Material Material Material Material Specification Specification Specification Specification

SCOPE OF APPLICATION PAGE
ALL
기술 표준 1/12
ENGINEERING STANDARD
ESTABLISHED BY SPEC NO.
Sheet Metal Development MATERIAL SPECIFICATION
MS111-1A
TFT
TITLE :
SPOT WELDING
CONTENTS
1. PURPOSE
2. SCOPE
3. DEFINITION
4. CLASSIFICATION OF WELD QUALITY
5. REQUIREMENTS OF EQUIPMENTS AND WELDING OPERATION
e 6. QUALITY OF WELD
c EMS50503 CONFIRMING CONTENTS ALL 2005-10-14 J.H.YOO

b APPEARANCE, SI UNIT, ALUMINUM
EMSS0074 ALL 1995-05-27 C.S.YOON
ALLOY
a NOMINAL THICKNESS, TENSILE
ESL-090 3,9,10/10 1990-04-14 D.S.HAN
STRENGTH
- EMS30270 ISSUE OF ENGLISH SPECIFICATION ALL 1985-10-01 D.S.HAN
SYM EO No. DESCRIPTION OF CHANGE REL.PAGE REV.DATE REV.BY
ESTABLISHMENT REFERENCE PREPARED CHECKED APPROVED
1981-12-10 BY BY BY
ORIGINAL FIELD AT SIGNED SIGNED SIGNED
IPIS J.H.YOO D.H.LEE J.D.LIM
(ES/MS Management System) 2010-06-14 2010-06-14 2010-06-15
1F-SG-00002 현대ㆍ기아 자동차
SE JONG IND CO LTD / 윤종열 / 2013-12-13 16:11/ 본 문서는 현대기아자동차의 정보자산이므로 무단으로 전재 및 복제할 수 없으며, 이를 위반할 시에는 당사 사규 및 관련 법규에 의해 제재를 받을 수 있습니다.
기 술 표 준 규격번호 페이지
(SPEC No) MS111-1A 1-1/12
(SHT/SHTS) 1/12
STANDARD
부호 EO 번호 변경내역 관련 PAGE 개정일자 작성자

SYM EO NO DESCRIPTION OF CHANGE REV. PAGE REV. DATE REV. BY
d EMS80311 CONFIRMING CONTENTS ALL 2008-12-09 Y.I.JUNG
e EMSA0171 ADDITION OF WELD QUALITY
8,9,10 2010-06-24 J.H.YOO
CRITERIA

HYUNDAI ㆍ KIA MOTOR
STANDARD (SPEC No) MS111-1A (SHT/SHTS) 2/12
1. PURPOSE
This specification outlines the physical requirements for spot welds used to assemble
Hyundai Motor and Kia Motor Corporation vehicles. It is used to verify the quality of welds
when called out on the engineering drawing(s). It is superseded by requirements specifically
written on the drawing(s).
2. SCOPE
This specification is applicable to resistance spot welds on all automotive sheet metal
components made from steel sheet (cold rolled or hot rolled) containing a maximum of .25%
C, stainless steel sheet, and aluminum alloy sheet materials. In addition, coated steel sheet
including galvanized (hot dipped zinc), galvannealed (hot dipped zinc-iron alloy), and
electrogalvanized (zinc or zinc-iron alloy) coatings are covered by this specification.
3. DEFINITION
1) Tensile Shear Load : The maximum load generated during tension shear testing of a
specimen with the dimensions described in Fig 4 of par. 6.12.
2) Nugget Diameter : The diameter of the re-solidified portion of the spot weld generated
between the individual sheets of the weld stack-up measured at the faying surfaces.
4. CLASSIFICATION OF WELD QUALITY

