螺母与螺栓凸焊(翻译)

I.1 Scope of Engineering Specification, General Statement ………….……….….

总体说明，本规范适用范围

I.2 Process Description ……………………………………………….………..……. 焊接过程描述

I.3 Design Guidelines 设计准则……………………………………………………………..…. I.3.1Fastener Size Relative to Base Sheet Metal Thickness 紧固件对板材厚度的相对尺寸 I.3.2Hole Size in Base Sheet Metal 板材上孔的尺寸 I.3.3Fastener Strength 紧固件强度

I.3.4Flatness of Base Sheet Metal 板材的平面度 I.3.5Location of Fastener 紧固件的位置

I.4 Applicable Materials 适用材料………………………………………………………

I.5 Joint Identification Symbols 焊接接头识……………………………………………………

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS

TESTS ……..

生产验证及过程测试总述

III. TEST PROCEDURES AND REQUIREMENTS ………………………………

试验过程及要求

III.1 Applicability of Test Procedures for PV- and IP-Test Phases …………………. PV试验阶段及IP试验阶段的适用性

III.2 Weld Parameter Monitoring 焊接参数监控……………………..…...………………… III.2.1 Introduction 简介

III.2.1 Welding Current over Time [A] 焊接电流 III.2.2 Electrode Force [N] 电极力

III.3 Dimensional and Visual Inspection of the Welded Fastener …………………… 被焊紧固件的尺寸校核及目视检查 III.3.1 Introduction 简介

III.3.2 Gap between Fastener and Base Sheet Metal 紧固件与板材的间隙 III.3.3 Burn Through into Base Sheet Metal 板材的烧穿 III.3.4 Deformation of Fastener Body 紧固件的变形 III.3.5 Cracks 破裂

III.3.6 Flash on Threads 螺纹上的毛刺 III.3.7 Metal spatter 金属飞溅

III.3.8 Position of Nut on Component 螺母在部件中的位置 III.3.9 Perpendicularity of Bolt 螺栓的垂直度

III.4 Inspection of Section Cuts 剖面切割检查…………………………………………… III.4.1 Introduction 简介

III.4.2 Gap between Fastener and Base Sheet Metal 紧固件与板材之间的间隙 III.4.3 Penetration into Base Sheet Metal 板材的焊透率 III.4.4 Porosity 气孔 III.4.5 Cracks 破裂

III.4.6 Inclusions 夹杂 III.4.7 Hardness 硬度

III.5 Destructive, Non-Destructive, and Functional Testing …………………………. 有损检测，无损检测及功能检测 III.5.1 Introduction 简介

III.5.2 Static Tensile Test 静态拉伸试验 III.5.3 Torque Test 扭矩试验

III.5.3.1 Torque Test (Destructive) 扭矩试验（有损） III.5.3.2 Torque Test (Non-Destructive) 扭矩试验（无损） III.5.4 Push Out / Pull Out Test (Destructive)推出/剥落试验（有损） III.5.5 Hammer/Chisel Test 榔头/凿子试验 III.5.6 Thread Test 螺纹测试 III.5.7 Leakage Test 密封性试验

III.5.8 Durability / Fatigue Test 寿命/疲劳测试

III.6 Permissible Repair Methods ……………………………………………...…...… 允许的返修方法

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

再验证要求

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

说明及注意事项

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

参考文件

I. GENERAL 综述

I.1 Scope of Engineering Specification, General Statement 总体说明，本规范适用范围

This Engineering Specification is issued to define design factors and performance requirements applicable to the joining of nuts and bolts using the projection welding process. It covers manual and automated projection welding on sheet steel having a minimum of 0.5 mm and a maximum of 3.0 mm thickness. It covers metric dimensions up to M16 and property class 4.8 and 8.8 fasteners, but not fasteners of the property class 10.9.

本规范用于规定螺母及螺栓凸焊的设计要素和焊接过程要求，它涉及厚度从0.5~3.0mm的钢板的手工凸焊和自动凸焊。本规范囊括了公制M16以下的紧固件，其性能等级为4.8和8.8，而不包括性能等级为10.9的紧固件。

This Engineering Specification harmonizes the requirements globally for Ford Motor Company and is applicable to new model programs. 本工程规范对全球的福特公司均有效并适用于新车型项目。

This Engineering Specification does not replace the requirements of the Ford world-wide fasteners standards, which focus on the performance of the fastener itself. Instead, it defines the requirements for the projection-

welded joint between the fastener and the base sheet metal. Applications that require special fasteners are not dealt with here and require a case-by-case approval by the appropriate Fastener, Body and Manufacturing Engineers.

本工程规范不替代全球通用的福特紧固件标准（该标准主要讨论紧固件本身的性能），而是规定紧固件和板材之间的凸焊接头的各种要求。采用特殊紧固件的情况不在本规范讨论之内，如有采用需经紧固件工程师，车身工程师和制造工程师逐项批准。

This Engineering Specification is a supplement to the released part drawing, and all requirements herein must be met in addition to all other requirements of the part drawing. Each section specifies the minimum measures necessary for documenting compliance with this specification.

本工程规范是所发放零件图纸的补充，除了要满足图纸的要求，也必须满足本规范的要求。每部分规定了遵从本规范的最基本的措施。

This Engineering Specification is intended to evaluate specific characteristics as a supplement to normal material inspections, dimensional checking and in-process controls, and should in no way adversely influence other inspection operations.

本工程规范作为常规的材料检查，尺寸检查和过程控制的说明补充，而决不能反过来影响其它的检查操作。

Preparation and submission of an acceptable control plan are the responsibility of the manufacturing source. The manufacturing source will retain the original control plan and any later revisions per QS-9000 and provide a copy to the design responsible Product Engineering activity.

制造资源有义务准备与提交一份可接受的控制计划，制造资源保留原有的控制计划和任何之后经过QS-9000标准的修订版本，并且复制一份给负责设计的工程小组。

I.2 Process Description 过程描述

Projection welding is a resistance welding process that produces a weld by the heat obtained from the resistance to the flow of the welding current. The resulting welds are localized at predetermined points by local or annularprojections. Figure 1 shows the sequence of the projection welding process.

凸焊是一种利用电流流过电阻产生热量进行焊接的焊接方法。发生焊接的位置位于预制的环形凸点上。图1所示即为凸焊的焊接过程。

Figure 1: Example of Projection Weld Sequence 图1.凸焊过程示例

Figure 2 shows the representative weld fasteners covered in this document. Fasteners not shown here are not covered by this engineering specification and need to be treated on a case-by-case basis.

图2所示为本规范包含的代表性焊接紧固件。没有在图表中列出来的紧固件不在本规范所涵盖的范围，这些紧固件要采取“逐项原则”（case-by-case原则）对待。

(a) Weld bolt with three circular projections (b) Weld bolt with “banana” projections (c) Weld bolt with four circular projections(NOT recommended for new FORD designs) (d) Weld bolt with continuous ring projections (e) Square weld nut with four projections (NOT recommended for new FORD designs) f) Piloted weld nut with three circular projections (NOT recommended for new designs) g) Flanged hexagon weld nut with three “banana” (h) Flanged round weld nut with three \"banana\" (i) Flanged hexagon weld nut with three circular (j) Flanged round weld nut with three circular Figure 2: Projection Fasteners Covered by this Specification (k) Flanged hexagon weld nut with continuous ring 图2.本规范涵盖的凸焊紧固件 (l) Flanged round weld nut with continuous ring I.3 Design Guidelines 设计准则

The following design guidelines describe the generic conditions for the proper projection welding application of nuts and bolts. It is the Design Engineer's responsibility to determine the design requirements for the weld fastener necessary to achieve the design objective.

以下设计准则描述了螺母和螺栓凸焊的一般情况。设计工程师负责决定焊接紧固件的设计要求及其所要达到的目标。

Many factors influence the choice of fastener type, such as loading conditions, sheet thickness and grade, manufacturing preferences, quality assurance, etc. In general, weld nuts are preferred over weld bolts. One should thoroughly consider the functionality of the fastener, whether it is intended to carry high static and/or fatigue loads, or only serve as an attachment point for earth wirings (grounds). It is important to establish which part of the fastener joint system is the limiting factor (thread strength or the fastener's attachment to the sheet part) in order to avoid expensive over-dimensioning.

