Report Weld Lobe Evaluation per General Motors WS-5 Section A on 1.00 mm DQ Mild Galvanneal. Sunke

Transcription

1 32711 Glendale Avenue Livonia Michigan Ph: Fx: Report 5109 Weld Lobe Evaluation per General Motors WS-5 Section A on 1.00 mm DQ Mild Galvanneal For Sunke Mr. Zhao Ji Hua Requisitioner sunke@tjsunke.com PH: Prepared by RoMan Engineering Services Technical Staff Donald F. Maatz, Jr. Welding Engineer This report is prepared for Sunke by RoMan Engineering Services Inc. This report may not be reproduced, except in full, unless written permission is obtained from Sunke & RoMan Engineering Services Inc. February 12, 2010 Form Revision 1 Test Report Page 1 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1 Retention: 3 Years

2 32711 Glendale Avenue Livonia Michigan Ph: Fx: GENERAL MOTORS WS-5, SECTION A SPOT WELDING ACCEPTANCE CRITERIA FOR BARE AND COATED LOW AND MEDIUM STRENGTH STEELS WELD LOBE 1.00 mm DQ Mild Galvanneal JOB NUMBER: REQUESTING VENDOR: CONTACT ENGINEER: DATE: 5109 Sunke Mr. Zhao Ji Hua 27-Jan-10 WELD SCHEDULE WELD CONTROLLER: ELECTRODE TYPE: WTC C30A (AC / CC) / 70 kva-tap 1 MWZ-6006 FORCE: 480 lbs. WT: 12, 14, 16 cyc. (60hz) TECHNICIANS: R. Miller SQZ. TIME: 90 cyc. HT: 2 cyc. COMMENTS: Lobe - nominal, min and max MINIMUM DIA: 4.0 mm OFF/WAIT TIME: n/a cyc. WELD TEST #: 5109r1a 17 WELD TIME (Cycles - 60 Hz) , , mm 6.5, 12 Point Verification 7.0 ka 8.3, 16 f Expulsion 8.3, , WELD CURRENT Below is the Weld Window Range in Amps, information is based on welding spec. minimum button criteria and also the weld time used. a. Electrode Cap 4.0 Minimum : 12 cycles = 1, cycles = 1, cycles = 1,900 Page 2 of r1_dfm - Rev 1

3 32711 Glendale Avenue Livonia Michigan Ph: Fx: GENERAL MOTORS WS-5, SECTION A SPOT WELDING ACCEPTANCE CRITERIA FOR BARE AND COATED LOW AND MEDIUM STRENGTH STEELS WELD LOBE 1.00 mm DQ Mild Galvanneal JOB NUMBER: REQUESTING VENDOR: CONTACT ENGINEER: DATE: 5109 Sunke Mr. Zhao Ji Hua 02-Feb-10 WELD SCHEDULE WELD CONTROLLER: ELECTRODE TYPE: Sunke SVF1-400 (AC / CC) / 70 kva-tap 1 MWZ-6006 FORCE: 480 lbs. WT: 10, 12, 13 cyc. (50hz) TECHNICIANS: R. Miller SQZ. TIME: MINIMUM DIA: 1500 ms HT: 33 ms COMMENTS: 4.0 mm OFF/WAIT TIME: n/a cyc. WELD TEST #: Lobe - nominal, min and max 5109r1b 14 WELD TIME (Cycles - 50 Hz) , , mm 6.1, 10 Point Verification 7.0 ka 8.7, 13 f Expulsion 8.8, , WELD CURRENT Below is the Weld Window Range in Amps, information is based on welding spec. minimum button criteria and also the weld time used. a. Electrode Cap 4.0 Minimum : 10 cycles = 2, cycles = 2, cycles = 2,800 Page 3 of r1_dfm - Rev 1

