.3.1 Welded structures are considered satisfactory when they carry the intended service loads for a required
period. Service loads on weldments in a vehicle are varied in both type and magnitude and cannot be addressed
by this standard. Therefore, while the weld quality criteria of this standard are consistent with service loading
requirements, they have been established specifically for use in process and product monitoring. Any attempted
application of this document to other uses, such as post-crash weld quality assessment, may lead to an
erroneous result or conclusion. Discrepant welds by retaining a portion of their engineering properties may still
contribute to the integrity of the assembly.
1.3.2 Clarification. For clarification of this specification or editorial comments, email the GM Global Welding and
Joining Council at weld.council@gm.com.
1.3.3 Proposed changes to this standard must be presented to the GM Global Welding and Joining Council at
weld.council@gm.com
1.3.4 As used in this standard, the words “shall” and “must” denote a requirement; the word “should” denotes a
guideline; and the word “may” denotes a choice.
2 References
Note: Only the latest approved standards are applicable unless otherwise specified.
2.1 External Standards/Specifications.
None
2.2 GM Standards/Specifications.
9984532 GMW14085 GMW16383 GMW16804
GMW14058 GMW15563 GMW16435 GMW17330
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---
2.3 Additional References.

• GM Global Quality Requirements for Corrective Action and Nonconforming Material. GM Plants refer to GM
to: https://gmweb.gm.com/quality/oq/QR/IQ_Global/default.aspx (Contact supplier quality for non-GM
plants.)
© Copyright 2018 General Motors Company All Rights Reserved
May 2018 Page 1 of 19
Copyright General Motors Company

Provided by IHS Markit under license with General Motors Company Licensee=Magna International Inc/5926707001, User=DE LA CRUZ, vFELPE
Reproduction, distribution or publication of these standards is expressly prohib Not for Resale, 09/11/2018 08:43:34 MDT
GM WORLDWIDE ENGINEERING STANDARDS Template For ENG STDS GMW14057
• GM Record Retention Schedule (GMRRS); https://gmrrs.gm.com/GMRRS/ (Contact suppler quality for non-
GM plants.)
• Midwest Thermal Spray CBF100 conductive body filler available at www.midwestthermal.com/cbf100.html
3 Requirements
3.1 General Acceptance Criteria.
3.1.1 Individual Spot Weld Criteria. There are multiple visual and measurable attributes that are used to
evaluate spot weld quality. These attributes are divided into two categories:
a. Attributes that affect conformance (including discrepancies).
b. Attributes that are undesirable for appearance or processing.
3.1.2 Categories of Spot Welds. There are two categories of spot welds:
a. Structural welds.
b. Process welds.
3.1.2.1 Structural Spot Welds. Structural spot welds are installed for performance of the welded product. All
spot welds are structural unless specifically noted as process welds on the weld design document.
3.1.2.2 Process Spot Welds. Process spot welds are installed to facilitate in-process assembly, but are not
required for structural performance of the product. Process spot welds must be approved by Product and
Manufacturing Engineering and shown on the weld design document.
3.2 Visual Acceptance Criteria.
3.2.1 Visual Attributes–Discrepant Welds. Welds that exhibit any of the following attributes are discrepant.
3.2.1.1 Cracks. Spot welds with crack(s) around the circumference that are visible without the aid of
magnification, are discrepant. Spot welds with surface cracks confined within the impression left by the
electrodes are not discrepant. See Appendix A, Figure A1. The aesthetic appearance criteria for cracks are listed
in Appendix A. See also 3.2.3.
3.2.1.2 Holes. All spot welds with holes do not conform and must be repaired. Structural spot welds that contain
through-holes that are at least 2 mm in diameter or holes that break the perimeter of the impression left by the
electrodes and that are visible without the aid of magnification are discrepant, see 3.4.1. Structural spot welds
that contain holes extending through the weld, that are visible without the aid of magnification but smaller than
2 mm and are contained within the impression left by the electrodes, shall have the welding process adjusted to
the qualified setup to eliminate the condition causing the hole. Process welds that contain holes extending
through the weld shall have the welding process adjusted to the qualified setup to eliminate the condition causing
the hole. See Appendix A, Figure A2. The aesthetic appearance criteria for holes are listed in Appendix A. Holes
repaired in Zones A, B, and C shall be metal finished to improve appearance. See also 3.2.3.
3.2.1.3 Edge Welds. Welds in which the spot weld impression left by the electrodes, is not contained within all
edges of the sheet metal being welded are discrepant. See Appendix A, Figure A3, welds E and F.
3.2.1.4 Missing Welds. When fewer welds exist than are specified on the weld design document, the omitted
welds are discrepant. See also note following 3.4.1.
3.2.2 Visual Attributes–Appearance and Processing Considerations. Welds that exhibit the following
attributes are undesirable either from an appearance or processing viewpoint. These attributes do not make the
weld discrepant and are not used in determining weld pattern conformance.
3.2.2.1 Extra Welds. The number of spot welds installed shall not exceed the number specified on the weld
design document, except as required by the repair methods described in 3.4. The welding process shall be
adjusted to eliminate extra welds.
3.2.2.2 Whiskers. Welds exhibiting whiskers shall have the welding process adjusted to minimize this condition
(Appendix A, Figure A4). The aesthetic appearance criteria for whiskers are listed in Appendix A, Table A1 for
whiskers found in special appearance zones A, B, C, and D (Appendix A, Table A2 and Figure A16) and in the
Roof Rail Air Bag areas (Appendix A, Figure A17). See Appendix A, Figure A4.
Note: Welds shall be free of whiskers when using ultrasonic inspection equipment to avoid damage to the
transducer.
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