紧固件类型的选择受多种因素的影响，比如加载状况，板料厚度及等级，制造偏好，质量保证等等。总的说来，焊接螺母优于焊接螺栓。我们必须彻底考虑紧固件的功能：它是否需要承受高的静态载荷和/或疲劳载荷，或者仅仅作为地线的一个附属点。为了避免采用过大尺寸的紧固件而造成更高的成本，确定焊接紧固件接头系统的限制性因素（螺牙强度或者与板材的连接强度）是很重要的。

For lower loads and small thread sizes (M6 and M8,) mechanically joined fasteners and weld fasteners could be considered as equal in their ability to carry load. In which case, the manufacturing process may dictate the type of fastener to use.

对于小载荷和小螺纹尺寸（M6和M8，），机械连接紧固件和焊接紧固件具有相同的承载能力。在这种情况下，制造过程决定所用的紧固件类型。

For higher loads and larger thread sizes, a welded fastener is recommended. For these conditions, it is also important to locate a weld nut on the side of the sheet component which is opposite to the loading direction. With such a design, the occurrence of weld discrepancies are of minor importance to the performance of the joint as the fastener has to be pulled through the sheet or nut plate. For high fatigue loads, fasteners with a continuous ring projection are the best choice, although these are also more difficult to weld.

对于大载荷和大尺寸螺纹，推荐使用焊接紧固件。对于这种情况，在板件上与载荷方向相反的另一边设置一个焊接螺母是很重要的。有了这种设计，焊接偏差的发生对于焊接接头性能的影响就不那么重要了，因为如果要产生破坏紧固件必须穿过板材或者螺母板。对于大的疲劳载荷，使用带有连续型环形凸块的紧固件是最好的，尽管这样也会增加焊接难度。

I.3.1 Fastener Size Relative to Base Sheet Metal Thickness 紧固件相对于板材厚度的尺寸大小

Table I.3.1 lists the permissible range of base sheet thickness for the respective size and type of nut and bolt. 表I.3.1列出了各种螺母螺栓的类型尺寸及其对应的允许使用的板材厚度范围。

Thread Size 螺纹尺寸 Minimum - Maximum Sheet Metal Thickness [mm]板材厚度范围 Square Nut 方螺母 Round/Hexagon Nut and Bolt 圆形/六角螺母和螺栓 Four Projections 四凸块 Three Banana- 三个香蕉形凸块 0.75 - 1.25 0.9 - 2.0 1.25 - 2.5 1.5 - 3.0 1.5 - 3.0 1.5 - 3.0 3) 1.5 - 3.0 3) Round/Hexagon Nut and Bolt 圆形/六角螺母和螺栓 Round/Hexagon Nut and Bolt 圆形/六角螺母和螺栓 Projections 三个环形凸块 0.5 - 0.8 0.8 - 2.0 1.25 - 2.0 Continuous Ring Three Circular 连续环状凸块 0.5 - 1.5 2) 0.75 - 2.5 2) 0.75 - 2.5 2) ShapedProjections Projection M6 1) M8 M10 7/16-20 UNF M12 M14 M16 0.5 - 1.5 0.75 - 2.5 0.75 - 2.5 1.5 - 3.0 1.0 - 3.0 1.0 - 3.0 2) 1.5 - 3.0 3) 1.5 - 3.0 3) 1.5 - 2.2 1.5 - 2.4 注：1) These values can be used for an M5 thread applied on an M6 nut body. 这些值可用于采用M5螺纹M6螺母身的螺母

2) Currently under validation in test program. Can be used until further notice. 目前正在测试验证当中，这些数据在下次通知之前有效。 3) Weld Nuts only 只对焊接螺母有效。

Table I.3.1: Minimum and Maximum Sheet Metal Thickness for Various Weld Fastener Sizes

表I.3.1:各种焊接紧固件所对应的钣金厚度范围

Note: Banana projections are assumed to match WE502 size requirements and circular projections are assumed to match WE500 size requirements.

注释：假设香蕉形凸块符合WE502尺寸要求；假设环状凸块符合WE500尺寸要求。

Deviations from these guidelines require the approval of both the relevant Body and Manufacturing Engineering departments.

采取与本准则有差异的方案需经与车身和制造有关的工程部门批准。

For optimum performance of non-standard fasteners: 为了得到最佳性能，非标准紧固件采用如下原则：

• Projection diameters/widths should be at least 2.5 times the attaching sheet thickness 凸块直径/宽度至少要达到所焊板材厚度的2.5倍。

• Projection heights should be at least 0.5 times the attaching sheet thickness 凸块高度至少要达到所焊板材厚度的0.5倍。

I.3.2 Hole Size in Base Sheet Metal 板材上孔的尺寸

Table I.3.2 lists the applicable sheet hole diameter for flanged and piloted weld nuts and weld bolts. 表I.3.2列出了焊接法兰螺母螺栓和带导向的螺母螺栓时板材上孔径的大小。

Thread size 螺纹尺寸 Hole Diameter for Weld Nuts [mm] 焊接螺母的板孔直径 Flanged Nut 1) 法兰螺母 + 0.5 / - 0.0 M6 M8 M10 7/16-20 UNF M12 M14 M16 7.5 9.5 11.4 11.4 13.9 15.9 18.0 Piloted Nut 导向螺母 + 0.15 / - 0.0 9.0 13.0 15.0 + 0.5 / - 0.0 6.3 8.3 10.3 10.3 12.3 Hole Diameter for Weld Bolts [mm]焊接螺栓的板孔直径 17.0 19.0 1) The category \"Flanged Nut\" includes Square Nuts.

法兰螺母包括了方螺母

Table I.3.2: Hole Size for Various Weld Fasteners 表I.3.2:各种焊接紧固件对应的板孔直径

I.3.3 Fastener Strength 紧固件强度

After the welding process, weld bolts and nuts must still meet the tensile and/or proof load values for the property class specified in the Worldwide Fastener Standards or on the individual part drawings.

焊接过程结束后，焊接螺栓和螺母的拉伸载荷和/或标准负荷值必须满足世界紧固件标准的规定或者图纸上的规定。

• Actual proof load values for bolts - as referenced in the Global Fastener Standard WA960 – are tabulated in ISO 898-1 for various property classes.

对不同性能等级的螺栓，其标准负荷数值在ISO898-1的列表中，亦可参考国际紧固件标准WA960。 • Actual proof load values for nuts - as referenced in the Global Fastener Standard WE960 - are tabulated in ISO 898-2.

对于螺母，其标准负荷数值在ISO898-2的列表中，亦可参考国际紧固件标准WE960. Figure 3 illustrates three potential loading conditions for fasteners that need to be considered in design. 图3所示为三种潜在的紧固件负载情况，这需要在设计时加以考虑。

Although the figure shows normal loading, actual design may require off-normal loading. 尽管图示的是常见的负载情况，实际设计中可能需要使用非常规的负载状况。

(a) Push-Out推出式 (b) Pull-Out拉出式 (c) Pull-Through拉入式 Figure 3: Potential Loading Conditions for Welded Fasteners 图3.紧固件潜在的加载情况

I.3.4 Flatness of Base Sheet Metal 板材的平面度

Figure 4 outlines the area condition needed to robustly weld a fastener to the parent sheet metal

图4画出了在母板金属上能稳固焊接紧固件的区域。

Ry = Outer radius of the weld fastener(nut size dependent, but typically15 mm for M5, M6, and M8 nuts) Ry=焊接紧固件的外径（由螺母尺寸决定，但对M5，M6和M8的螺母一般为15mm） Ø1 = Functional hole diameter [mm] according to Table I.3.2 Ø1 =作用的孔的直径[mm]根据表I.3.2求得

Ø2 = Area with flatness requirements where Ø2 = 2 x (Ry + 2) [mm] Ø2 =有平面度要求的区域直径Ø2 = 2 x (Ry + 2) [mm]

Figure 4: Flatness Requirements平面度要求

I.3.5 Weld Equipment Clearance焊接设备间隙

The product design shall provide sufficient clearance for the electrodes of the production weld equipment. The two zones to consider are above and below the welded fastener. The upper electrode is applied on the same side as the fastener, while the lower electrode is applied on the opposite side of the fastener. Figure 5 illustrates various joint geometries. Tables I.3.5-1 and -2 define the required clearances for different fastener types and sizes.

产品设计时要提供生产时电极所需要的足够的间隙。需要考虑的是紧固件上方和下方的两个区域。上电极作用在和紧固件相同的一侧，而下电极作用在与紧固件相反的另一侧。图5示意各种焊接接头结构。表I.3.5-1和-2规定了不同类型和尺寸的紧固件所需的间隙。

NOTE: Option 3 is NOT available with Weld Bolts.

