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PRC-0009 Rev.

D
Process Specification for the Resistance Spot
Welding of Battery and Electronic Assemblies
Engineering Directorate
Structural Engineering Division
February 2!
National Aeronautics and
Space Administration
"yndon B# $ohnson Space %enter
Houston, Texas
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PRC-0009 Rev. D
Process Specification for the Resistance Spot
Welding of Battery and Electronic Assemblies
Prepared by ' Signature on File 2/17/04
Daniel #. R$%ic&i
'aterials and Processes
Tec(nolo$ )ranc(*+S,
Date
Approved by' Signature on File 2/17/04
#ose- '. Hernande.
'aterials and Processes
Tec(nolo$ )ranc(*+S,
Date
R+/0S01NS
/+RS01N CHAN2+S DAT+
-- 1riinal version April !993
A +xpanded content t(rou(out. Re-speci"$ 4uali"ication
re4uirements.
!0*59*96
) 7ormattin c(aned process o8ner, re8rite numerous
sections "or clari"ication, deleted re4uirement "or 90R,
deleted section :.5 on audits, added section :.; on
91P<.
06*55*99
C Add tolerance rane to %ase material component
t(ic&ness=es>, remove re4uirement "or certi"ication o"
8eldin inspectors %$ t(e A9S, remove NASA*'S7C
re"erence documents in ,.0, add item 5! to Ta%le !,
revise 3.!, 6.0, 6.!, 6.;, :.!, :.5, and :.;.
0;*5,*5000
D Routine 0S1 revie8. 05*!6*500,
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PRC-0009 Rev. D
(# S%)PE
T(is process speci"ication provides t(e re4uirements t(at overn t(e Resistance Spot
9eldin =RS9> o" %atter$ ta%s and component 8ires*leads to %atteries, %atter$ ta%s, or
ot(er associated electronic components. Procedural and 4ualit$ assurance
re4uirements are iven. All 8or& instructions and 9eld Procedure Speci"ications
=9PSs> used durin 8eldin s(all satis"$ t(e re4uirements o" t(is process speci"ication
and it-s applica%le documents.
2# APP"*%AB*"*+,
T(is process speci"ication applies to t(e RS9 o" %atter$ assem%lies and associated
electronic "li(t and non "li(t (ard8are "a%ricated under t(e control o" t(e
NASA*#o(nson Space Center =#SC>. RS9 8it( opposed electrodes =i.e., re"erred to
(erein as ?opposed 8eldin@> is considered as 8ell as RS9 8it( apped electrodes
=i.e., re"erred to (erein as ?series 8eldin@>. )atter$ assem%lies are considered to %e
non structural 8it( no load carr$in capacit$ and s(all %e eit(er potted, taped, s(rin&
8rapped, or installed in a riid containment to preclude stressin t(e ta%s and lead
8ires.
-# .SA/E
T(is process speci"ication s(all %e called out on t(e enineerin dra8in %$ a dra8in
note 8it( t(e "ollo8in eneral "ormat A
WE"D A0D *0SPE%+ PER 0ASA1$S% PR%23
-#( DES*/0 RE4.*RE5E0+S
a> T(e desin o" 8elded Boints s(all con"orm to t(e applica%le (ard8are desin
(and%oo&s contained in t(e +nineerin Standards Ci%rar$.
%> All enineerin dra8ins s(all depict 8elded Boints usin t(e applica%le s$m%ols
descri%ed in A9S A5.,.
c> As re4uired, all enineerin dra8ins s(all speci"$ t(e minimum num%er and
maximum num%er o" resistance 8elded spots re4uired "or eac( connection. 0n
an$ case, t(ere s(all %e no less t(an t8o 8eld spots per connection.
Connections 8(ic( 8ill accommodate onl$ one spot s(all %e avoided 8(ere
possi%le.
d> As applica%le, all enineerin dra8ins s(all speci"$ t(e maximum electrical
resistivit$ allo8ed "or eac( connection. 9(ere resistivit$ is not speci"ied,
measurements s(all not exceed !.0 m.
e> 9(en 8eldin occurs onto %atter$ cells, t(e parts list s(all contain t(e %atter$
manu"acturer, si.e, model*t$pe no., and voltae ratin.
