welding process control procedure

1、1. 范圍1.1 目的本標(biāo)準(zhǔn)詳細(xì)說明了SGM焊接產(chǎn)品生產(chǎn)者的焊接檢查和焊接設(shè)備工藝控制要求.1.2 應(yīng)用本標(biāo)準(zhǔn)涉及的要求適用于上海通用汽車制作或裝配工廠所采用的焊接及連接工藝.2. 參考GM9621P3. 流程3.1 過程評估3.1.1 設(shè)備過程監(jiān)控設(shè)備過程監(jiān)控包括工藝參數(shù)的測量以及設(shè)備功能性運(yùn)轉(zhuǎn)的目視評估。有關(guān)各種焊接工藝的設(shè)備過程監(jiān)控要求。3.1.2 設(shè)備維護(hù)每個區(qū)域都要有設(shè)備維護(hù)的書面計劃。設(shè)備維護(hù)的進(jìn)度表應(yīng)該和制造商的建議一致。3.2 產(chǎn)品控制和檢查產(chǎn)品控制和檢查包含對焊接產(chǎn)品的評估，參照適用的SGM工程標(biāo)準(zhǔn)來識別、包含和返修不一致的焊接模式。所有焊接的產(chǎn)品控制和檢查計劃必須有書面流程

2、或在標(biāo)準(zhǔn)化操作中描述。 注意：對于鋁點(diǎn)焊，Peel測試是首選方法，Chisel測試是不可接受的方法。1. Scope1.1 PurposeThis standard defines weld inspection and welding equipment process control requirements for producers of SGM welded or mechanical clinched product. 1.2 ApplicationThe requirements of this standard are applicable to welding and joi

3、ning processes utilized by a Shanghai General Motors fabricating and/or assembly plant to join automotive parts and assemblies.2ReferencesGM9621P3. Procedure3.1 Process Evaluation.3.1.1 Equipment Process MonitoringEquipment process monitoring consists of measuring the process parameters established

4、during tool qualification as well as visual evaluation of the equipment functional operation.3.1.2 Equipment MaintenanceEach location shall have documented plans for the maintenance of equipment. The equipment maintenance schedule should be consistent with the tool or equipment manufacturers recomme

5、ndations3.2 Product Monitoring and Inspection.Product monitoring and inspection consist of evaluating the welded product with the released design and the applicable SGM Engineering Standards to identify, contain, and repair nonconforming weld patterns. Methodologies for physical testing of resistanc

6、e welds are contained in ISO 10447, Welding Peel and chisel testing of resistance spot, projection or seam welds. The product monitoring and inspection plan for all welds must be described in written procedures or standardized work.Note: Peel testing is the preferred method of inspection for aluminu

7、m spot welds. Chisel testing is not an acceptable method of inspection for aluminum spot welds.3.2.1 過程中檢查和測試（電阻點(diǎn)焊）在每班的均勻間隔中，對所有點(diǎn)焊（所有類型和所有單元）推薦執(zhí)行4次形變或超聲波的非破壞性檢查。至少對每把焊槍和每種板材匹配檢查一次，每班如此執(zhí)行四次。執(zhí)行形變檢查的同時，目視檢查指定位置的膠水，并根據(jù)適用的產(chǎn)品圖紙和SGM工程標(biāo)準(zhǔn)來目視檢查所有焊接的一致性。3.2.2 過程中檢查和其他測試除了3.2.1以外的焊接和連接方法必須通過目視化標(biāo)準(zhǔn)加以檢驗(yàn)，每班至少4次。3.2

8、.3 焊接破壞性檢查 總成工廠在系統(tǒng)填充的開始階段，每種車型的整車破壞性檢查頻率至少為每月一次，持續(xù)到工藝能力得到論證并書面成文。工藝能力由連續(xù)三次破壞性檢查達(dá)到要求來衡量。之后，每種車型的破壞性檢查頻率可以減少為每季度一次。3.2.4 焊接破壞性檢查 制造工廠生產(chǎn)開始階段，每個總成零件的破壞性檢查頻率至少為每月一次，持續(xù)到工藝能力得到論證并書面成文。工藝能力由連續(xù)三次破壞性檢查達(dá)到要求來衡量。之后，每種零件總成的破壞性檢查頻率可以減少為每季度一次。3.3 焊接圖像分析用來對焊接截面進(jìn)行圖像分析的檢查、測量、試驗(yàn)等設(shè)備必須滿足精度0.01毫米的測量標(biāo)準(zhǔn)。焊接截面使用15X或以下放大倍率來觀察。