4 32711 Glendale Avenue Livonia Michigan Ph: Fx: GENERAL MOTORS WS-5, SECTION A SPOT WELDING ACCEPTANCE CRITERIA FOR BARE AND COATED LOW AND MEDIUM STRENGTH STEELS WELD LOBE 1.00 mm DQ Mild Galvanneal JOB NUMBER: REQUESTING VENDOR: CONTACT ENGINEER: DATE: 5109 Sunke Mr. Zhao Ji Hua 02-Feb-10 WELD SCHEDULE WTC C30A (AC / CC) / 70 kva-tap 1 WELD CONTROLLER: Sunke SVF1-400 (AC / CC) / 70 kva-tap 1 ELECTRODE TYPE: MWZ , 14, 16 cyc. (60hz) WT: FORCE: 480 lbs. 10, 12, 13 cyc. (50hz) TECHNICIANS: R. Miller SQZ. TIME: 90 / 1500 cyc. / ms HT: 2 / 33 cyc. / ms COMMENTS: Lobe - nominal, min and max MINIMUM DIA: 4.0 mm OFF/WAIT TIME: n/a cyc. WELD TEST #: 5109r1 Weld Lobe Comparison WELD TIME (Cycles - 60 Hz) WTC Lobe Sunke Lobe WELD CURRENT WELD TIME (Cycles - 50 Hz) Page 4 of r1_dfm - Rev 1

5 PO Box 71128, Dequindre Rd. Madison Hgts., MI Ph: Fx: GENERAL MOTORS WS-5, SECTION A SPOT WELDING ACCEPTANCE CRITERIA FOR BARE AND COATED LOW AND MEDIUM STRENGTH STEELS WELD LOBE 1.00 mm DQ Mild Galvanneal JOB NUMBER: REQUESTING VENDOR: CONTACT ENGINEER: DATE: 5109 Sunke Mr. Zhao Ji Hua 27-Jan-10 WELD SCHEDULE WELD CONTROLLER: ELECTRODE TYPE: WTC C30A (AC / CC) / 70 kva-tap 1 MWZ-6006 FORCE: 480 lbs. WT: 12, 14, 16 cyc. (60hz) TECHNICIANS: SQZ. TIME: 90 cyc. HT: 2 cyc. COMMENTS: R. Miller Imprints - Lobe MINIMUM DIA: 4.0 mm. OFF/WAIT TIME: n/a cyc. WELD TEST #: 5109r1a Electrode Imprints Page 5 of r1_dfm - Rev 1

6 PO Box 71128, Dequindre Rd. Madison Hgts., MI Ph: Fx: GENERAL MOTORS WS-5, SECTION A SPOT WELDING ACCEPTANCE CRITERIA FOR BARE AND COATED LOW AND MEDIUM STRENGTH STEELS WELD ENDURANCE 1.00 mm DQ Mild Galvanneal JOB NUMBER: REQUESTING VENDOR: CONTACT ENGINEER: DATE: 5109 Sunke Mr. Zhao Ji Hua 02-Feb-10 WELD SCHEDULE WELD CONTROLLER: ELECTRODE TYPE: Sunke SVF1-400 (AC / CC) / 70 kva-tap 1 MWZ-6006 FORCE: 480 lbs. WT: 10, 12, 13 cyc. (50hz) TECHNICIANS: R. Miller SQZ. TIME: 1500 ms HT: 33 ms COMMENTS: Imprints - Lobe MINIMUM DIA: 4.0 mm. OFF/WAIT TIME: n/a cyc. WELD TEST #: 5109r1b Electrode Imprints Page 6 of r1_dfm - Rev 1

7 Test : 5109r1a - Weld Lobe Test Date: 27-Jan-10 Test Type: Weld Lobe Job No.: 5109 Material Type: 1.00 mm DQ Mild Galvanneal Company: Sunke Welding Machine: WTC C30A (AC / CC) / 70 kva-tap 1 Contact: Mr. Zhao Ji Hua Welding Parameters Electrode Type: MWZ-6006 Welding Rate: n/a Weld Lobe Electrode Body Dia.: 16.0 mm. Electrode Coolant Flow: 2.0 lpm/cap Electrode Face Dia.: 4.8 mm. Material Thickness: mm All Weld s are Round s (RB) Force: 480 lbs. SWS: n/a mm or Oval s (OB) unless otherwise noted Squeeze Time: 90 cyc. MWS: 4.0 mm Total Weld Time: 12, 14, 16 cyc. (60 Hz) Tap : 1 Cool Time: n/a cyc. Hold Time: 2 cyc. Meter: Miyachi SO20931 Wait/Off Time: n/a cyc. Force Gauge: Sensor Development (Amps) S1 S N n/m N n/m DEVELOP BUTTON BUTTON > MWS S2 S N n/m -200A N WELDS CONDITIONING BEGIN 16~ 1 S N n/m CHANGED TO 16 CYCLES WELD TIME N n/m L -500A 3 S N n/m N n/m L +100A 5 S N n/m N n/m L +100A 7 S N n/m N n/m L +100A 9 S N n/m N n/m L +100A 5109r1a - Lobe WTC 7 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