注：第三种情况不能用于焊接螺栓。

Figure 5: Electrode Clearance Requirements for Various Configurations 图5：各种情况下的电极间隙要求 Fastener Type A > B > C < D > H < 紧固件类型 Square Weld Nuts 30 60 60 180 50 焊接方螺母 Flanged Weld Nuts 38 76 60 200 50 焊接法兰螺母 Weld Bolts NA 30 60 60 50 焊接螺栓 1) L= Nominal length of bolt

I > 140 140 140 + L 1) L=螺栓公称长度

Table I.3.5-1: Required weld equipment clearances for dimensions A-D, H-I. All values in mm.

表I.3.5-1:焊接设备要求的间隙尺寸A-D, H-I 所有的数值单位为mm

表I.3.5.2 焊接设备要求的间隙尺寸F和G 所有的数值单位为mm

Deviations from the recommended clearances require the approval of both the relevant Body and Manufacturing Engineering departments. The possibility of using special electrodes to get into smaller spaces may be considered, but this will lead to higher equipment or operating costs.

当采用不同于推荐的间隙值时需得到车身和制造相关工程部门的允许。也可以考虑采用特殊电极以达到小空间，但这会提高设备成本和操作成本。

I.4 Applicable Materials适用材料

Base Sheet Metal Specification金属板材规范

This Engineering Specification covers the use of the following steels categories in uncoated and coated condition: 本规范包含以下种类的钢材（有镀层或无镀层）

FORD MATERIAL SPECIFICATION NO 福特材料规范号 Applicable to Ford of Europe, VCC 对欧洲福特和VCC适用 WSS-M1A344-A1/A2 WSS-M1A345-A1/A2/A3/A4 CATEGORY TYPES OF STEEL钢类别 MS Applicable to Ford North America 对北美福特适用 WSD-M1A333-A1/A2/A3/A4 的类型 Mild Steels, Hot and Cold Rolled, Low Carbon低碳钢，热轧或冷轧 DR Dent Resistant Steels including Bake Hardening, 包括烘烤硬化 High Strength IF,高强度IF Isotropic and Rephosphorised Steels 各向同性钢和回磷钢 HSLA DP 1) TRIP 1) MSW 1) BORON 1) High Strength Low Alloy Steels高强度低合金钢 Dual Phase Steels 双相钢 TRIP Steels相变诱发塑性钢 Martensitic Steels马氏体钢 TBD Boron Steels硼钢 WSS-M1A322-A3 WSS-M1A183-D WSB-M1A322-A1 (Uncoated) WSS-M1A357-A1 (Coated) 2) WSS-M1A358-A1 (Coated) 2) 1) DP, Trip, MSW, and Boron Steels are included in this Engineering Specification within a limited applicability. Use of these materials needs to be checked with the relevant Body and Manufacturing Engineering Departments on a case-by-case basis.

1) 本规范中DP, Trip, MSW, and Boron钢有限制的采用。这些材料的采用须经车身和制造相关工程部门的逐项确认。

2) WSS-M99P39-A1/A2/A3/A4 performance specification must be called out with these Boron steels. WSS-M99P39-A1/A2/A3/A4性能规范必须遵从这些硼钢。

WSS-M1A346-A1/A2/A3 WSS-M1A347-A1/A2/A3 WSS-M1A348-A1/A2/A3/A4/ WSS-M1A348-A1/A2/A3/A4/ A5/A6/A7/A8/A9 WSS-M1A351-A1/A2/A3 A5/A6/A7/A8/A9 WSS-M1A351-A1/A2/A3 WSB-M1A215-E1/F1 WSS-M1A341-A1/A2/A3/A4/ WSS-M1A341-A1/A2/A3/A4/ A5/A6/A7/A8/ A9/A10 A5/A6/ A7/A8/A9/A10 Table I.4-1: Applicable Categories of Base Sheet Steels Covered by this Specification 表I.4-1:本规范涵盖的适用的板材种类

The text of the referenced Ford material specifications is available from the following web link http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html, Metals 1A-99A.

福特材料参考规范可以参照以下链接：http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html，

New steel types are under constant development. In the case of steel types not covered by Table 7 of this Engineering Specification, the relevant Body and Manufacturing Engineering departments shall be contacted. 新的钢材种类正在持续的开发当中，如果使用超出本规范中表7所示的钢材时，需经车身和制造相关工程部门确认。

Laminated steel applications are not covered by this Engineering Specification and need to be treated as special case. For such application it’s preferred to use the punched fastener rather then a welded one.

本规范未涉及层压复合钢板，如有使用应将其归入特殊钢板。并且在这种情况下使用冲压紧固件比焊接紧固件较好。

Standard Base Sheet Metal Coatings标准板材镀层

Projection welding of fasteners supports the following coatings in all combinations:

紧固件的凸焊支持以下镀层

Specification Type规格种Specification No. Coating Type 类 规格牌号 镀层种类 60G60G EL, 50G50G EL WSS-M1P94-A Electro-galvanized电镀锌 55A55A HD WSS-M1P94-A Galvannealed镀锌 60G60G HD, 50G50G HD WSS-M1P94-A Hot Dip Galvanized热镀锌 AlSi coating WSD-M1A295-A2 Hot Dip Aluminized热镀铝 Table I.4-2: Standard Base Metal Coatings Covered by this Specification 表I.4-2:本规范涉及的标准板材镀层

The use of coatings not listed in Table I.4-2 requires the approval of both, the relevant Body and Manufacturing Engineering departments.

使用未在表I.4-2中列出的镀层时需经车身部门和制造相关部门的同意。

I.5 Joint Identification Symbols 接头检测标识

The identification symbols shall be in accordance with the individual requirements of the Ford Motor Company

brands as outlined below:

检测标识必须与福特各品牌的要求保持一致，具体如下所示： • Ford 福特

The current Ford Engineering CAD and Drafting Standard D-3 (Welding Symbols and Specifications) does not require a specific identification of nuts and bolts welded in accordance with this engineering specification. 现行的福特CAD和制图标准D-3（焊接标识和规范）没有要求一个遵从本规范的螺母螺栓检测规范。 • Volvo Car Corporation 沃尔沃

The fastener symbols shall be in accordance with Volvo Car Corporation standard VCS 5027,4, Indication of single and combined joints, available at http://www.tech.volvo.se/standard/eng/stdnum.html.

紧固件标识必须与沃尔沃标准VCS5027,4保持一致。单个和组合的焊接接头标识可在以下网站查看http://www.tech.volvo.se/standard/eng/stdnum.html.

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS 生产验证和过程中测试综述

Production Validation (PV) tests are used to obtain an initial estimate of the process potential to produce parts that conform to engineering requirements, and to identify causal or predictive relationships between significant design and process characteristics (to be used for process control). The tests must be completed successfully using initial parts from production tooling and production process before Part Submission Warrant (PSW) approval and authorization of production parts can be issued. Sampling plans for PV testing must be included in the control plan.

生产验证（PV）测试的目的是获得按照工程要求生产的过程潜能的初始评价，并且识别有效设计和过程特性之间的因果关系（用于过程控制）。该测试必须使用生产工装上和生产过程中的首件，并且必须在PSW通过和产品流出之前。PV测试的抽样方法必须包含在控制计划中。

In addition, tests can be done on prototype level parts or vehicles to the same extent as outlined for PV-testing. This does not replace the necessity to run PV-phase testing as described above.

此外，测试也可以在与PV测试同样大小的原型零件或汽车上进行。但这不能替代如上所述的PV阶段的测

试。

In-Process (IP) tests are used to further understand the relationship between significant design and process characteristics and to establish a basis for continuing improvement. Tests must be completed with production parts on an ongoing basis. Sampling plans for both IP testing and evaluation of the significant process characteristics must be included in the control plan. When the process is found to be out of control or the test acceptance criteria are not met, the reaction plan approved in the control plan shall be invoked.

过程（IP）测试目的在于进一步了解有效设计和过程特性的关系并且确立改进方法。该测试必须使用在持续生产过程中的部件。对IP测试和重要的过程特征评估的抽样方法都需要包含在控制计划中。当过程失控时或者该测试无法满足接收标准时，必须采取控制计划允许的应对措施。

Welded fasteners that do not meet the requirements outlined in Section II., Summary of Production Validation and In-Process Tests, and Section III., Test Procedures and Requirements, of this Engineering Specification need to be repaired following the reworking procedure as outlined in Section III.5.

当焊接紧固件无法满足第II部分《生产验证测试和过程中测试综述》和第III部分《测试过程及要求》时，必须按第III.5部分的要求进行返修。

The tables that follow summarize the various PV and IP tests and the acceptance parameters for each. They form the basis on which to develop a complete control plan for these and their related significant process characteristics. The control plan will include frequencies, sample sizes and reaction plans; see Ford Quality System Requirements, QS-9000.