9、3.3.1 焊接截面焊接截面采樣所需的數(shù)目取決于指定的焊接長度，參見下表：3.2.1 In-Process Inspection and Test (Resistance Spot Welds)A deformation or ultrasonic nondestructive check of all spot welds (for all styles and all cells) is recommended to occur 4 times per shift at evenly spaced intervals. The minimum frequency is one check

10、per weld gun and metal stack-up, sampled four times per shift.Concurrent with the deformation checks, visually inspect for sealer presence if specified and visually inspect all welds for conformance to the applicable product drawing and SGM Engineering Standard.3.2.2 In-Process Inspection and Other

11、TestsWelds and joining techniques other than those mentioned in 3.3.1 should be verified for conformance to the visual acceptance criteria of the applicable standard a minimum of 4 times per shift. 3.2.3 Weld Destruct Test Assembly PlantsAt the Start of System Fill the frequency of full body destruc

12、t is one of each new body style per month until process capability is demonstrated and documented. Process capability consists of completing three consecutive destruct tests that meet requirements. The frequency can then be reduced to a quarterly destruct test of each body style.3.2.4 Weld Destruct

13、Test Fabricating PlantsAt Start of Production the frequency of destruct tests is to be one of each assembly per month until process capability is demonstrated and documented. Process capability consists of completing three consecutive destruct tests that meet requirements. The frequency can then be

14、reduced to a quarterly destruct test of each assembly.3.3 Weld Image AnalysisInspection, measuring and test equipment to perform the image analysis of weld cross sections must be capable of evaluating the specified measurable criteria to an accuracy of 0.01 millimeters. The use of the Native America

15、n Technologies Weld Measuring System (NAMeS) is recommended. Weld cross sections are to be viewed at 15X or less magnification.3.3.1 Weld Cross SectionThe number of required weld cross section samples is to be determined by the specified length of the weld bead in accord with the following table.Tab

16、le 1: Weld Beads vs Cross SectionsSpecified Weld Bead Length (mm) Number of Cross Sections Location of Cross Sections 30 or less 1 Midpoint of weld 31 100 2 Equally spaced from each other and from the ends of the welds 100+ 3 Equally spaced from each other and from the ends of the welds 4 非破壞性評估4.1

17、在人員和工藝具有資格的情況下，可以在需要形變檢查或破壞性檢查的電阻點(diǎn)焊區(qū)域采用超聲波評估。5 安全如果遵循適當(dāng)?shù)牧鞒?，并采取必要的防范措施，焊接、切割、連接等工藝可以安全的操作。6 發(fā)布和修訂6.1 發(fā)布。本流程創(chuàng)建于2004年7月，7 附件A. B. 焊接質(zhì)量控制流程C. 焊接質(zhì)量問題跟蹤單D. 焊接質(zhì)量檢查計劃E. 焊接非破壞性檢查規(guī)定F. 焊接破壞性檢查規(guī)定G. 焊接質(zhì)量問題返修作業(yè)規(guī)定H. 焊接參數(shù)更改規(guī)定Table 1: Weld Beads vs Cross SectionsSpecified Weld Bead Length (mm) Number of Cross Sectio

18、ns Location of Cross Sections 30 or less 1 Midpoint of weld 31 100 2 Equally spaced from each other and from the ends of the welds 100+ 3 Equally spaced from each other and from the ends of the welds 4 Nondestructive Evaluation (NDE)4.1 Ultrasonic evaluation of resistance spot welds can be utilized

19、in place of the required deformation or destruct tests provided the personnel and process have been qualified in accord with GMN10072, Personnel and Process Qualification for Ultrasonic Testing of Resistance Spot Welds.5 SafetyWelding, cutting and allied processes can be performed safely with minima

20、l health risk, provided proper procedures are followed and necessary precautions are taken. An informative reference that provides guidance for personnel in the safe set-up and use of welding and cutting equipment is the ANSI Z49.1, Safety in Welding, Cutting, and Allied Processes document.6 Release