8 (Amps) 11 S N n/m N n/m L MWS ACHIEVED X1 13 S N N R MWS ACHIEVED X2 15 S N N C MWS NOT ACHIEVED +100A 17 S N N L MWS ACHIEVED X1 19 S N N R MWS ACHIEVED X2 21 S N N C IMIN ACHIEVED X3 6.4 ka for 16~ WELD TIME 23 S N N/M N/M N/M 59.6 IMIN 16~ MET SAMPLE N N/M N/M N/M 59.6 L CHANGE TO 14 CYCLES WELD TIME BEGIN 14 CYCLES WELD TIME 25 S N N L MWS ACHIEVED X1 27 S N N R MWS ACHIEVED X2 29 S N N C IMIN ACHIEVED X3 6.4 ka for 14~ WELD TIME 31 S N N/M N/M N/M 59.7 IMIN 14~ MET SAMPLE N N/M N/M N/M 59.7 L CHANGE TO 12 CYCLES WELD TIME BEGIN 12 CYCLES WELD TIME 33 S N N L MWS ACHIEVED X1 35 S N N R MWS ACHIEVED X2 5109r1a - Lobe WTC 8 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

9 (Amps) 37 S N N C MWS NOT ACHIEVED +100A 39 S N N L MWS ACHIEVED X1 41 S N N R MWS ACHIEVED X2 43 S N N C IMIN ACHIEVED X3 6.5 ka for 12~ WELD TIME 45 S N N/M N/M N/M 59.7 IMIN 12~ MET SAMPLE N N/M N/M N/M 59.7 L CHANGE TO 16 CYCLES WELD TIME BEGIN 16 CYCLES WELD TIME 47 S N N/M N/M N/M N N/M N/M N/M 60.6 L 49 S N N/M N/M N/M N N/M N/M N/M 60.9 L 51 S N N/M N/M N/M N N/M N/M N/M 61.3 L 53 S N N/M N/M N/M N N/M N/M N/M 65.4 L 55 S E N/M N/M N/M N N/M N/M N/M 66.3 L 57 S E N/M N/M N/M N N/M N/M N/M 67.2 L 59 S E N/M N/M N/M N N/M N/M N/M 70.4 L 61 S E N L LARGEST 16~ PEEL SAMPLE 5109r1a - Lobe WTC 9 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

10 (Amps) 63 S E N/M N/M N/M E N/M N/M N/M 71.3 L IMAX ACHIEVED 8.3 ka FOR 16~ WELD TIME 65 S E N/M N/M N/M 72.6 IMAX 16~ MET SAMPLE E N/M N/M N/M 72.8 L CHANGE TO 14 CYCLES WELD TIME BEGIN 14 CYCLES WELD TIME 67 S E E L IMAX ACHIEVED 8.3 ka FOR 14~ WELD TIME 69 S E N/M N/M N/M 73.4 IMAX 14~ MET SAMPLE E N/M N/M N/M 73.4 L CHANGE TO 12 CYCLES WELD TIME BEGIN 12 CYCLES WELD TIME 71 S E E L IMAX ACHIEVED 8.3 ka FOR 12~ WELD TIME 73 S E N/M N/M N/M 73.7 IMAX 12~ MET SAMPLE E N/M N/M N/M 73.8 L END OF LOBE 5109r1a - Lobe WTC 10 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