3.2.2.3 Distortion. Spot welds in which the sheet surfaces are distorted > 25 degrees from the normal plane
shall have the welding process adjusted to the qualified setup in order to reduce the distortion to < 25 degrees.
See Appendix A, Figure A5. The aesthetic appearance criteria for distortion are listed in Appendix A. See also
3.2.3.
3.2.2.4 Thinning and Indentation. Spot welds exhibiting thinning > 30% of the total metal stack-up shall have
the welding process adjusted to the qualified setup in order to reduce the thinning to < 30%. See Appendix A,
Figure A6. The aesthetic appearance criteria for indentation are listed in Appendix A. See also 3.2.3.
3.2.2.5 Trim Edge Deformation. Welds in which the original edge of the weld flange is deformed by the
electrodes but whose spot weld impression is contained within all edges of the sheet metal being welded are not
discrepant. Nonetheless, the process shall be adjusted to the qualified setup to minimize the condition. See
Appendix A, Figure A3, welds C and D. The aesthetic appearance criteria for trim edge deformation are listed in
Appendix A. See also 3.2.3.
3.2.2.6 Surface Eruption. Surface eruption is an upsurge of the sheet surface adjacent to the electrode
impression. See Appendix A, Figure A7. The appearance criteria for surface eruption are listed in Appendix A.
See also 3.2.3.
3.2.2.7 Spatter. Spatter is weld metal expulsion that remains attached to surface(s) adjacent to the weld. See
Appendix A, Figure A4. The appearance criteria for spatter are listed in Appendix A. See also 3.2.3.
3.2.2.8 Non-Concentric Welds. Weld symmetry is a purely aesthetic criterion that does not affect conformance.
The aesthetic appearance criteria for concentric welds are listed in Appendix A. See also 3.2.3.
3.2.3 Perceptual Quality Requirements. Spot welds visible to the customer in strategic areas of the body affect
Perceptual Quality (PQ). The special appearance zones (listed in Appendix A, Table A1, Table A2, and
Figure A16) are consistent with the GM Global Customer Audit. Spot welds not meeting appearance standards
shall have the process adjusted to the qualified setup to minimize the undesirable condition. Moreover, metal
finish may be required to meet the aesthetic requirements in these zones.
3.3 Measurable Acceptance Criteria.
3.3.1 Weld Location. Spot welds must be properly located relative to design location as indicated on the weld
template and to each other as follows:
• A single in-line grouping or row of welds in which a distinct product feature provides visual reference to the
end weld, an end weld installed > 10 mm in radial distance from the design location is a discrepant weld. A
distinct product feature is a visible trim edge or other recognizable part feature that is perpendicular or nearly
perpendicular to the row of welds and within 30 mm of the end weld.
• For all other welds, a resistance spot weld installed > 20 mm in a radial distance from the design location is
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---
a discrepant weld.
• If the spacing between two adjacent welds in a single in-line grouping or row of welds exceeds the design
spacing by > 20 mm, the weld furthest from the design location is discrepant.
• The aesthetic appearance criteria for weld location are listed in Appendix A.
3.3.2 Weld Size. The weld size may be measured by either using the weld button (Appendix A, Figure A8), the
weld nugget (Appendix A, Figure A9), or the fusion zone. A spot weld is discrepant when the measured weld
size at each faying surface is less than the minimum acceptable weld size specified in Table 1.
Table 1: Minimum Acceptable Weld Size