21、 and Revisions6.1 Release. This procedure originated in July 2004 and approved by the Weld Committee in July 2004. It was first published in July 2004.6.2 Revisions.7 AppendixA. B. Weld Quality Control ProcedureC. Weld Quality Issue Follow SheetD. Weld Quality Control PlanE. Weld Pry CheckF. Weld De

22、structive CheckG. Weld Repair WorkH. Weld Schedule ModificationAppendix A （返回）（返回）Appendix C （返回） 日期：焊接質(zhì)量問題跟蹤單車型：工段：工位號：焊槍號：焊點(diǎn)號：實(shí)施者：問題描述：原因：措施：質(zhì)量跟蹤建議：焊接參數(shù)改動：是；否；Sch No.焊接參數(shù)改動前改動后備 注 預(yù)壓時間 (CY) 焊接脈沖數(shù)(IMP) 脈沖中焊接時間(CY) 焊接電流(KA) 冷卻時間 (CY) 維持時間 (CY) 壓力 (LBS) STEPPER記錄者：跟蹤記錄：車輛識別號：第一輛第五輛第十輛第二十輛第四十輛電極帽更換次數(shù)第

23、一次第二次第三次第四次焊接質(zhì)量關(guān)閉日期：生產(chǎn)工段長：焊接工程師：注：1. 如果調(diào)整飛濺、毛刺等，跟蹤周期選擇電極帽更換次數(shù) 2. 對于分拼等工位可以不填寫車輛識別號 3. 跟蹤階段如有問題需及時通知焊接工程師 4. 跟蹤階段此單須放置于問題工位，由生產(chǎn)班組長保管 5. 完成跟蹤后須將此單交由焊接工程師保留Appendix D （返回） 焊接質(zhì)量檢查計劃一、 概述為滿足白車身焊接檢查需要，特制定本計劃指導(dǎo)書。本指導(dǎo)書規(guī)定了車身車間焊接檢查的時間和頻率。二、 適用范圍本標(biāo)準(zhǔn)適用于車身車間焊接質(zhì)量控制。三、 職責(zé)由各生產(chǎn)工段負(fù)責(zé)車身焊接質(zhì)量控制。四、 內(nèi)容1破壞性檢查 在試生產(chǎn)階段，TRYOUT、N

24、S和S的各批次做一次破壞性檢查。如果在S階段，連續(xù)3次焊接合格率在97%以上，則可改為兩個批次(僅指在S階段)做一次破壞性檢查。在正式生產(chǎn)階段，開始按每周一次破壞性檢查進(jìn)行；如連續(xù)3次保持焊接破壞性檢查合格率在97%以上，則焊接破壞性檢查可改為每個月一次(如在S階段最后3次的焊接合格率連續(xù)在97%以上，則可跳過該階段，直接進(jìn)入每月一次的檢查頻率)；之后， 如連續(xù)3次保持焊接破壞性檢查合格率在99%以上，則焊接破壞性檢查可改為每三月一次。 對二種以上產(chǎn)品共線生產(chǎn)可適當(dāng)降低檢查頻次, 但不得低于每產(chǎn)品每六個月一次的焊接破壞性檢查要求。另外進(jìn)行分總成破壞性檢查若檢查合格率未達(dá)到97%以上，則要進(jìn)行問

25、題分析和解決，并增加破壞性檢查，直到合格率達(dá)到要求。2非破壞性檢查 在試生產(chǎn)階段，每個產(chǎn)品都必須進(jìn)行一次非破壞性檢查。 在正式生產(chǎn)階段，每種車型每班須進(jìn)行不少于四次非破壞性檢查(在每班的均勻間隔時段內(nèi))。如每班生產(chǎn)時間超過或達(dá)到10小時，則每班必須增加檢查一次(即不少于五次檢查)。各工段可根據(jù)實(shí)際情況增加檢查次數(shù)，確保焊接質(zhì)量受控于車身車間內(nèi)部。Appendix E （返回）焊接非破壞性檢查規(guī)定一. 檢查頻率具體見焊接質(zhì)量檢查計劃。二. 檢查范圍檢查崗位中“焊接非破壞性檢查單”所包含的所有焊點(diǎn)。三. 檢查依據(jù)GM4488M, GM6122M, GM6435M, GMN7027四. 操作步驟1