1) Welds shall be classified into two types including a safety portion and a general portion as
shown in Table 1 based on required part quality. See sections 6.10 and 6.12 of this
specification for details regarding the differences between these classifications.
Table 1
Classification Mark Indication Remark
(Two plate spot weld,
Safety Portion ● : Two plate spot weld
safety portion )
: Three plate spot weld
(Four plate spot weld,
General Portion : Four plate spot weld
general portion )
2) Welds shall be classified, based on desirable appearance, into class A, B, C and D as

shown in par. 6.1.
5. REQUIREMENTS OF EQUIPMENTS AND WELDING OPERATION

1) All welding equipment including but not limited to the welding machine, Ampere –

meter, pressure meter, cycle counter, and tension tester shall be maintained
adequately and operated within normal conditions.
2) Calibration tests for welding machines, determination of the welding schedule, and the
frequency of routine maintenance shall be established and performed under the approval
of the Body Assembly Department, Maintenance Department and Body Engineering
Department to obtain the quality of welds in par. 6.
6. QUALITY OF WELD
Quality of welds shall be in accordance with the following items.
6.1 Quality of Appearance

When the classification notation for quality of appearance (Class A, B, C but no notation
for class D) is specified on the drawing, the quality of appearance shall conform to Table
2.
Table 2
Classification Notation Quality of Appearance
High quality of appearance is required.
-A Surface shall be even and free from
Class A
indentation, cracks and pits by visual
inspection
Good quality of appearance is required.
-B The depth of indentation shall be lower than
those of following figures.
Surface shall be free from cracks, distortion,
pits, expulsion and surface flash.
Class B
a : 0.1 mm
b : 0.1 mm
Medium quality of appearance is required.

-C The depth of indentation shall be lower than
Class C
those of following figures.
Surface shall be free from cracks,
distortion, pits, expulsion and surface

flash.
a : 0.3 mm
b : 0.2 mm
It shall be applied on the portion which

(No
Class D particular consideration is not required.
notation)
However, surface shall be free from cracks.
Remarks
(1) Appearance quality of each class shall be better than the Standard sample approved by Body
Engineering Department.
(2) Even though a spot weld point has no appearance notation in the drawings, when it is
considered evidently unsuitable to apply Class D, discussion shall be taken between the related
departments.
(3) The appearance quality of a face welding shall conform to Class A.
6.2
6.2 Cracks
The weld surface shall be free from cracks when evaluated with the unaided eye.
6.3 Indentation
In case of Class D welds, the depth of indentation shall not exceed 30 percents of sheet
metal thickness.
6.4 Distortion
For the Class D welds, permissible distortion shall conform to Figure 1.

(a)
a ＞ 30˚ rejected
a ≤ 30˚ acceptable
(b)
A A ＞ 2t rejected
A ≤ 2t acceptable
t
t
(c)
A t A ＞ 2t rejected
A ≤ 2t acceptable
Figure 1
6.5 Edge Weld

A weld must not be extended beyond the edge of any sheet being welded.
Acceptable
Reject
Figure 2
6.6 Welding Pitch

The pitch of spot welds shall not vary by more than ± 20 % of the dimension denoted on
the drawing(s).

6.7 The Number Of Spot Welds

The number of spot welds shall not vary by more than + 20 % of the number specified on
the drawing(s).
6.8 Length Of Unwelded Flange Weld

End welds must be within 12 mm to the end of the flange as shown if Figure 3.
Figure 3
6.9 Location of Spot Welds

An acceptable variation in location of spot welds of safety portion shall conform to
agreements between the Body Design Department and the Body Engineering Department.
Weld location for general spot welds shall be within 10 mm of the position specified in
the drawing.
6.10 The Number of Defective Spot Welds

(1) A defective spot weld is defined for the purpose of comparison to Table 3 as any
weld that is missing, cold/stick, contains visible cracks/holes or is undersized (as
defined by nugget diameter in Tables 4, 5, or 6). Cosmetic and weld placement
issues including edge welds are not used for comparison to Table 3 but require
adjustment to the spot welding process to eliminate the condition.
(2) There shall be no defective spot welds for designated safety welds irrespective of the
number of spot welds.
(3) For general spot welds, the permissible number of defective welds identified by visual
inspection or wedge testing shall be in accordance with Table 3.