以下表格概括了各种PV和IP测试及其可接受的数值。它们是形成完整的控制计划及相关过程特性的基础。控制计划包括测试频率，采样大小和应对措施。具体参考福特质量体系要求QS-9000。

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cont.) PV测试和IP测试综述 Weld Parameter Monitoring

焊接参数监控 Test Number Test Lower Target Characteristic Tolerance Value 测试特征 Limit 目标值 下限 Welding Current over Time [A] 焊接电流 As determined in PV testing 根据PV测试结果 As determined in PV testing Upper Tolerance Limit 上限 As determined in PV testing Minimum Sample Size 最小采样大小 see 1) 参见注解1）Minimum Sample Frequency最小采样频率 see 1) 参见注解1）III.2.2 III.2.3 Electrode Force [N] 电极力 As determined in PV testing As determined in PV testing As determined in PV testing see 1) 参见注解1）see 1) 参见注解1） 1) Ford 福特

Minimum Sample Size and Frequency to be determined by the manufacturing plant personnel responsible for the control plan in conjunction with the design responsible body-engineering activity and the relevant quality departments as well as other appropriate functions. Reference: Ford of Europe: Document VOPQUE-612,

available at http://www.voqoeu.ford.comFord North America: Document VOPSSN-008, available at http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf 最小试样尺寸和最小检测频率由制造工厂的控制计划负责人与车身工程及质量工程相关部门协同确认，其它有关功能亦由此方法确定。参考欧洲福特文件VOPQUE-612,详见http://www.voqoeu.ford.com 北美福特文件VOPSSN-008，详见http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf

Volvo Car Corporation: Minimum Sample Size and Frequency to be defined by the relevant manufacturing unit. 沃尔沃：最小试样尺寸和最小抽样频率由有关制造单元决定。

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cont.)

PV测试和IP测试综述

Inspection of the Visible Part of the Weld

焊接可见部分的检测

Test Number Test Characteristic 测试特征 Lower Target Tolerance Value Limit 目标值 下限 Not applicable After welding, the fastener matching surface shall lie on metal. 焊接后紧固件配合面要贴合在板件上 the base sheet Upper Tolerance Limit 上限 Maximum gap 0.1 mm 最大间隙0.1mm Minimum Sample Size 最小样件尺寸 see 1) 见注解1）Minimum Sample Frequency 最小抽样频率 see 1) 见注解1）III.3.2 Gap Between Fastener Metal 紧固件与板材间的间隙 and Base Sheet 不适用 III.3.3 Base Sheet Metal Burn Through Not applicable不适用 Not applicable不适用 Not applicable不适用 Not present 未表述 Not present 未表述 Not present 未表述 Not applicable 不适用 Not applicable不适用 Not applicable不适用 see 1) 见注解1）see 1) 见注解1） III.3.4 Deformation of Fastener Body 紧固件体的变形 see 1) 见注解1）see 1) 见注解1） III.3.5 Cracks 破裂 see 1) 见注解1）see 1) 见注解1） III.3.6 Flash Threads 螺牙毛刺 on Not applicable不适用 Not applicable不适用 Not applicable不适用 Not present 未表述 Not present 未表述 As outlined on assembly Drawing如装配图所示 Not applicable不适用 see 1) 见注解1）see 1) 见注解1） III.3.7 Metal Spatter 金属飞溅 See Section see 1) III.3.7见第III.3.7部分 As outlined on assembly drawing. Shadowing of base sheet metal hole is not permissible.如装配图所示，不允许遮蔽板材上的孔 see 1) 见注解1）见注解1）see 1) 见注解1） III.3.8 Position of Nut on Component 板件上螺母的位置 see 1) 见注解1） III.3.9 Perpendicularity - 5 degrees of Bolt from Normal 垂直方向-5° As outlined on assembly Drawing如装配图所示 + 5 degrees see 1) from normal 垂直方向+5° 见注解1）see 1) 见注解1） 螺栓的垂直度 1) Ford 福特

Minimum Sample Size and Frequency to be determined by the manufacturing plant personnel responsible for the control plan in conjunction with the design responsible body-engineering activity and the relevant quality departments as well as other appropriate functions. Reference:

Ford of Europe: Document VOPQUE-612, available at http://www.voqoeu.ford.com Ford North America: Document VOPSSN-008, available at http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf

最小试样尺寸和检测频率由制造工厂的控制计划负责人与车身工程及质量工程相关部门协同确认，其它相关功能亦由此方法确定。参考欧洲福特文件VOPQUE-612,详见http://www.voqoeu.ford.com 北美福特文件VOPSSN-008，详见http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf

Volvo Car Corporation: Minimum Sample Size and Frequency to be defined by the relevant manufacturing unit. 沃尔沃：最小试样尺寸和抽样频率由有关制造单元决定。

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cont.)

生产验证和过程测试总述（续） Inspection of Section Cuts剖切面的检验

测试号 测试特征 公差下限 目标值 公差上限 最小样本大小 III.4.2 紧固件和主体金属件的间隙 III.4.3 主体金属件的熔深 初始焊脚高度的30% III.4.4 气孔 不适用 初始焊脚高度的50% 未提供 基体金属厚度的90% 气孔面积不超过凸焊区域的25% III.4.5 裂纹 不适用 未提供 裂纹长度不超过凸焊宽度的20% III.4.6 夹杂 不适用 未提供 夹杂区域不超过凸焊区域的20% III.4.7

1) Ford

最小采样频率 见1） 不适用 无间隙 最大0.1mm 见1） 见1） 见1） 见1） 见1） 见1） 见1） 见1） 见1） 硬度 不适用 不适用 具体见III.4.7章 见1） 见1） 福特

Minimum Sample Size and Frequency to be determined by the manufacturing plant personnel responsible for the control plan in conjunction with the design responsible body-engineering activity and the relevant quality departments as well as other appropriate functions. Reference:

Ford of Europe: Document VOPQUE-612, available at http://www.voqoeu.ford.com Ford North America: Document VOPSSN-008, available at http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf 最小抽样尺寸和最小抽样频率及其他有关功能由制造工厂负责控制计划的工程师和负责车身设计及质量部门协同确定。

参考：欧洲福特，VOPQUE-612http://www.voqoeu.ford.com

北美福特：VOPSSN-008http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf

Volvo Car Corporation: Minimum Sample Size and Frequency to be defined by the relevant manufacturing unit.

VCC：最小采样大小和采样频率由相关的制造单位制定。

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cont.)

生产验证和生产进程测试总述（续）

Destructive, Non-Destructive, and Functional Testing

破坏性测试，非破坏性测试，和功能测试 测试号 III.5.2 测试特征 拉入试验（破坏性） 公差下限 目标值 公差上限 最小最小样本采样大小 频率 不适用 见1） 见1） 不适用 超过该紧固件的校验值 III.5.3 推出试验和拉出试验（破坏性） 对于凸点数≥3的凸焊，允许有1个凸点不符合要求；对于环状焊脚，连续的环形焊接区域至少为全长的70% 对于凸点式焊脚，不能有不符合要求的凸点产生；对于环形焊脚，连续的环形焊接区域要达到100%。 不适用 见1） 见1） III.5.4.1 III.5.4.2 扭矩测试（破坏性） 扭矩测试（非破坏性） 不适用 只能在刚好超过最小破坏性扭矩值时发生接头部分或全部分离 不适用 见1） 见1） 不适用 在超过最小非破坏性扭矩测试值之前不能发生接头的部分或全部分离和破裂。 不适用 见1） 见1） III.5.5.1 敲打/凿击试验（破坏性） 对于凸点≥3凸焊：允许有1个凸点不符合要求；对于环状焊脚，连续的环形焊接区域至少为70% 对于凸点式焊脚，不能有不符合要求的凸点产生；对于环形焊脚，连续的环形焊接区域要达到100%。 不适用 见1） 见1） III.5.5.2 敲打/凿击试验（非破坏性） 不适用 焊接接头没有发生部分或者全部的脱离。 不适用 见1） 见1） III.5.6 III.5.7 III.5.8 螺纹测试 密封测试 耐久性/疲劳测试 不适用 不适用 不适用 通过测试 通过测试 根据CETP00.00-R310，在整车PASCAR车第一阶段和PASCAR第二阶段阶段的50%完成时在焊接区域和热影响区不发生破裂和分离。 不适用 不适用 不适用 见1） 见1） 见1） 见1） 见1） 见1）

1) Ford

福特

Minimum Sample Size and Frequency to be determined by the manufacturing plant personnel responsible for the control plan in conjunction with the design responsible body-engineering activity and the relevant quality departments as well as other appropriate functions. Reference:

Ford of Europe: Document VOPQUE-612, available at http://www.voqoeu.ford.com Ford North America: Document VOPSSN-008, available at http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf 最小抽样尺寸和最小抽样频率及其他有关功能由制造工厂负责控制计划的工程师和负责车身设计及质量部门协同确定。

参考：欧洲福特，VOPQUE-612http://www.voqoeu.ford.com

北美福特：VOPSSN-008http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf

Volvo Car Corporation: Minimum Sample Size and Frequency to be defined by the relevant manufacturing unit.