Determining Thickness (DT) Minimum Acceptable Weld Size
0.60 mm to 0.64 mm 3.0 mm
0.65 mm to 1.29 mm 4.0 mm
1.30 mm to 1.89 mm 5.0 mm
1.90 mm to 2.59 mm 6.0 mm
2.60 mm to 3.25 mm 7.0 mm

3.3.2.1 Two-Thickness Welds. To determine the acceptable weld size for a two-thickness weld (two loose
pieces or one loose to two previously welded), use the metal thickness (T) of the thinner of the two layers being
welded to determine the weld size as listed in Table 1.
3.3.2.2 Three-Thickness Welds. To determine the acceptable weld size for a three-thickness weld (three loose
pieces) use the metal thickness (t) of the thinner of the two layers at each interface to determine the acceptable
weld size. However, in the case where the thinnest layer is stacked between two thicker layers use the second
thickest piece (t) to determine the acceptable weld size for both welds.
3.3.2.3 Single Fusion Zone (SFZ) Welds. Three-thickness welds designated as SFZ welds (1T to 2T) only
require fusion at a single interface of the three layers, see Appendix A, Figure A15. To determine the acceptable
weld size at the required interface of the SFZ weld, use the metal thickness (t) of the thinner of the two layers at
the required interface.
3.3.2.4 Fusion Mode. There are several different fusion modes that are commonly observed in destructively
tested steels. The mode of fracture is not an assessment of the quality of the weld; rather, it is an indication of
the weakest fracture path through or around the weld in the context of the strength of the material surrounding
the weld.
•
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---
Button Pull is common in welds that involve softer, thinner steels. When a rapidly quenched steel spot weld
is significantly stronger than the steel surrounding it, the steel tears at the periphery of the nugget. When
this tearing propagates to the surface of the base metal substrate, a button results.
• Partial Thickness Fracture is similar to button pull but occurs more often in a thick piece of relatively low
strength steel. When the tearing propagates around the periphery of surface of the weld nugget, but does
not propagate to the surface, a partial thickness button results.
• Interfacial Fracture is the opposite extreme of button pull. It is most common in joints involving thick, high
strength steels. When relatively highly alloyed steel surrounding the rapidly quenched weld nugget is no
longer weak in comparison to the weld, the fracture mode switches from fracturing along the weld nugget
periphery to a fracturing though the weld. This does not indicate that the weld is weak insomuch as it
indicates that the base metal substrate surrounding the weld is very strong.
• Combinations of button, partial thickness failure, and interfacial fracture are sometimes observed when the
random orientation of steel grains together with naturally occurring shrinkage porosity change the localized
directional strength within the nugget. The result can be a weld that pulls nuggets (or partial thickness
fractures) surrounded by (or next to) areas of interfacial fracture.
In these cases involving interfacial fracture or partial thickness fracture, examination of the fusion zone must be
used to determine weld size. When available, cross sectioning can be used to definitively assess the nugget
size. Fracture analysis can also be used to differentiate between interfacial fracture and unfused welds. When a
product quality standard is released by product engineering, this standard shall be used to evaluate the fusion
zone. Welds that exhibit partial thickness fracture or interfacial fracture are fused welds.
3.3.2.5 Unfused Welds. Weld locations that do not produce a weld button after a destruct test and are not
interfacial fractures are unfused welds. (Welds with interfacial fractures also demonstrate nuggets upon cross
sectional analysis.) Unfused welds are discrepant. See Note in 3.4.1 Spot Weld Pattern Conformance Criteria.
3.3.2.6 Laminated Vibration Damping Steel. The minimum weld size specified in Appendix A, Table A1 is
required only at the faying surface for laminated steel. There are no minimum weld size requirements for the
interface between the layers of the laminated steel.
For purposes of determining the minimum weld size, the laminated steel shall be treated as one sheet whose
thickness is equal to the sum of the two outer sheets and the inner viscoelastic layer as shown in Appendix A,
Figure A10.
3.4 Disposition/Repair Procedure.
3.4.1 Spot Weld Pattern Conformance Criteria. A pattern is a collection of discrete joints to which a tolerance
is applied to meet structural requirements and for determining manufacturing acceptance of the product. The
default pattern (when not otherwise stated on the weld design document) is all structural discrete joints on the
structure installed at the same manufacturing plant. The quantity tolerance for the single default pattern (when
not otherwise stated on the weld design document) is no more than 5% of the total joint/weld count being
discrepant. However, any weld pattern may have at least one discrepant weld, regardless of the pattern tolerance
percentage. (This affects patterns of fewer than 20 welds where the default percentage of 5% would be less