Table 3
Specified number of
Acceptable number of
spot welds on the
defective spot welds (MAX.)
drawing(s)
Less than 7 0
8 ~ 12 1
13 ~ 20 2
21 ~ 28 3
29 ~ 36 4
37 ~ 44 5
45 ~ 52 6
53 ~ 60 7
61 ~ 68 8
69 ~ 76 9
77 ~ 84 10
85 ~ 92 11
93 ~ 100 12
Remarks
(1) Edge welds are not considered to be defective for the purpose of evaluation with table 3.
(2) Defective spot welds shall be reinforced by at least 3 surrounding satisfactory welds.
(3) Welds at portion jointed with the other sheet on flange shall be considered as edge welds.
(4) The both side welds of the middle portion where the welds are discontinued on flange shall be
considered as edge welds.
(5) The welds closer than 10 mm to the corner where the flange direction is crossed with over 30°
one another shall be considered as edge welds.
(6) Welds for lapped sheet of more than 3 shall not include a defective weld at all.
6.11 Wedge Test

There are both destructive and non-destructive variations of this test. A pry check
involves placement of a chisel between the sheets of the weld flange and applying
enough pressure to separate and detect cold welds without plastically deforming the
sheet metal. A chisel test plastically deforms the surrounding material until a button is
pulled from around the spot weld. The button should be measured with knife edge
calipers and compared to the minimum requirements specified in Tables 4, 5, or 6.
These tests are for quality control purposes and should be performed at a frequency
determined by Quality Control personnel.

6.12 Tensile Shear Load and Nugget Diameter

1) The tensile shear load and nugget diameter of a weld for cold or hot rolled steel sheet,
zinc coated or aluminum coated steel sheet, terne sheet shall be equal to or exceed
the value shown in Table 4. New production spot weld setups and/or new material
combinations can be validated using tensile shear samples with dimensions that
conform to Fig. 4.
Unit : mm
Nominal
Width : W Length : L
thickness : t
under 0.8 20 75
0.8 to 1.3 excl. 30 100
1.3 to 2.5 excl. 40 125
over 2.5 incl. 50 150
Figure 4
e 2) Measuring methods for weld nuggets include the use of calipers and metallographic
techniques :
(1) Knife edge calipers are used to measure the longest and shortest dimensions of
the weld nugget. An average of these two measurements is used to describe the
nuggets diameter.
(2) Metallographic method: Some material grade and thickness combinations will not
pull nuggets readily but instead tend to fail interfacially. For these instances or
when the greatest accuracy is desired, spot welds can be sectioned, mounted,
polished and chemically etched to reveal the structure of the weld nugget. Care
must be taken to section the nugget slightly off center and then grind/polish the
sample to the center of the nugget. A stereo scope with calibrated measuring
equipment is used to measure the re-solidified material between the faying
surfaces.
(a)
(b)
Figure 5