26、電阻點(diǎn)焊 （詳見GM4488M） 1.1 將被檢查的部件放至檢查崗位。 1.2 目視檢查：檢查焊接和工件是否異常。 A. 清點(diǎn)焊點(diǎn)個數(shù)。B. 檢查焊點(diǎn)位置。C. 檢查是否存在不可接受的焊點(diǎn)。 1.3 鑿檢： 將專用鑿子(見附圖一)在離焊點(diǎn)3-10mm處插入至一定深度(與被檢查焊點(diǎn)內(nèi)端齊平)，上下扳動鑿子以檢查焊點(diǎn)是否松動。注意事項(xiàng)見附圖二。 1.4 拔出鑿子，用0.5-1鎊錘子還原零件。 1.5 對于無法鑿檢的焊點(diǎn)，可以應(yīng)用超聲波檢測的方法。 在“焊接非破壞性檢查單”上做好記錄。如發(fā)現(xiàn)異常焊點(diǎn)，在相應(yīng)的焊點(diǎn)號上做好異常狀態(tài)記錄，并執(zhí)行焊接質(zhì)量控制流程。2 弧焊 （詳見GM6122M）3. 電阻

27、凸焊螺母、螺柱 （詳見GM6435M） 3.1 對于板片凸點(diǎn)焊，用鋼絲鉗或其它自制工具夾住板片向垂直于板片的方向左右扳動，板片發(fā)生變形而凸焊點(diǎn)未脫落，則認(rèn)為凸焊點(diǎn)合格。檢查結(jié)束后將零件恢復(fù)原狀。3.2 對于螺母凸焊，用0.5-1磅榔頭從側(cè)面猛擊被檢查螺母。如凸焊處未出現(xiàn)脫落， 則認(rèn)為凸焊合格。檢查結(jié)束后，將零件恢復(fù)原狀。（改用扭力扳手）4. 提弧焊螺母、螺柱 (詳見GMN7027) 3.1 對于螺柱凸焊，用焊接組規(guī)定的扭力扳手套住螺柱，左右扳動34次后，檢查螺柱根部，無裂紋的為合格。(具體標(biāo)準(zhǔn)見附表一)附表一螺柱焊檢驗(yàn)工具扭力對應(yīng)表序號螺柱型號檢具型號扭力值(kg)1T5x14.6WM1000

28、53.212T5x25WM100053.217M6x20WM100063.92813L/F M6 STUDWM100135.289T 5x9(PIN STUD)WM10005A3.21附圖一：附圖二：鑿子頂端與焊點(diǎn)內(nèi)端齊平不正確正確3-10mm不正確，太遠(yuǎn)不正確，太近Appendix F （返回）焊接破壞性檢查規(guī)定一 檢查頻率具體見焊接質(zhì)量檢查計劃。二. 檢查范圍 破壞性檢查零件上所包括的所有點(diǎn)焊，凸焊，混合氣體保護(hù)焊，螺柱焊焊接質(zhì)量。三. 檢查依據(jù)GM4488M, GM6122M, GM6435M, GMN7027四. 操作步驟 按各工段的標(biāo)準(zhǔn)操作單進(jìn)行如下操作1 目視檢查A. 清點(diǎn)焊點(diǎn)個數(shù)。B.檢查焊點(diǎn)位置。C.檢查是否存在不可接受的焊點(diǎn)。2 破壞性檢查焊點(diǎn)的焊接強(qiáng)度利用液壓張力鉗或氣動鑿子將所有焊點(diǎn)全部撕開。如在一件母材上留下撕洞，在 另一件母材上附有焊核，且焊核尺寸符合標(biāo)準(zhǔn)要求，則此焊點(diǎn)合格，否則為不合格?？山柚螛?biāo)卡尺或直尺對焊核尺寸進(jìn)行測量。3 在焊接破壞性檢查單上做好記錄，并通知焊接工程師，焊接工程師在采取改進(jìn)措 施后，應(yīng)填寫好焊接質(zhì)量問題跟蹤單放于發(fā)生問題的工位。生產(chǎn)現(xiàn)場負(fù)責(zé)做好跟蹤和記錄。4 檢查完畢后，清理工作場地，填寫報