than one weld.) A joint pattern is conforming when the number of non-discrepant discrete joints/welds (per the
requirements of GMW14057, GMW14058, GMW14085, GMW16383, GMW16435, GMW16804, or GMW17330)
meets or exceeds the pattern tolerance described in the preceding. Manufacturing acceptance of product is
based on all patterns conforming. Disposition of product nonconforming to this standard shall be handled in
accord with GM Global Quality Requirements for Corrective Action and Nonconforming Material.
Note: Two or more adjacent missing or unfused welds cause pattern nonconformance regardless of the quantity
tolerance. All welds with holes that are visible without the aid of magnification do not conform and require a
repair regardless of the quantity tolerance.
3.4.2 Repair Exceptions. An exception to specified product repair requirements may be permitted provided
there is documented review and approval by the responsible product engineer allowing the suspect product to
deviate from specification and pattern conformance criteria.
3.4.3 Surface Appearance. Spot weld surface appearance criteria are not used in determining weld pattern
conformance.
3.4.4 Disposition of Process Spot Welds. Process spot welds are not used in determining weld pattern
conformance. Process welds containing holes that are visible without the aid of magnification shall be repaired;
see 3.4.5.5.
3.4.5 Repair Methods. When required, weld repairs shall follow the repair method authorized by the responsible
product engineer. In the absence of an engineering approved repair methods, the following repair methods shall
be used in the following order of preference:
3.4.5.1 Resistance Spot Weld Repair. Spot weld with a weld gun that is qualified for the metal types and
thicknesses to be welded. One repair spot weld shall be added for each spot weld being repaired. Repair spot
welds must meet the requirements of this standard. Locate repair spot welds as close as possible to the
designated weld location without overlapping the existing spot weld.
3.4.5.2 Arc Weld Repair. Arc weld repair of laminated steels is not permitted. Arc weld repair closer than 30 mm
of sealer, adhesive, or mastic is not permitted.
3.4.5.3 Arc Spot or Plug Weld Repair. For each spot being repaired, weld using Metal Inert Gas (MIG) plug or
Arc spot with steel filler wire. The Arc spot or MIG weld shall conform to the applicable arc spot and plug weld
acceptance criteria standard. All repair personnel using this method of repair must be periodically qualified and
approved following local procedures/ methods.
3.4.5.4 Arc Fillet Weld Repair. A MIG fillet weld may be used for two metal thickness joints. The MIG repair
weld must be located as close as possible to the designated weld location and must be a minimum of 20 mm in
length. The repair welds must conform to GMW14058. All repair personnel using this method of repair must be
periodically qualified and approved following local procedures/ methods.
3.4.5.5 Welds with Holes. Welds with holes that require repair shall be follow the method called out in Table 2.
All repair personnel using MIG repair methods must be periodically qualified and approved following local
procedures/ methods. Holes repaired in Zones A, B, and C may also require metal finished to improve
appearance. See also 3.2.3.
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Table 2: Repairs for Welds with Holes

Weld Type Hole Hole Inside Hole > 30 mm from Repair
< 2 mm Impression Left Sealer, Mastic, or
by Electrode Adhesive
Structural Yes Yes Either Use sealer released by
Weld Yes or No responsible product engineer
(e.g., Midwest Thermal Spray
CBF100 conductive body filler for
repairs before paint; 9984532 for
repairs after paint)
Structural Yes No Yes Repair with MIG welding
Weld
Structural Yes No No Contact responsible product
Weld engineer for repair/disposition.
Structural No Either Yes Repair with MIG welding
Weld Yes or No
Structural No Either No Contact responsible product
Weld Yes or No engineer for repair/disposition.
Process Either Either Either Use sealer released by
Weld Yes or No Yes or No Yes or No responsible product engineer
(e.g., Midwest Thermal Spray
CBF100 conductive body filler for
repairs before paint; 9984532 for
repairs after paint)
4 Manufacturing Process
4.1 Process Control. The welding source is responsible for establishing practices and test methods to assure
that the criteria of this standard are met and are consistent with GMW15563 (for non-GM manufacturing facilities)
and Process Quality Requirement System (PQRS) process control plans (for GM manufacturing facilities).
4.2 Process Qualification. All welding processes must be qualified (during initial weld verification or subsequent
requalification). Process qualification must be documented and retained per the GM Record Retention
Schedule (GMRRS).
5 Notes
5.1 Glossary.
Adjacent Welds: Two welds located on the same surface that are laid out in a row, string or geometric
arrangement (e.g., square, rectangle, circle, curvilinear path, etc.) If in a geometric arrangement, welds are only
adjacent to their immediate neighbors and not welds located diagonally across the geometric arrangement.
Same surface with respect to adjacent welds means a surface whose curvature between adjacent welds would
allow for welding (ignoring stamped holes). Welds around a corner are not adjacent.
Arc Spot: A weld type which uses a timed arc welding process to penetrate through the surface sheet into
adjoining sheets fusing them together.
Base Metal: The metal or alloy being welded.
Crack: A fracture type discontinuity characterized by a sharp tip and high ratio of length to width of opening
displacement on the exterior surface. See Appendix A, Figure A1.
Discrete Joint: Discrete joints are non-continuous joints that work together to create the entire joint. These
discrete joints include resistance spot welds, arc spot welds, arc plug welds, arc plug brazes, non-fastener