Table 4
Safety Portion General Portion
Nomi- Tensile shear load (kN) Tensile shear load (kN)
nal
Thick- Tensile strength of base metal (MPa) Nugget Tensile strength of base metal (MPa) Nugget
ness dia. dia.
(mm) ≥ 390 ≥ 490 ≥ 590 ≥ 780 (mm) ≥ 390 ≥ 490 ≥ 590 ≥ 780 (mm)
<390 ≥ 980 <390 ≥ 980
<490 <590 <780 <980 <490 <590 <780 <980
0.4 1.23 1.63 2.04 2.35 2.79 3.04 3.3 0.74 0.98 1.23 1.42 1.76 1.91 2.6
0.5 1.72 2.26 2.86 3.23 3.82 4.17 3.6 1.03 1.37 1.72 2.01 2.45 2.70 2.9
0.6 2.21 2.93 3.68 4.31 5.10 5.54 4.0 1.32 1.76 2.20 2.65 3.23 3.53 3.2
0.7 2.79 3.71 4.66 5.44 6.37 6.91 4.3 1.67 2.21 2.77 3.28 4.02 4.36 3.4
0.8 3.47 4.62 5.82 6.47 7.64 8.28 4.5 2.06 2.73 3.42 3.97 4.85 5.29 3.6
0.9 4.12 5.48 6.87 7.79 9.16 10.0 4.8 2.45 3.25 4.08 4.70 5.78 6.32 3.8
1.0 4.80 6.39 8.02 9.02 10.6 11.6 5.0 2.94 3.92 4.9 5.54 6.76 7.35 4.0
1.2 6.17 8.21 10.3 11.9 14.0 15.2 5.5 3.72 4.95 6.18 7.30 8.92 9.75 4.4
1.4 7.64 10.2 12.8 15.2 17.7 19.3 6.0 4.61 6.13 7.65 9.31 11.4 12.3 4.8
1.6 9.21 12.3 15.4 18.1 21.4 23.2 6.3 5.88 7.84 9.80 11.1 13.5 14.7 5.0
2.0 12.7 16.9 21.3 25.6 30.1 32.7 7.1 7.64 10.2 12.7 15.8 19.2 21.0 5.7
2.3 15.5 20.6 25.9 31.9 37.5 40.8 7.7 9.31 12.4 15.5 19.7 24.0 26.3 6.2
2.6 18.7 24.9 31.3 38.9 45.7 49.7 8.3 11.3 15.0 18.7 23.7 28.9 32.7 6.6
3.2 26.1 34.7 43.6 54.2 63.7 69.3 9.4 15.7 20.9 26.1 33.1 40.5 44.2 7.5
REMARKS
(1) For metal thicknesses over 3.2mm or for values different from that specified in Table 4, the value
shall be denoted on the drawings after discussion with the Sheet Metal Development TFT.
(2) For welds composed of different material grades, the value for the material with the smallest tensile
strength shall be used.
e (3) For two thickness (2T) welds, the thinnest value shall be used. For three thickness (3T) welds, the
thinnest values for sheet1-sheet2 join and sheet2-sheet3 join shall be used respectively.
3) The tensile shear load and nugget diameter of a weld for stainless steel shall be equal
to or exceed the value shown in Table 5.
Table 5
Safety Portion General Portion
Tensile shear load (kN) Tensile shear load (kN)
Nominal Tensile strength of base metal (MPa) Tensile strength of base metal (MPa)
Thickness Nugget Nugget
(mm) diameter diameter
≥ 480 ≥ 610 (mm) ≥ 480 ≥ 610 (mm)
<480 <480
<610 <1020 <610 <1020
0.4 0.980 1.16 1.33 2.3 0.774 0.921 1.07 1.8
0.5 1.31 1.59 1.86 2.7 1.06 1.27 1.49 2.2
0.6 1.74 2.06 2.37 3.0 1.39 1.65 1.9 2.4
0.7 2.11 2.54 2.99 3.4 1.69 2.04 2.39 2.8
0.8 2.6 3.14 3.68 3.7 2.08 2.51 2.94 3.0
0.9 3.09 3.72 4.36 4.0 2.47 2.98 3.49 3.2
1.0 3.58 4.36 5.15 4.3 2.86 3.48 4.12 3.5
1.2 4.61 5.73 6.86 4.8 3.68 4.59 5.49 3.9
1.4 5.78 7.25 8.72 5.3 4.61 5.8 6.98 4.3
1.6 6.96 8.82 10.7 6.0 5.57 7.06 8.55 4.8
2.0 9.6 12.2 14.7 6.6 7.68 9.72 11.8 5.3
2.3 11.8 14.7 17.6 7.0 9.41 11.8 14.1 5.6
2.6 13.7 17.2 20.6 7.4 11 13.7 16.5 6.0
3.2 17.4 22.1 26.7 8.0 14 17.6 21.3 6.4
REMARKS; See page 10/12