11 Test : 5109r1b - Weld Lobe Test Date: 02-Feb-10 Test Type: Weld Lobe Job No.: 5109 Material Type: 1.00 mm DQ Mild Galvanneal Company: Sunke Welding Machine: Sunke SVF1-400 (AC / CC) / 70 kva-tap 1 Contact: Mr. Zhao Ji Hua Welding Parameters Electrode Type: MWZ-6006 Welding Rate: n/a Weld Lobe Electrode Body Dia.: 16.0 mm. Electrode Coolant Flow: 2.0 lpm/cap Electrode Face Dia.: 4.8 mm. Material Thickness: mm All Weld s are Round s (RB) Force: 480 lbs. SWS: n/a mm or Oval s (OB) unless otherwise noted Squeeze Time: 1500 ms MWS: 4.0 mm Total Weld Time: 10, 12, 13 cyc. (50 Hz) Tap : 1 Cool Time: n/a cyc. Hold Time: 33 ms Meter: Miyachi SO20931 Wait/Off Time: n/a cyc. Force Gauge: Sensor Development (Amps - One leg) S1 S N 18.4 DEVELOP BUTTON N MODE 8 S2 S N N MODE 7 S3 S N N CONDITIONING WELDS SET TO LONG W. T CYC/50Hz 1 S N 16.6 BEGIN 13 CYCLES/50 Hz N L +100 A 3 S N N L +100 A 5 S N N L MWS ACHIEVED X1 7 S N N R MWS NOT ACHIEVED +100 A 5109r1b - Lobe Sunke 11 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

12 (Amps - One leg) 9 S N N L MWS ACHIEVED X1 11 S N N R MWS ACHIEVED X2 13 S N N C IMIN ACHIEVED X3 5.9 ka for 13~ WELD TIME 15 S N N/M N/M N/M 19.2 IMIN 16~ MET SAMPLE N N/M N/M N/M 22.6 L CHANGE TO 12 CYC/50Hz WELD TIME BEGIN 12 CYC/50Hz WELD TIME 17 S N N L MWS ACHIEVED X1 19 S N N R MWS ACHIEVED X2 21 S N N C IMIN ACHIEVED X3 5.9 ka for 12~ WELD TIME 23 S N N/M N/M N/M 24.7 IMIN 12~ MET SAMPLE N N/M N/M N/M 24.5 L CHANGE TO 10 CYC/50Hz WELD TIME BEGIN 10 CYC/50Hz WELD TIME 25 S N N L MWS NOT ACHIEVED +100 A 27 S N N L MWS NOT ACHIEVED +100 A 29 S N N L MWS ACHIEVED X1 31 S N N R MWS ACHIEVED X2 33 S N N C IMIN ACHIEVED X3 6.1 ka for 10~ WELD TIME 5109r1b - Lobe Sunke 12 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

13 (Amps - One leg) 35 S N N/M N/M N/M 22.6 IMIN 10~ MET SAMPLE N N/M N/M N/M 23.6 L CHANGE TO 13 CYC/50Hz WELD TIME BEGIN 13 CYC/50Hz WELD TIME 37 S N N/M N/M N/M N N/M N/M N/M 26.0 L 39 S N N/M N/M N/M N N/M N/M N/M 25.8 L 41 S N N/M N/M N/M N N/M N/M N/M 30.1 L 43 S N N/M N/M N/M N N/M N/M N/M 28.7 L 45 S N N/M N/M N/M N N/M N/M N/M 28.2 L 47 S N N/M N/M N/M N N/M N/M N/M 32.7 L 49 S N N/M N/M N/M N N/M N/M N/M 25.6 L 51 S N N/M N/M N/M N N/M N/M N/M 29.5 L 53 S N N/M N/M N/M N N/M N/M N/M 29.9 L 55 S N N/M N/M N/M N N/M N/M N/M 37.0 L 57 S N N/M N/M N/M N N/M N/M N/M 36.9 L 59 S N N/M N/M N/M N N/M N/M N/M 30.8 L 5109r1b - Lobe Sunke 13 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