--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

resistance projection welds, laser stitch welds, laser spot welds, self-piercing rivets, self-piercing and extruding
screws, and mechanical clinches.
Distortion: Angle of displacement that the sheet surfaces are distorted from the normal plane. See Appendix A,
Figure 5.
Edge Weld: A condition in which the spot weld impression left by the electrode faces is not contained within all
edges of the sheet metal being welded. See Appendix A, Figure A3, welds E and F.
Extra Welds: The number of spot welds that exceed the number specified on the weld design document.
Faying Surface: The mating surface of two members to be welded. See Appendix A, Figure A11.
Fusion: Melting together of the two base metal substrates at the faying surface to produce a weld. Melting of
relatively low melting temperature coatings (such as zinc or aluminum) at the faying surface without melting the
substrates is not fusion. Fusion is demonstrated by either producing a weld button upon destructive testing,
creating an interfacial fracture through the weld upon destructive testing, and/or indicating a fused nugget upon
cross-section analysis.
Hole: A perforation in the spot weld that allows light to travel through the material from one exterior surface to
the opposing exterior surface of the weld. See Appendix A, Figure A2.
Indentation: The depression on the sheet surfaces caused by the welding electrodes. See Appendix A,
Figure A6.
Interfacial Fracture: A fracture mode of a spot weld where all or part of the weld nugget separates through the
plane of the weld at the faying surface.
Metal Inert Gas (MIG): MIG welding is welding in an atmosphere of inert gas, which means welding with a
shielding gas that does not react with other substances. The process is also called MIG welding even when the
inert gas is mixed with small quantities of O2, CO2, H2 or similar substances. MIG also may be referred to as
solid wire welding or Gas Metal Arc Welding.
Missing Welds: The number of spot welds not installed as specified on the weld design document.
Qualified Setup: The weld parameters established and documented during the last process qualification.
Pearls: See Weld Spatter.
Radial Distance: The distance between two points. For spot weld location tolerance, the radial distance is the
measurement from the center of the spot weld design location to the center of the installed spot weld.
Substrate: The base metal sheet to which a coating is applied.
Surface Eruption: Upsurge of the metal surface adjacent to the weld electrode impression. See Appendix A,
Figure A7.
Thinning: The amount of the original total metal stack-up thickness reduced by the welding process. See
Appendix A, Figure A6.
Trim Edge Deformation: A condition in which the original edge of the weld flange is deformed by the electrodes
but whose electrode face impression is contained within all edges of the sheet metal being welded. See
Appendix A, Figure A3, welds C and D.
Unfused Weld: A resistance spot weld that was attempted but does not demonstrate fusion of the base metal
substrates is an unfused weld. A weld that melts the base metal coatings but does not melt the base metal
substrates is unfused.
Weld Button: That part of the weld that tears out in a peel or chisel test. See Appendix A, Figure A8.
Weld Button Size: The weld button size of a concentric (round) button is the diameter of the button. The weld
button size of a non-concentric (oval or oblong) button is calculated by adding the measurement of the major
axis to the measurement of the minor axis and dividing by two. See Appendix A, Figure A12. The measurements
are to be taken at the faying surface. See Appendix A, Figure A13.
Weld Design Document: A product document that describes welding requirements such as number of welds,
location of welds, applicable weld standards, weld patterns, surface appearance classification, weld notes, etc.
Weld Expulsion: Molten metal that is extruded from between the sheets being welded or from the interface
between the outer sheet metal surface and the electrode(s). See Appendix A, Figure A4.
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Weld Impression: The depressed mark left in the metal surface by the electrodes during welding. See
Appendix A, Figure A3.
Weld Nugget: The weld nugget is that part of the weld where fusion is evident at the faying surface and
extending into the parent metal resulting in a metallurgical structure change. See Appendix A, Figure A9.
Weld Nugget Size: The weld nugget size is the dimension of the fusion zone measured from a macro-section
examination or weld cross-section. See Appendix A, Figure A9.
Weld Size: Resistance Spot Weld (RSW) size refers to either the weld button size or the weld nugget size. With
certain steels or types of loading, a weld button may not always result from a peel or tensile test. In these cases
of interfacial fracture of partial thickness fracture, examination of the fusion zone must be used to determine
weld size.
Weld Spatter: Weld expulsion metal that remains attached to an adjacent metal surface away from the
electrodes. The visible weld spatter is sometimes referred to as pearls. See Appendix A, Figure A4.
Weld Template: An inspection device used to evaluate weld location. Templates are typically created by plotting
the weld spot location as defined by the weld design document on a transparent overlay for comparison to the
actual weld locations. See Appendix A, Figure A14.
Whiskers: Sharp, thin protrusions of metal that remain attached the metal surface adjacent to the weld electrode
impression and are caused by rapidly solidified metal that was expelled from the weld. See Appendix A,
Figure A4.
5.2 Acronyms, Abbreviations, and Symbols.
DT Determining Thickness
GMRRS GM Record Retention Schedule
MIG Metal Inert Gas
PQ Perceptual Quality
PQRS Process Quality Requirement System
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---
RSW Resistance Spot Welding
SFZ Single Fusion Zone
t Thickness (metal)
6 Coding System
This standard shall be referenced in other documents, drawings, etc., as follows:
GMW14057