4) The tensile shear load and nugget diameter of a weld of aluminum alloy shall be equal
to or exceed the value shown in Table 6.
Table 6
Nominal Tensile strength of base metal(MPa)
thickness
≥ 255, ≤ 300
of sheet
(mm) Tensile shear load(kN) Nugget diameter(mm)
0.4 0.64 2.5

0.5 0.80 2.8
0.6 0.97 3.1
0.7 1.12 3.3
0.8 1.28 3.6
0.9 1.46 3.8
1.0 1.61 4.0
1.2 1.92 4.4
1.4 2.25 4.7
1.6 2.58 5.1
2.0 3.22 5.7
2.3 3.70 6.1
2.6 4.16 6.4
3.2 5.13 7.2
REMARKS; See page 10/12
6.13 Penetration
Penetration of the fused zone shall not be less than 35% of the original sheet thickness
nor should it exceed 90 % of the original sheet thickness.


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SCOPE OF APPLICATION PAGE

4. CLASSIFICATION OF WELD QUALITY

5. REQUIREMENTS OF EQUIPMENTS AND WELDING OPERATION

c EMS50503 CONFIRMING CONTENTS ALL 2005-10-14 J.H.YOO

1F-SG-00002 현대ㆍ기아 자동차

부호 EO 번호 변경내역 관련 PAGE 개정일자 작성자

1F-SG-00002 현대ㆍ기아 자동차

4. CLASSIFICATION OF WELD QUALITY

2) Welds shall be classified, based on desirable appearance, into class A, B, C and D as

5. REQUIREMENTS OF EQUIPMENTS AND WELDING OPERATION

1F-SG-00002 현대ㆍ기아 자동차

6.1 Quality of Appearance

Medium quality of appearance is required.

distortion, pits, expulsion and surface

It shall be applied on the portion which

1F-SG-00002 현대ㆍ기아 자동차

6.5 Edge Weld

6.6 Welding Pitch

1F-SG-00002 현대ㆍ기아 자동차

6.7 The Number Of Spot Welds

6.8 Length Of Unwelded Flange Weld

6.9 Location of Spot Welds

6.10 The Number of Defective Spot Welds

1F-SG-00002 현대ㆍ기아 자동차

6.11 Wedge Test

1F-SG-00002 현대ㆍ기아 자동차

6.12 Tensile Shear Load and Nugget Diameter

1F-SG-00002 현대ㆍ기아 자동차

0.4 0.980 1.16 1.33 2.3 0.774 0.921 1.07 1.8

0.5 1.31 1.59 1.86 2.7 1.06 1.27 1.49 2.2

0.6 1.74 2.06 2.37 3.0 1.39 1.65 1.9 2.4

0.7 2.11 2.54 2.99 3.4 1.69 2.04 2.39 2.8

0.8 2.6 3.14 3.68 3.7 2.08 2.51 2.94 3.0

0.9 3.09 3.72 4.36 4.0 2.47 2.98 3.49 3.2

1.0 3.58 4.36 5.15 4.3 2.86 3.48 4.12 3.5

1.2 4.61 5.73 6.86 4.8 3.68 4.59 5.49 3.9

1.4 5.78 7.25 8.72 5.3 4.61 5.8 6.98 4.3

1.6 6.96 8.82 10.7 6.0 5.57 7.06 8.55 4.8

2.0 9.6 12.2 14.7 6.6 7.68 9.72 11.8 5.3

2.3 11.8 14.7 17.6 7.0 9.41 11.8 14.1 5.6

2.6 13.7 17.2 20.6 7.4 11 13.7 16.5 6.0

3.2 17.4 22.1 26.7 8.0 14 17.6 21.3 6.4

REMARKS; See page 10/12

1F-SG-00002 현대ㆍ기아 자동차

0.4 0.64 2.5

1F-SG-00002 현대ㆍ기아 자동차

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