VCC：最小采样大小和采样频率由相关的制造单位制定。

III. TEST PROCEDURES AND REQUIREMENTS 测试过程和要求

III. 1 Applicability of Test Procedures for Production Validation (PV) and In-Process (IP) Test Phases 生产确认（PV）和生产进程（IP）测试过程的适用性。

测试号 III.2 焊接参数的监控 III.3 焊点的外观检查和尺寸检查 III.4 对剖切面的检查 可选的 车身工程和制造工程部门决定是否需要进行剖面分析（通常只需对与未知的主体板件结合时进行典型分析）。 III.5 破坏性测试，非破坏性测试和功能测试 强制的 强制的 可选的 可用于对根本原因的分析 强制的 建立目标值和公差上下限 强制的 强制的 强制的 测试特征 PV测试阶段 IP测试阶段 对于带开口环焊脚的螺母或螺栓：破坏性试验或非破坏性试验； 除III5.2的拉入试验，III5.7的密封测对于带连续环焊脚的螺母或螺栓：不允许使用非破坏性试验。 当可使用多种破坏性或非破坏性测试时，可以选其中一个作为最优的测试。这必须规定在其控制计划上。 车身和制造工程部门决定是否进行密封测试 试和III5.8的耐久性/疲劳强度测试。 对于带连续环焊脚的螺母或螺栓：不允许使用非破坏性试验。 当多种破坏性或非破坏性测试存在于一种给定的紧固件中时，可以选其中一个作为最优的测试。这必须规定在其控制计划上。 表III.1 测试过程和要求的适用性

III.2 Weld Parameter Monitoring 焊接参数的监控 III.2.1 Introduction 简介

Projection welding equipment used for the production of parts according to this Engineering Specification shallbe equipped with a built-in weld parameter control and monitoring unit. The target values and the upper andlower tolerance limits for the parameters below shall be determined in Product Validation (PV) testsindividually for each projection welding application. They shall be included in the process control plan and laterbe applied on the basis of a 100 % sampling rate for In Process (IP) conformance testing. Non-conforming welds should be marked and processed for additional inspection and possible rework.

用于零件产品生产的凸焊设备，根据工程说明书需要装备有内嵌的焊接参数控制和监测的单元。以下参数的目标值和公差上/下限在每次进行凸焊时需要单独地在生产确认（PV）测试中制定。他们应该包含在过程控制计划中并且需要在随后的生产进程（IP）一致性测试中进行100%的采样率时应用。不符合要求的焊点需要标示出来并且进行额外的检查和可能的返工处理。

III.2.2 Welding Current over Time [A] 焊接电流（A）

During IP-monitoring, the welding current over time shall stay within the welding current window as defined in PV-testing individually for each projection welding application.

在IP监测过程中，随时间变化的焊接电流必须保持在每次凸焊中的PV测试规定的焊接电流窗口内。

III.2.3 Electrode Force [N] 电极压力[N]

During IP-monitoring, the electrode force shall stay within the force window as defined in PV-testing individually for each projection welding application. Note that 100% sampling may only be possible if the weld gun is equipped with a load cell or transducer

在IP监测过程中，电极压力必须保持在每个凸焊应用中的PV测试规定的电极压力窗口范围内。只有在焊枪装备有压力传感器时才有可能进行100%采样。

III.3 Dimensional and Visual Inspection of the Welded Fastener 焊接紧固件的尺寸检查和外观检查

III.3.1 Introduction 简介

Dimensional and visual inspection of welded fastener is performed as “naked eye-inspection” and, if required, scales or calliper gages can be employed to:

• Verify that the number and the location of the welded fasteners are as outlined on the engineering drawing or the relevant CAD model.

• Detect obvious discrepancies such as out-of-position conditions, unacceptable gap conditions, base sheet metal burn-through or weld fastener deformation.

焊接紧固件的尺寸检查和外观检查一般是通过“肉眼检查”来执行的，如果有要求，可以借助标尺或者卡尺：





依据工程图或者相关的CAD模型核对焊接紧固件的位置和数量。

检测明显的不符合要求的地方比如位置偏移的情况，不可接受的间隙，底板金属焊穿或者焊接紧固件变形情况等。

III.3.2 Gap Between Fastener and Base Sheet Metal 底板金属与紧固件之间的间隙

After welding, the fastener matching surface shall lie on the base sheet metal. However, a maximum gap of 0.1 mm may be allowed.

焊接过后，紧固件的配合面应该贴合在底板金属上。然而，有时允许有0.1mm的最大间隙。

III.3.3 Base Sheet Metal Burn-Through 底板金属的焊穿

Not permissible 不被允许。

III.3.4 Deformation of Fastener Body 紧固件本体的变形

Plastic deformation of the fastener caused by over-heating is not permitted. Non metallic inserts in nuts shall not be damaged.

过热引起的紧固件塑性变形是不被允许的。而且不允许破坏螺母中的非金属镶嵌物。

III.3.5 Cracks 破裂

Cracks in the base sheet metal are not permitted. 不允许底板金属产生破裂。

III.3.6 Flash on Threads 丝牙上的飞溅

The weld fastener or screw attachment is discrepant if weld flash is on the threads, or area to be threaded, results in excessive assembly driving-torque values.

如果在螺纹丝牙或者有螺纹的区域上有焊接飞溅，就会使得焊接紧固件或者螺钉连接物发生差异，导致

装配的扭矩值过大。

III.3.7 Metal Spatter 金属飞溅

Fasteners cannot be placed on Class 1 surfaces. For Class 2 (Class 3 or 4 for VCC) surfaces, metal spatter (molten metal that has resolidified) is not permitted. Metal spatter on Class 3 (Class 5 for VCC) surfaces should be avoided, but may be permitted if it does not affect internal or external customer requirements.

紧固件不能放置于第一类表面上。对于第二类（VCC的第三类和第四类）表面，金属飞溅物（再次凝固的熔融金属）是不被允许的。在第三类（VCC的第五类）表面上的金属飞溅物应该避免，但是如果它不影响

内部顾客或外部顾客的要求也可以被允许。

III.3.8 Position of Nut on Component 螺母在构件上的位置

The position of a nut, including tolerance, must be specified on the engineering drawing or relevant CAD model. Locating a nut outside of this position is not permitted. Visual check should be carried out to ensure no obstructions (shadowing) of base sheet metal due to off position of the nut.

螺母的位置，包括公差要求，必须与在工程图或者相关CAD模型上详细的标出。不允许将螺母放置在上

述位置以外。可以通过目视检查来确保不会由于螺母位置的偏移而造成底板金属对螺母孔遮挡。

III.3.9 Perpendicularity 垂直度

Bolts should be welded perpendicular (90 degrees) to the base sheet metal. At a maximum, this type of fastener can be five degrees off perpendicular

螺栓需要与底板金属垂直地（90度）进行焊接。这种紧固件最多可以偏离垂直方向5度。

III.4 Inspection of Section Cuts 剖切面的检查 III.4.1 Introduction 简介

Dimensional and visual inspection of a section cut gives an insight into the weld properties and could be used during the series of PV- or IP-tests. Section cuts should be analyzed as they help to detect discrepancies such as large gaps, insufficient penetration, porosity, cracks, or inclusions.

剖切面的尺寸检查和外观检查对焊接特性有了一个认识并且可以应用在PV测试和IP测试这一系列测试中。需要对剖切面进行分析是因为他能够帮助我们发现缺陷，比如间隙过大，弱焊，气孔，裂纹以及夹杂等。

III.4.2 Gap Between Fastener and Base Sheet Metal 紧固件和底板金属之间的间隙

The projections shall be fully fused. However, a maximum gap of 0.1 mm may be allowed, as shown in Fig. 6. 焊脚应该充分的融合。然而允许有0.1mm的最大间隙，如图6所示。

间隙≤ 0.1 mm

Figure 6: Fusion with Maximum Gap of 0.1mm

图6：最大间隙为0.1mm的融合

III.4.3 Penetration into Base Sheet Metal 底板金属的熔深

Target is 50 % of initial projection height value. Minimum requirement is 30 % of the initial projection height value. Weld should not extend beyond 90% of base sheet metal thickness.