7 Release and Revisions

This standard was originated in August 2004. It was first approved by the CCRW Global Council in
December 2005. It was first published in January 2006.
Issue Publication Date Description (Organization)
1 JAN 2006 Initial publication.
2 OCT 2009 Reformat to approved GMW Welding template. Revised weld surface
appearance criteria, clarified weld size measurement criteria. Moved and
renumbered figures to Appendix A. (GM Global Weld Council)
3 AUG 2011 Update to address acceptance criteria for adjacent missing or breaking welds
and for welds with visible surface cracks or holes. (GM Global Weld Council)
4 OCT 2012 Updated to align weld appearance requirements with Perceptual Quality Best
Practices (section 3.2.3). (GM Global Weld Council)
5 JAN 2014 Edits to section 2.3, 3.2.2.4, 3.2.3, 3.3.1, and 3.4.1. Section 3.2.2.6 (thinning)
combined with 3.2.2.4 (renumbered paragraphs as necessary), and radial
distance added to glossary. (GM Global Weld Council)
6 APR 2014 Changed references of Gas Metal Arc Welding to MIG. Edit to Table 1 and
added two and three thickness welds to Section 3.3. Eliminated Appendix B.
(GM Global Weld Council)
7 MAY 2018 Edited 2.2; 2.3; 3.1.1; 3.1.3; 3.2.1.1, 3.2.1.2; 3.2.1.4; 3.2.2.2; 3.2.2.3; 3.2.2.4;
3.2.2.5; 3.2.2.6; 3.2.2.7; 3.2.2.8; 3.2.3; 3.3.1; 3.3.2.4; 3.3.2.5; 3.4.1; 3.4.4;
3.4.5; 3.4.5.2; 3.4.5.5; 4.1; and 5. Added discrete joints in patterns (3.4.1).
Added Single Fusion Zones (3.3.2.3, renumbering as necessary). Described
fusion mode (3.3.2.4); Added Figure A15. Added Table A2. Added Table 2.
Renamed repair procedures to repair methods (3.4). Updated process control
procedure (4.1). Added process qualification requirement (4.2). Changed
“original qualified setup” to “qualified setup” throughout. Changed process
adjustments to requirements rather than guidelines (3.2.2.2; 3.2.2.4; 3.2.3).
Clarified that a single discrepant weld in a small pattern does not cause
nonconformance (3.4.1). Added/changed definitions for Adjacent Welds; Base
Metal; Fusion; Substrate; Unfused Weld; Weld Size; & Whiskers. Removed
reference to PQ documents; Added Tables A1and A2 for appearance zones;
Added Figures A16 and A17 for Appearance Zones and Whiskers in Roof Rail
Air Bag Area. Added Deviation for RSW of stainless steel assemblies for
powertrain/propulsion systems. (Global Welding and Joining Council)
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Appendix A
Figure A1: Surface Cracks Figure A2: Hole
Figure A3: Edge Weld Figure A4: Weld Expulsion
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Figure A5: Distortion Figure A6: Indentation and Thinning
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---
Figure A7: Surface Eruption Figure A8: Weld Button