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PRC-0009 Rev. D
"> T(e parts list s(all contain t(e ta% or contact material, speci"ication, t(ic&ness,
8idt(, metallurical condition =e.., D (ard, E (ard, etc.> and sur"ace "inis( as
applica%le.
> T(e parts list s(all contain component leads =i.e., diode leads> ae, material, and
metallurical condition =e.., metallurical, sur"ace "inis(, etc.> and sur"ace "inis(
as applica%le.
(> Stranded 8ire s(all not %e resistance spot 8elded.
-#2 W)R6 *0S+R.%+*)0S
9or& instructions s(all %e enerated "or implementin t(is process speci"ication. T(e
8or& instructions s(all contain su""icient detail to ensure t(at t(e manu"acturin process
produces consistent, repeata%le products t(at compl$ 8it( t(is speci"ication. At #SC,
t(ese 8or& instructions are approved as Detailed Process 0nstructions =DP0s> t(at
descri%e in a detailed, step-%$-step "ormat t(e re4uired procedures, e4uipment, and
materials to %e used "or conductin a iven process.
0" t(is manu"acturin process is to %e per"ormed %$ an outside vendor, 8or& instruction
development s(all %e t(e responsi%ilit$ o" t(e vendor. T(e contractor s(all ensure t(at
t(e 8or& instructions meet t(e re4uirements o" t(is process speci"ication.

-#- DEF*0*+*)0S
Essential &ariable F An identi"ied varia%le in t(e 8eldin process t(at must %e
controlled to ensure repeata%le 8eld 4ualit$.
)pposed Welding - RS9 8(ic( utili.es t8o electrodes positioned exactl$ opposite,
and in line 8it( eac( ot(er =electrodes s(are a common axis>. See 7iure 5. +ac(
electrode contacts a sinle piece o" %ase material. +ac( 8eld c$cle produces onl$ one
"used spot.
Series Welding - RS9 8(ic( utili.es t8o electrodes positioned adBacent to eac( ot(er
%ut separated %$ an air ap or ot(er dielectric. See 7iure 5. +ac( electrode contacts
t(e same sur"ace o" %ase material. T(is t$pe o" 8eldin is utili.ed 8(ere access to
%ot( sides o" t(e 8eld Boint is p($sicall$ restricted or i" component damae 8ould result
i" t(e 8eldin current 8ere allo8ed to s(unt t(rou( t(e s$stem circuit or electrical
component. Support toolin opposin t(e "orce o" t(e electrodes is insulated "rom t(e
8eldin circuit and t(ere"ore does not s(unt current "rom t(e 8eldin circuit. +ac( 8eld
c$cle produces t8o "used spots. T(e electrodes can %e positioned parallel or at a "ixed
anle to eac( ot(er.
.ni7ue Weld +ype - T(ose 8eld Boint con"iurations t(at di""er "rom one anot(er in an$
o" t(e "ollo8in respectsA
!. )atter$ anode and*or cat(ode cross sectional t(ic&ness =!0G>,
5. Anode and*or cat(ode material, metallurical condition, and sur"ace "inis(,
;. #umper ta% cross sectional t(ic&ness =!0G>,
,. #umper ta% material or metallurical condition,
H. Component lead*8ire material, metallurical condition, and sur"ace "inis(,
3. Component lead material*8ire cross sectional diameter =!0G>.
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PRC-0009 Rev. D
Figure 2 2 )pposed and Series Welding
+lectrodes
)PP)SED WE"D*0/
Ta%, 9ire
or Cead
829
8:9
SER*ES WE"D*0/
8:9
Support 7ixturin Support 7ixturin
+lectrodes
Ta%, 9ire
or Cead
829
829
8:9
!# REFERE0%ES
T(e standards listed %elo8 s(all %e considered a part o" t(is speci"ication to t(e extent
speci"ied (erein. Inless ot(er8ise indicated, t(e revision t(at is in e""ect on t(e date o"
invitation "or %ids or t(e date o" re4uest "or proposals s(all appl$.