目标值为初始焊脚高度的50%。要求的最小值为初始焊脚高度的30%。焊点不能延伸超过底板金属厚度的90%。

P hp= initial projection height P= Depth of penetration hp=初始焊脚高度 P=熔深 0.3 * hp ≤ P ≤ 0.5 * hp

Figure 7: Fusion with Penetration into Base Sheet Metal

图7：底板金属被焊透的熔接

III.4.4 Porosity气孔

Pores are cavity type discontinuities formed by gas entrapment during solidification. Pores should not be present, but are permitted in the center of the weld at an individual or umulative size of 25% of the weld area.

气孔是在金属凝固过程中夹杂的气体残留而形成的不连续空腔。应该避免出现气孔，但是当气孔在焊点中心的单个或者累积尺寸为焊接面积的25%时是被允许的。

III.4.5 Cracks裂纹

裂纹是由于尖锐的电极帽和高的长宽比导致开口位移而形成的破裂型不连续缺陷？？。。应该避免出现

裂纹，但是当裂纹在焊点中心的单个或者累积尺寸小于焊接面积的20%时是被允许的。

III.4.6 夹杂

Cracks are fracture type discontinuities characterized by a sharp tip and high ratio of length and width to opening displacement. Cracks should not be present, but are permitted in the center of the weld at an individual or cumulative size of 20% of the weld width.

夹杂是如杂质混在焊点中的外来固体物质。夹杂是不应该出现的，但是当夹杂在焊点中心的单个或者累积尺寸为焊接面积的20%时是被允许的。

Figure 8: Fusion with Imperfections 图8：非理想的熔接

NOTE: The relevant Body and Manufacturing Engineering departments shall be consulted if these imperfections occur off the center of the weld and/or if more than one discrepancy occurs in a single weld.

注意：当这种非理想的熔接发生在远离中心的区域并且/或者在一个焊点中有多种缺陷出现时，需咨询车身和制造相关工程部门。

III.4.7 Hardness硬度

Hardness testing shall be performed in accordance with ISO 14271 on weld section cuts to determine the Vickers hardness (low-load range, HV 1) of the weld, the heat-affected zone and the parent sheet metal

硬度测试应该参照ISO 14271标准在焊点的剖切面上进行，以确定焊点和热影响区以及母材金属的维氏硬度（低负荷范围，HV1）。

Initial Parent Sheet Metal Hardness [HV 1] 初始母材硬度（HV1） Hardness In Weld [HV 1] 焊点中的硬度（HV1） <120 >120…<200 >200…<300 >300 <350 <450 <550 <600 Table III.4.7: Hardness Increase Limits 表III.4.7 硬度增长极限

hardness based on the initial parent sheet metal hardness.The material used and the welding techniques employed shall be such that the hardness of the weld and the heat-affected zone do not exceed the limits listed in Table II.4.7. 表III.4.7列出了在基于初始母材金属硬度容许的硬度增长。采用的材料和焊接技术需要能够使焊点和热影响区的硬度不超过表III.4.7所列出的极限。

NOTE: Consult the relevant Body and Manufacturing Engineering departments in case these limits cannot be met.

提示：当无法满足以上硬度上限时需咨询相关的车身工程部门和制造工程部门。

III.5 Destructive, Non-Destructive, and Functional Testing 破坏性测试，非破坏性测试以及功能测试 III.5.1 Introduction 简介

Weld strength tests are performed as PV- and IP-tests to ensure that the projection weld joint meets the individual performance requirements in terms of static and dynamic loads.

For destructive tests, the acceptance criteria are based on the theory that the application of the weld process shall not weaken the integrity of the joint in any way. For steel with tensile strength ≥

600 MPa and/or high material

gauges relative to the fastener size, a fracture during a test can occur. Fractures in welds shall show evidence of good metal fusion, i.e. the interfacial fracture face is crystalline, with possible distortion of the parent metal around the weld.

For non-destructive tests, the load or torque applied shall indicate the fastener is fused to the base sheet metal without partial or complete separation of the joint.

焊接强度测试在PV测试和IP测试是用于保证凸焊接头能够在静态载荷和动态载荷下满足特殊的性能需求。

对于破坏性测试，其验收准则是基于任何情况下焊接过程的应用都不能减弱接头的完整性理论。对于抗

拉强度≥600MPa并且/或者相对于紧固件尺寸有更大材料尺寸的钢，在测试过程中会产生破裂。焊点中的裂

缝能够表明良好的金属熔接，也就是说界面的断裂面是结晶的，伴随着焊点周围母材金属可能产生扭曲变形。

对于非破坏性测试，载荷或者扭矩必须不使紧固件和底板金属熔接接头发生部分或者全部的分离。

III.5.2 Pull Through (Destructive 拉入测试（破坏性）

This test consists of tearing the fastener completely off the sheet by pulling the fastener using a machine

specifically set up for this purpose. The test specimen is loaded gradually and continuously until separation occurs. The load to separate should exceed the proof value for specified fastener.

这种测试是通过使用专用的机器来拉动紧固件使其从底板上完全的撕裂下来。在测试试样上施加逐渐的连续的载荷直到发生脱落。发生脱落的载荷需要超过规定紧固件的校验值。

III.5.3 Push-Out / Pull-Out Test (Destructive) 推出测试和拉出测试（破坏性）

This test consists of tearing the fastener completely off the sheet by pushing or pulling the fastener using a machine specifically set up for this purpose. The push-out test device shall be shaped as a tool with a pin for each nut size and a flat tool to press on the threaded-in screw head. Examples are shown in Figures 9 and 10. The test specimen is loaded gradually and continuously until separation occurs.

• Fasteners with ≥ 3 weld projections – no more than one discrepant projection is allowed. • Continuous ring projection fasteners – at least 70 % of total ring shall be fully welded.

这种测试是通过使用专用的机器来推出或者拉出紧固件使其从底板上完全的撕裂下来。推出测试装置需要做成带有根据每个螺母尺寸而定的销子的工具并且带挤压螺纹旋入式螺钉头的扁平式工具。例子参见图9和图10。对测试试样施加逐渐的连续载荷直到发生脱落。  

设计时需要与压机保持一致 对于凸点数≥3的紧固件，允许最多1个凸点不符合要求； 对于环状焊脚的紧固件，连续的环形焊接区域至少为70%

螺母尺寸 M6 M8 M10 M12 M14 M16 a（mm） 4.5 6.5 8.0 9.5 11.0 12.5 b（mm） 8 10 11 12 14 18 Figure 9: Example of Nut Push-Out Tool Table III.5.3: Relationship Between Size of Push-Out Tool and Nut Size

图9：螺母顶出工具示例 表 III.5.3:顶出装置和螺母尺寸之间的对应关系

Example of Counterhold to Pressing Tool

• For HP nuts M6 and M8 and unthreaded ground nuts UTG M6 and UTG M8, the inner diameter of the counterhold is 24 mm.

• For HP nuts M10 and M12, the inner diameter of the counterhold is 30 mm.

• For subframe nuts M12, M14 and M16, the inner diameter of the counterhold is 50 mm.

挤压工具的支撑台面的示例

  

对于M6和M8的HP螺母以及无螺纹的UTG M6和UTG M8螺母，支撑台面的内径为24mm 对于M10和M12的HP型螺母，支撑台面的内径为30mm

对于M12,M14和M16的subframe螺母，支撑台面的内径为50mm

Figure 10: Example of Counterhold to a Pressing Tool

图10：挤压工具的支撑台面的示例

III.5.4 Torque Test 扭矩测试

The strength of a projection weld joint can be tested with torque applied to the nut or bolt. A torque wrench that contacts the fastener shall be tailored to suit the fastener geometry. The torque wrench shall be included in the tool control plan.

通过扭矩测试而得出螺母和螺栓凸焊接头强度。需要使用特制的接触紧固件的扭力扳手来适应紧固件的几何形状。扭力扳手需要包含在工具的控制计划中。

III.5.4.1 Torque Test (Destructive)扭矩测试（破坏性）

Destructive torque tests are performed to verify the integrity of the joint. When a destructive torque test is performed, the torque shall be applied gradually and continuously until separation occurs. No partial or complete separation of the welded joint shall occur before the minimum destructive torque value listed in Table III.5.4.1 is exceeded. After separation, the joint shall be inspected visually to check compliance with the discrepancy limits listed below. See III.5.1 for the permissibility of a fracture in the weld. The relevant Body and Manufacturing departments shall be contacted if the applied torque results in excessive deformation of the base sheet metal. In this case, the push out test shall be the preferred test method.