Figure A9: Weld Nugget Size Figure A10: Laminated Steel
Figure A11: Faying Surface Figure A12: Weld Button Size
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Figure A13: Weld Button Measurement Figure A14: Weld Template
Figure A15: Single Fusion Zone (SFZ)
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Table A1: Additional Spot Weld Surface Appearance Criteria by Surface Classification
Zones A, B and C (1 of 2)
Attributes GMW14057 Size/Description Zone A Zone B Zone C
Reference
Cracks 3.2.1.1 Visible Aesthetic Repair No Additional No Additional
Required Requirement Requirement
Holes 3.2.1.2 Any Size Aesthetic Repair Aesthetic Aesthetic
Required Repair Repair
Required Required
Whiskers 3.2.2.2 Visible Process Process Process
Adjustment and Adjustment Adjustment
Aesthetic Repair and Aesthetic and Aesthetic
Required Repair Repair
Required Required
Distortion 3.2.2.3 Visible Process Process Process
Waviness Adjustment Adjustment Adjustment
Indentation 3.2.2.4 Visible Aesthetic Repair Process Process
Required Adjustment Adjustment
Exposed Trim 3.2.2.5 Visible Process Process Process
Edge Adjustment and Adjustment Adjustment
Deformation Aesthetic Repair
Required
Surface 3.2.2.6 ≥ 0.5 mm Aesthetic Repair Process Process
Eruptions Required Adjustment Adjustment
Any Size > 1/100 mm > 1/100 mm No Additional
Aesthetic Repair Aesthetic Requirement
Required Repair
Required
Small > 1/100 mm > 1/100 mm No Additional
> 1 mm to < 2 mm Aesthetic Repair Aesthetic Requirement
Required Repair
Spatter (Pearls) 3.2.2.7 Required
Medium Aesthetic Repair Aesthetic No Additional
≥ 2 mm to < 4 mm Required Repair Requirement
Required
Large Aesthetic Repair Aesthetic Aesthetic
≥ 4 mm Required Repair Repair
Required Required
Non-Concentric 3.2.2.8 Visible Aesthetic Repair Process Process
Welds Required Adjustment Adjustment
Misaligned 3.3.1 Visible Aesthetic Repair Process Process
Welds Required Adjustment Adjustment
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Table A1: Additional Spot Weld Surface Appearance Criteria by Surface Classification
Zone D and Unexposed Secondary Surfaces (2 of 2)
Attributes GMW14057 Size/Description Zone D Unexposed
Reference Secondary
Surfaces
Cracks 3.2.1.1 Visible No Additional No Additional
Requirement Requirement
Holes 3.2.1.2 Any Size Normal Repair Normal Repair
Whiskers 3.2.2.2 Visible Process Process
Adjustment and Adjustment
Aesthetic Repair
Required Aesthetic Repair
when discovered
in Roof Rail Air
Bag areas
Distortion 3.2.2.3 Visible No Additional No Additional
Waviness Requirement Requirement
Indentation 3.2.2.4 ≥ 1 mm No Additional No Additional
Exposed Trim 3.2.2.5 Visible Process Process
Edge Deformation Adjustment Adjustment
Surface Eruptions 3.2.2.6 ≥ 0.5 mm No Additional No Additional
Any Size No Additional No Additional
Small No Additional No Additional
> 1 mm to < 2 mm Requirement Requirement
Spatter (Pearls) 3.2.2.7
Medium No Additional No Additional
≥ 2 mm to < 4 mm Requirement Requirement
Large No Additional No Additional
≥ 4 mm Requirement Requirement
Non-Concentric 3.2.2.8 Visible No Additional No Additional
Welds Requirement Requirement
Misaligned Welds 3.3.1 Visible No Additional No Additional
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Table A2: Appearance Zones

