SGM焊接工艺控制流程

1. 范围

1.1 目的

本标准详细说明了SGM焊接产品生产者的焊接检查和焊接设备工艺控制要求.

1.2 应用

本标准涉及的要求适用于上海通用汽车制作或装配工厂所采用的焊接及连接工艺.

2. 参考

GM9621P

3. 流程

3.1 过程评估

3.1.1 设备过程监控

设备过程监控包括工艺参数的测量以及设备功能性运转的目视评估。有关各种焊接工艺的设备过程监控要求。

3.1.2 设备维护

每个区域都要有设备维护的书面计划。设备维护的进度表应该和制造商的建议一致。

3.2 产品控制和检查

产品控制和检查包含对焊接产品的评估，参照适用的SGM工程标准来识别、包含和返修不一致的焊接模式。所有焊接的产品控制和检查计划必须有书面流程或在标准化操作中描述。

注意：对于铝点焊，Peel测试是首选方法，Chisel 测试是不可接受的方法。1.1 Purpose

This standard defines weld inspection and welding equipment process control requirements for producers of SGM welded or mechanical clinched product.

1.2 Application

The requirements of this standard are applicable to welding and joining processes utilized by a Shanghai General Motors fabricating and/or assembly plant to join automotive parts and assemblies. 2．References

GM9621P

3. Procedure

3.1 Process Evaluation.

3.1.1 Equipment Process Monitoring

Equipment process monitoring consists of measuring the process parameters established during tool qualification as well as visual evaluation of the equipment functional operation.

3.1.2 Equipment Maintenance

Each location shall have documented plans for the maintenance of equipment. The equipment maintenance schedule should be consistent with the tool or equipment manufacturers’ recommendations 3.2 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 resistance 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 aluminum spot welds. Chisel testing is not an acceptable method of inspection for aluminum spot welds.

在每班的均匀间隔中，对所有点焊（所有类型和所有单元）推荐执行4次形变或超声波的非破坏性检查。至少对每把焊枪和每种板材匹配检查一次，每班如此执行四次。

执行形变检查的同时，目视检查指定位置的胶水，并根据适用的产品图纸和SGM工程标准来目视检查所有焊接的一致性。

3.2.2 过程中检查和其他测试

除了3.2.1以外的焊接和连接方法必须通过目视化标准加以检验，每班至少4次。

3.2.3 焊接破坏性检查–总成工厂

在系统填充的开始阶段，每种车型的整车破坏性检查频率至少为每月一次，持续到工艺能力得到论证并书面成文。工艺能力由连续三次破坏性检查达到要求来衡量。之后，每种车型的破坏性检查频率可以减少为每季度一次。

3.2.4 焊接破坏性检查–制造工厂

生产开始阶段，每个总成零件的破坏性检查频率至少为每月一次，持续到工艺能力得到论证并书面成文。工艺能力由连续三次破坏性检查达到要求来衡量。之后，每种零件总成的破坏性检查频率可以减少为每季度一次。

3.3 焊接图像分析

用来对焊接截面进行图像分析的检查、测量、试验等设备必须满足精度0.01毫米的测量标准。焊接截面使用15X或以下放大倍率来观察。

3.3.1 焊接截面

焊接截面采样所需的数目取决于指定的焊接长度，参见下表：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 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 Tests

Welds 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 Plants

At the Start of System Fill the frequency of full body destruct 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 Test – Fabricating Plants

At 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 reduced to a quarterly destruct test of each assembly.

3.3 Weld Image Analysis

Inspection, 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 American Technologies Weld Measuring System (NAMeS)™ is recommended. Weld c ross sections are to be viewed at 15X or less magnification.

3.3.1 Weld Cross Section

The 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.