• Fasteners with ≥ 3 weld projections – no more than one discrepant projection is allowed. • Continuous ring projection fasteners – at least 70 % of total ring shall be fully welded.

进行破坏性扭矩测试是来检验接头完整性。当进行破坏性扭矩测试时，施加逐渐的连续的载荷直到发生脱落。焊接接头不能在未达到表III.5.4.1列出的最小破坏性扭力值之前发生部分或者全部脱落。发生脱落之后，焊接接头需要通过外观检查来核对其是否符合以下列出的差异极限。参考 III.5.1 中的焊点裂纹允许

值。如果使用扭力而导致底板金属变形过大，那么相关的车身工程部和制造工程部就需要进行接触讨论。这种情况下，最好采用推出测试的方法。  

对于凸点数≥3的紧固件，允许不超过1个不符合要求的凸点； 对于环状焊脚的紧固件，连续的环形焊接区域至少为70%。

破坏性测试—最小检测扭力值（Nm） 螺纹尺寸 方形1)和六边形螺母 3-4个凸点的焊脚； 连续性环形焊脚； M6 M8 M10 7/16-20 UNF M12 M14 M16 20 40 70 70 130 200 200 7.5 16 33 33 13 33 70 70 焊接螺栓 等级4.8 1) 焊接螺栓 等级8.8 1)可以在现行的设计中找到，但是在新的模型中没有应用 Table III.5.4.1: Minimum Torque Values for Destructive Testing 表III.5.4.1:破坏性测试的最小扭矩值

III.5.4.2 Torque Test (Non-Destructive) 扭矩测试（非破坏性）

Non-Destructive torque test are performed to verify that the fastener can robustly withstand the assembly torques used in production. When a non-destructive torque test is performed, the torque shall be applied gradually and continuously to the minimum torque value shown in Table III.5.4.2. The tests shall verify no partial or complete separation of the welded joint and no cracks occur before the minimum non-destructive torque value is exceeded. The maximum torque shall not exceed 110% of the torque defined in Table III.5.4.2 and be limited to preclude the risk of permanent deformation of the fastener or the base material.

The relevant Body and Manufacturing departments shall be contacted, in case that the applied torque results in deformation of the base sheet metal.

进行非破坏性扭矩测试是用来检验紧固件是否能够稳固的抵抗用在产品上的装配扭矩。当进行破坏性扭矩测试时，需要施加逐渐的连续的载荷直到达到表III.5.4.2中的最小扭矩值。测试要核实焊接接头在未达到最小非破坏性扭力值之前没有发生部分或者全部脱落。最大扭力值不能超过表III.5.4.2中规定扭矩值的110%并且需要限制在能够消除紧固件或者母材存在残余变形风险的扭矩值范围内。

当所加的扭矩导致底板金属的变形，相关的车身工程部和制造工程部需要进行接触讨论。 Note: The minimum and maximum torque values shall be documented in the control plan.

提示：最小和最大的扭矩值应规定在控制计划中 非破坏性测试—最小检测扭力值（Nm） 螺纹尺寸 正方形1)和六角螺母 3-4个凸点的焊脚； M6 M8 M10 7/16-20 UNF M12 11.5 28 55 55 92 焊接螺栓 等级4.8 1) 6 12 27 27 焊接螺栓 等级8.8 11.5 28 55 55 M14 M16 153 230 1)可以在如今的设计中找到，但是在新的模型中没有应用 Table III.5.4.2: Minimum Torque Values for Non-Destructive Testing 表III.5.4.2:破坏性测试的最小扭矩值

NOTE: For hexagon and round body weld nuts, the torque shall be applied to the body. Alternatively, if this is not possible, it can be applied to a screw mounted in the nut (see Figure 11). The screw shall have a head that fully overlaps the weld nut.提示：对于六角状焊接螺母和圆形焊接螺母，扭矩应该应用在螺母本体上；如果上述方法不可行，可以将扭矩加在安装于螺母里的螺钉上（见图11）。螺钉头应该能和螺母完全的配合。 图11装配工具的示例

The non-destructive torque test is less suitable for weld nuts and bolts with a continuous ring projection. In this case, destructive testing is mandatory.

Non-destructive testing shall always be supplemented with destructive testing when changing electrodes as well as in connection with new installations and audits. 非破坏性扭矩测试更不适用于连续性环形焊脚的焊接螺母和螺栓。因此，只能强制使用破坏性测试。 当改换新电极而且与新设备和新审核方法相关时，非破坏性测试就需要经常进行破坏性测试来补充。

Figure 11: Example of Assembly Too

III.5.5 Hammer/Chisel Test 敲打/凿击试验

The strength of a projection weld joint can be tested with an impact force applied to the fastener. A hammer or chisel is used to tap the fastener to ensure it is fused to the base material.

凸焊接头强度可以通过加在紧固件上的冲击力来测试。用锤子或者凿子轻击紧固件来验证它和母材的熔接。

III.5.5.1 Hammer/Chisel Test (Destructive) 敲打/凿击试验（破坏性）

When the hammer/chisel test is performed as a destructive test, the impact is applied until the fastener separates from the base sheet metal. Fracture of the specimen is acceptable in the base metal, HAZ, or fastener. Fracture in the weld is not acceptable. See Section III.5.1 for permissibility of fractures.

当使用敲打/凿击试验作为破坏性测试时，冲击力的加载一直要持续到紧固件从底板金属上脱离。在母材，热影响区和紧固件中的试样裂纹是可以接受的。但是焊点中的裂纹是不可接受的。参见III.5.1章节的裂纹允许值。

III.5.5.2 Hammer/Chisel Test (Non-Destructive) 敲打/凿击试验（非破坏性）

When the hammer/chisel test is performed as a non-destructive test, the impact is applied to the fastener in a way that precludes the risk of permanent deformation of the fastener or the base material. No partial or complete separation of the welded joint is permitted.

当使用敲打/凿击试验作为非破坏性测试时，加在紧固件上的冲击力在某种程度上消除了母材或者紧固件上产生残余变形的风险。不允许焊接接头发生部分或者全部的脱离。

III.5.6 Thread Test 螺纹测试

Functional tests on threaded nuts shall be performed with thread gages. An example of one is shown in Figure 12. The gage would be applied through the sheet panel and all the way to the top of the nut. The test shall be applied to detect spatter on the threads, damaged threads due to overheating, and bad top thread due to damaged electrode. 带螺纹螺母的功能性测试需要用螺纹规来执行。图12是其中的一个示例。螺纹规的使用需要穿过板材并且最终要到达螺母的顶部。测试是用来检测螺纹上的飞溅物，过热引起的螺纹损坏以及由于变形电极产生的不好的螺纹端部等。

图12 螺纹规图示

III.5.7 Leakage Test 密封性测试

Functional leakage test shall be performed in accordance with VCS 5911,79 or locally-approved procedure. 功能性密封试验需要依照VCS 5911,79标准或者局部认证程序进行。

III.5.8 Durability / Fatigue Test 耐久性/疲劳试验

Full vehicle durability testing according to CETP 00.00-R310 (PASCAR test) shall be performed on a test vehicle equipped with the relevant welded joints. These joints shall be welded to meet all requirements of this specification. No fatigue cracks in the welded seam and no lack of compliance to full vehicle PASCAR Phase 1 and completion of half of PASCAR Phase 2 - testing.

相关焊接接头的测试需要在依据CETP 00.00-R310 (PASCAR 测试)的整车耐久性测试上进行。这些接头需要在焊后满足本规范的要求。焊缝中不允许存在疲劳裂纹，并且充分服从全车的第一阶段PASCAR测试和半程的第二阶段PASCAR测试。

III.6 Permissible Repair Methods 允许的修理方法

If possible, repair is done by projection welding a new weld nut or weld bolt. Alternatively, gas metal arc welding

(GMA-W) can be used if approved by the responsible Design Engineering department. Two fillet welds are required, each 25% of the circumference of nut or bolt outer diameter and located on opposite sides of the fastener. The wire use shall conform to ESB-M4A170 (AWS A5.18M Grade ER70S-3 or -6) welding wire for North America or WSS-M4A182-A for Europe.

如果可能，可以利用焊接一个新的螺母或者螺栓来进行修理。另一种做法就是：如果负责设计工程的部门批准，可以使用金属极惰性气体保护电弧焊（GMA-W）来修理。需要两条焊缝，每条焊缝等于螺母或者螺栓外径周长的25%以及位于圆周上处于相对位置。对于北美福特，参考ESB-M4A170 (AWS A5.18M 等级为ER70S-3或者-6)焊丝标准，对于欧洲福特焊丝的选用参考WSS-M4A182-A标准。

NOTE: Leak tight applications may require special repair considerations that need to be agreed upon by Body and Manufacturing Engineering departments.