Zone “A”
Exterior:
• 50 cm to 200 cm from ground height
• Roofs < 170 cm from ground height
• Including panel radii
Interior:
• Forward of rear seatback (visible from interior with panels closed)
Zone “B”
Exterior:
• Ground Level to 50 cm in height and > 200 cm off ground level|
• Roofs ≥ 170 cm from ground height
• Areas on front/rear closures that are only visible with panel open
Interior:
• Door inner panels (excluding Front door hinge area and other areas covered by the D zone)
Includes rear door return flange
• Door openings (excluding hinge areas and other areas covered by the D zone)
• Rearward of rear seatback (visible from interior with panels closed)
• Entire surfaces of rear closures (including hinge areas)
• Cargo door inner panel and opening
• Decklid inner panel and opening
• Liftgate inner panel, opening
• Swing gate inner, opening
• Non Pick Up tailgate inner, opening
Zone “C”
• Pick Up Box inner (including enclosed)
• Pick Up Tailgate inner panel, opening
• Back panel on incomplete trucks (frame exposed)
• Trunk compartment (excluding areas covered by carpet, trim, etc.)
• Fuel door inner and opening
• Outside Rear View Mirror housing underside
• Other visible areas which are not defined as any other zone
Zone “D”
• Cargo van (cargo compartment) - B-pillar and behind (areas not covered)
• Engine compartment (only includes the fender rails, top surfaces of shock towers and front end tie bar)
• Hood inner
• Hooks, tie-downs and trailer hitches
• Spare tire area
• Sun roof water channel
• Wheel arch
Interior:
• Door inner Lower area below door pad and hinge area
• Door opening hinge area
• Areas only visible when the seat is not in the mid position
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Figure A16: Appearance Zones

--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Figure A17: Whiskers in Roof Rail Air Bag Area
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---

Deviations
For the stainless steel resistance spot welding in powertrain/propulsion systems applications:
The purpose of this deviation is to provide supplemental acceptance criteria for resistance spot welding of
stainless steel sheet for powertrain/propulsion systems applications.
Dev 1.1 Purpose. This standard provides the acceptance criteria and repair methods for resistance spot welds
in automotive powertrain/propulsion system assemblies for which GM is responsible for establishing or approving
product design.
Note: This standard applies to stainless steel approved by GM for Resistance Spot Welding (RSW).
Dev 3.3.2 Weld Size. The weld size may be measured by either using the weld button (Appendix A, Figure A8),
the weld nugget (Appendix A, Figure A9), or the fusion zone. A spot weld is discrepant when the measured weld
size at each faying surface is less than the minimum acceptable weld size specified in Table Dev 1.
Table Dev 1: Minimum Acceptable Weld Size

Determining Thickness (DT) Minimum Acceptable Weld Size
0.15 mm to 0.30 mm 1.0 mm
--`,`,,,,`,,,,,,`,`,,,,``,``,,``-`-`,,`,,`,`,,`---
0.60 mm to 0.64 mm 3.0 mm

0.65 mm to 1.29 mm 4.0 mm
1.30 mm to 1.89 mm 5.0 mm
1.90 mm to 2.59 mm 6.0 mm
2.60 mm to 3.25 mm 7.0 mm
Dev 3.3.2.1 Two-Thickness Welds. To determine the acceptable weld size for a two-thickness weld (two loose
pieces or one loose to two previously welded), use the metal thickness (t) of the thinner of the two layers being
welded to determine the weld size as listed in Table Dev 1.


GMW14057

Uploaded by

Copyright:

Available Formats

You might also like

GMW14057

Uploaded by

Document Information

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

GMW14057

Uploaded by

Copyright:

Available Formats

Template For ENG STDS

Weld Acceptance Criteria and Repair Methods

2.3 Additional References.

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 1 of 19

Copyright General Motors Company

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 2 of 19

Copyright General Motors Company

Table 1: Minimum Acceptable Weld Size

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 3 of 19

Copyright General Motors Company

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 4 of 19

Copyright General Motors Company

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 5 of 19

Copyright General Motors Company

Table 2: Repairs for Welds with Holes

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 6 of 19

Copyright General Motors Company

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 7 of 19

Copyright General Motors Company

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 8 of 19

Copyright General Motors Company

7 Release and Revisions

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 9 of 19

Copyright General Motors Company

Figure A1: Surface Cracks Figure A2: Hole

Figure A3: Edge Weld Figure A4: Weld Expulsion

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 10 of 19

Copyright General Motors Company

Figure A5: Distortion Figure A6: Indentation and Thinning

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 11 of 19

Copyright General Motors Company

Figure A9: Weld Nugget Size Figure A10: Laminated Steel

Figure A11: Faying Surface Figure A12: Weld Button Size

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 12 of 19

Copyright General Motors Company

Figure A13: Weld Button Measurement Figure A14: Weld Template

Figure A15: Single Fusion Zone (SFZ)

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 13 of 19

Copyright General Motors Company

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 14 of 19

Copyright General Motors Company

© Copyright 2018 General Motors Company All Rights Reserved

May 2018 Page 15 of 19

Copyright General Motors Company

Table A2: Appearance Zones