14 (Amps - One leg) 61 S E N/M N/M N/M N N/M N/M N/M 40.0 L 63 S E N/M N/M N/M N N/M N/M N/M 37.0 L 65 S E N/M N/M N/M N N/M N/M N/M 40.3 L 67 S E N/M N/M N/M N N/M N/M N/M 47.7 L 69 S E N L LARGEST 13~ PEEL SAMPLE 71 S E N/M N/M N/M E N/M N/M N/M 28.7 L IMAX ACHIEVED 8.7 ka FOR 13~ WELD TIME 73 S E N/M N/M N/M 41.9 IMAX 13~ MET SAMPLE E N/M N/M N/M 28.8 L CHANGE TO 12 CYC/50Hz W.T. BEGIN 12 CYC/50Hz W.T. 75 S E N L LARGEST 12~ PEEL SAMPLE 77 S E N/M N/M N/M E N/M N/M N/M 38.9 L IMAX ACHIEVED 8.8 ka FOR 12~ WELD TIME 79 S E N/M N/M N/M 38.7 IMAX 12~ MET SAMPLE E N/M N/M N/M 44.1 L CHANGE TO 10 CYC/50Hz W.T. BEGIN 10 CYC/50Hz W.T. 81 S E E L IMAX ACHIEVED 8.8 ka FOR 10~ WELD TIME 83 S E N/M N/M N/M 12.7 IMAX 10~ MET SAMPLE E N/M N/M N/M 42.3 L END OF LOBE 5109r1b - Lobe Sunke 14 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

15 Test : 5109r1a - Weld Point Verification Test Date: 05-Feb-10 Test Type: Weld Point Verification Job No.: 5109 Material Type: 1.00 mm DQ Mild Galvanneal Company: Sunke Welding Machine: WTC C30A (AC / CC) / 70 kva-tap 1 Contact: Mr. Zhao Ji Hua Welding Parameters Electrode Type: MWZ-6006 Welding Rate: n/a Electrode Body Dia.: 16.0 mm. Electrode Coolant Flow: 2.0 lpm/cap Electrode Face Dia.: 4.8 mm. Material Thickness: mm All Weld s are Round s (RB) Force: 480 lbs. SWS: n/a mm or Oval s (OB) unless otherwise noted Squeeze Time: 90 cyc. MWS: 4.0 mm Total Weld Time: 14 cyc. (60 Hz) Tap : 1 Cool Time: n/a cyc. Hold Time: 2 cyc. Meter: Miyachi SO20931 Wait/Off Time: n/a cyc. Force Gauge: Sensor Development (Amps) 1 S N PEEL SHUNT WELD ON 1ST COUPON N S N N S N N S N N S N N S N N S N N r1a - Point WTC 15 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

16 (Amps) 15 S N N S N N S N PEEL SHUNT WELD ON LAST COUPON N END OF POINT VERIFICATION 5109r1a - Point WTC 16 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

17 Test : 5109r1b - Weld Point Verification Test Date: 04-Feb-10 Test Type: Weld Point Verification Job No.: 5109 Material Type: 1.00 mm DQ Mild Galvanneal Company: Sunke Welding Machine: Sunke SVF1-400 (AC / CC) / 70 kva-tap 1 Contact: Mr. Zhao Ji Hua Welding Parameters Electrode Type: MWZ-6006 Welding Rate: n/a Electrode Body Dia.: 16.0 mm. Electrode Coolant Flow: 2.0 lpm/cap Electrode Face Dia.: 4.8 mm. Material Thickness: mm All Weld s are Round s (RB) Force: 480 lbs. SWS: n/a mm or Oval s (OB) unless otherwise noted Squeeze Time: 1500 ms MWS: 4.0 mm Total Weld Time: 12 cyc. (50 Hz) Tap : 1 Cool Time: n/a cyc. Hold Time: 33 ms Meter: Miyachi SO20931 Wait/Off Time: n/a cyc. Force Gauge: Sensor Development (Amps - One leg) 1 S N N/M N/M N/M N N/M N/M N/M S E N/M N/M N/M 36.3 EXPULSION - RESTART TEST WITH N/M N/M N/M N/M N/M N/M LOWERED SECONDARY CURRENT -300 Amps (MEASURED) 5 S N PEEL SHUNT WELD ON 1ST COUPON N S N N S N N S N N S N N r1b - Point Sunke 17 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1

18 (Amps - One leg) 15 S N N S N N S N N S N N S N PEEL SHUNT WELD ON LAST COUPON N END OF POINT VERIFICATION 5109r1b - Point Sunke 18 of 18 K:\REPORTS'10\Intermax\ Timer\5109r1_dfm - Rev 1