提示：当密封处需要返修时，需要车身和制造工程部门就特殊返修方法达成一致。 IV. REVALIDATION REQUIREMENTS 需求的重新生效

Validation (PV) tests as agreed upon by the relevant Body and Manufacturing Engineering Departments. ●Process Change - Any change in the process which could alter its capability to meet the design requirements or durability of the product. This includes:

〇 New, different, relocated, or rehabilitated production machinery or equipment

〇 Any change in subcontracted products or services including the use of engineering-approved alternate materials 〇 Changes to rework methods

〇 Changes in the sequence of operations

〇 Changes in chemical compounds such as lubricants, which are part of the product

● Engineering Change - Any change in the part(s) initiated by Ford Motor Company.

● Material and Coating Change - Any change in the material or coating, when optional materials or coatings are specified. This includes:

〇 A switch from mild steel to high strength steel with a yield strength > 260 MPa

〇 A change in steel supplier for steels having a yield strength equal to or exceeding 310 MPa (representing DP600)

in the \"as received condition\"

● Sub-Supplier Change - Any change in the source of subcontracted components.

● Adopting Optional Design - Any change where the supplier incorporates optional designs specified on the released engineering drawing or relevant CAD model.

以下任何影响凸焊操作的条件需要按照车身和制造工程部的要求重新做生产验证（PV）测试： 

过程改变：过程中任何改变满足产品设计要求或者耐久性要求的能力的因素。包括：

○ 新的，不同的，重新定位的，或者修复过的产品机器和装备。

○ 任何工程许可的替换产品的产品转包或者服务的改变，包括允许的替代材料的使用。 ○ 返工方法的改变。 ○ 操作顺序的改变。

○ 产品某部分化合物如润滑剂的改变。

 

工程变更：任何在由福特公司引导的零件变更。

材料和镀层的改变：当可选择的材料和镀层规定后，任何材料或者镀层的改变。包括： 〇从低碳钢切换为屈服硬度＞260MPa的高强度钢；

〇对于接收条件为屈服强度≥310MPa（表示为DP600）钢的钢材供应商发生改变；  

NOTE: See QS-9000, Control of Subcontracted Suppliers; Retention of Inspection and Test Samples; Notification of Completion of Inspection and Testing; Changes in Manufacturing Process; Change Approval

下级供应商改变：任何转包组件来源的改变。

采用备选的设计：任何采用所发布的工程图或者相关的CAD模型上规定的备选设计方案的改变。

提示：参见QS-9000中，转包供应商的控制，检验样品和测试样品的保留，检验和测试完成的通知，制造过程的改变，改变的批准。 Certain process parameters will have a great influence on the weld quality. The control plan, as defined in Ford QS 9000, is an essential part of a quality product. Some process variables to include in the control plan could be:

● Electrode force ● Weld current over time

某些工艺参数对焊接质量有很大的影响。根据福特QS9000规定的控制计划是产品质量的一个重要部分。控制计划中包含的工艺变量应该有：

● 电极压力

● 随时间变化的焊接电流

V. INSTRUCTIONS AND NOTES 说明和注意事项

Item characteristics. They describe the process potential studies that will be performed for product validation (including PV tests) and the ongoing product and process evaluation for continuing improvement (including IP tests). They include acceptance criteria, sample size, frequencies, data analysis methods and reaction plans. The control plan is developed, and updated as necessary by the manufacturing source in conjunction with the design-responsible product-engineering activity and other appropriate functions such as Supplier Technical Assistance (STA). The control plan defines the management of the upstream production process and part variables (significant process characteristics) that affect the outcome of the ES tests or other significant design characteristics. The control plan also identifies the specific ES tests, with their sample sizes and frequencies that will be performed in order to:

• Confirm whether the process is being managed effectively • Further identify significant process characteristics • Evaluate performance of marginal processes

• Better anticipate the customer effect of proposed process improvements.

控制计划填写有所有重要的设计和工艺特点，包括ES测试和控制项目的特点。控制计划描述了对产品验证（包括PV测试）和在制产品的潜在过程研究以及对连续性提高（包括IP测试）的过程评估。还包括验收准则，样品尺寸，频率，数据分析方法以及反应计划。控制计划是发展的，并且必要时要结合设计可靠产品工程的活动和其他适当功能比如供应商技术支持（STA）来更新。控制计划规定了生产过程前期的管理以及影响ES测试结果或者其他重要设计特性的产品变量（重要的过程特性）以便： ●确认过程是否处于有效的管理中； ●进一步规定了重要的过程特性； ●评估后期过程的表现；

●更好的提前获取顾客提出的对过程提升的影响。

For any part on which ES tests have been specified, the manufacturing source must present the control plan and any revisions to the design-responsible product-engineering activity for review. This Product Engineering activity has flexibility to honor business relationships with suppliers having proprietary processes.

对于任何在ES测试中规定的零件，生产的来源地必须出现在控制计划中，并且任何对审查的设计可靠的生产工程活动的修订也应出现在控制计划中。这种生产工程活动对于与拥有专门工艺并有良好商业关系的供应商是灵活的。

Examples of formats for control plans are shown in Quality System Requirements, QS-9000. Internal reference documents can also be found in procedure VOPQUG-051 (Control Plans – Vehicle Operations Procedure – Global).

控制计划的格式示例可以查看质量体系要求，内部参考文件也可以在VOPQUG-051（控制计划—车辆操作程序—全球）程序上找到。

VI. COMPILATION OF REFERENCE DOCUMENTS 参考文献

A. QS-9000, Quality System Requirements 质量体系要求，QS-9000。

B. Ford Material Specifications available at http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html,

Metals 1A-99A.

Ford材料规范，http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html,Metals 1A-99A.

C. Volvo Car Corporation Standards available at http://www.tech.volvo.se/standard/eng/stdnum.html

• VCS 8632,49 - Projection Welding of Weld Nuts

• VCS 5027,4 - Joining of Thin Sheet Metal Structures (Symbolic Representation) VCC标准，http://www.tech.volvo.se/standard/eng/stdnum.html • VCS 8632,49 – 凸焊螺母

• VCS 5027,4 – 薄板金属结构的连接 (表示符号)

D. Ford Engineering Specification - Sheet Metal Surfaces and Edges (ESF75B-11007-AA) available at

http://forddoc.secure24.ford.com/ Ford工程说明书 –金属薄片的表面和边界(ESF75B-11007-AA)http://forddoc.secure24.ford.com/

E. JoinNet Database available at http://gbwux014.gothenburg.vcc.ford.com/mtdatab/joinnet/

JoinNet 数据库，http://gbwux014.gothenburg.vcc.ford.com/mtdatab/joinnet/

F. ISO 14271:2000, Vickers hardness testing of resistance spot, projection and seam welds

ISO 14271:2000,电阻点焊，凸焊和缝焊的维氏硬度测试。

G. Vehicle Operations Operating procedure VOP QUE-612, Uniform test and Evaluation Program For Welding

and other joining Operations; available at http://www.voqoeu.ford.com 车辆操作程序VOP QUE-612, 焊接和其他连接方法的一致性测试和评估程序，http://www.voqoeu.ford.com

H. ISO 898: Mechanical properties of fasteners made of carbon steel and alloy steel. States property

requirements for threaded bolts and nuts.

ISO 898: 低碳钢和合金钢紧固件的机械性能，带螺纹的螺栓和螺母的状态性能需求。.

I. Ford Worldwide Fastener Standards available at

https://www.tc2.ford.com/ts/METS/Shared%20Documents/Standards/fastener_standards_teamconnect.htm Ford全球性紧固件标准

https://www.tc2.ford.com/ts/METS/Shared%20Documents/Standards/fastener_standards_teamconnect.htm

J. EUCD Technical Bulletins (referred to as \"Red card\") available at

http://www.rd.volvocars.ford.com/std/fast/doc/eucd_tib_046.pdf EUCD 技术公告 (被称为“红牌”)

http://www.rd.volvocars.ford.com/std/fast/doc/eucd_tib_046.pdf

K. Weld Quality Program Procedure, VOPSSN-008, available at

http://www.vo.ford.com/ss/procedures/procdfiles/ssn008c.pdf

焊接质量程序过程, VOPSSN-008, http://www.vo.ford.com/ss/procedures/procdfiles/ ssn008c.pdf