a# American Welding Society 8AWS9 Standards
ANS0*A9S A5., Standard Symbols for Welding, Brazing and
Nondestructive Testing
ANS0*A9S A;.0 Standard Welding Terms and Definitions
b# 0ASA1$S% Documents
#P2 !600.!2 NASA/JS !e"uirements #andboo$ for Safety, #ealt%
and &nvironmental 'rotection
+'-006.! 're(aration and !evision of 'rocess S(ecifications
T0-0000-0, Training )or Welders and Welding *(erators
c# RW5A Documents
No Document Num%er !esistance Welding +anual, !esistance Welder
+anufacturers- Association .!W+A/
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d# SAE1Aerospace 5aterial Specification 8A5S9 Documents
A'S 5390 'arallel 0a( Welding
;# 5A+ER*A" A0D E4.*P5E0+ RE4.*RE5E0+S
All materials used in t(e 8eldin o" electronicall$ related "li(t (ard8are s(all meet t(e
re4uirements o" an applica%le #SC material speci"ication unless ot(er8ise speci"ied. 0"
a #SC material speci"ication is not availa%le, an applica%le commercial speci"ication or
a manu"acturerJs speci"ication s(all %e used.
;#( E4.*P5E0+
T(e e4uipment used to produce t(e 8elds s(all consist o" an electrical ener$ source,
electrodes, and a means o" appl$in mec(anical pressure to t(e materials to %e
8elded.
;#(#( P)WER S.PP",
T(e po8er suppl$ s(all (ave an ade4uate means o" controllin and indicatin t(e
ener$ applied to t(e 8eld .one. T(e po8er suppl$ s(all (ave means "or internal
voltae reulation i" t(ere is no suc( reulation on t(e primar$ AC po8er line source.
Reulation s(all %e 8it(in 5G "or line voltae variations o" !0G. +ner$ source
meters s(all (ave a minimum accurac$ o" 5G.
;#(#2 WE"D*0/ <EAD
T(e 8eldin (ead s(all %e o" lo8-inertia desin and provide a means o" e""icientl$
controllin electrode "orce. T(e electrode "orce s(all %e repeata%le to 8it(in HG.
;#(#- E"E%+R)DES
T(e composition o" electrodes s(all con"orm to t(e Resistance 9elder 'anu"acturer-s
Association =R9'A> allo$ classi"ications or t(e electrode manu"acturer-s
classi"ications. +ac( electrode s(all %e identi"ied accordin to t(e R9'A cateor$ or
manu"acturer-s classi"ication, %od$ si.e, con"iuration, and tip si.e. Custom electrodes
are allo8ed (o8ever, t(e speci"ic electrode materials and con"iuration s(all %e
considered an essential varia%le.
;#(#! +))"*0/ A0D F*=+.RES
Toolin re4uired to locate or assist in t(e assem%l$ o" %atteries to %e 8elded s(all %e
desined to preclude an$ secondar$ current pat( t(at 8ill allo8 current to %e s(unted
a8a$ "rom t(e electrodes or t(rou( %atter$ cells.
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PRC-0009 Rev. D
;#(#; WE"D*0/ E4.*P5E0+ 4.A"*F*%A+*)0
T(e 8eldin e4uipment s(all %e 4uali"ied as a s$stem t(at includes at a minimum, t(e
po8er suppl$, 8eld (ead, electrodes, and interconnectin ca%les. <uali"ication o" a
9eldin Procedure Speci"ication also 4uali"ies t(e s$stem. 1t(er8ise, 4uali"ication o"
a s$stem s(all %e per 3.5.5.
;#(#> F)R%E /A./E
Devices used to determine electrode "orce s(all (ave a minimum accurac$ o" HG.
># PR)%ESS RE4.*RE5E0+S
All 8eldments s(all %e "a%ricated accordin to t(e re4uirements o" t(is process
speci"ication. T(e re4uirements o" t(e applica%le codes and standards listed in Section
,.0 s(all %e met as speci"ied %$ t(is PRC %ased on t(e desin and intended "unction o"
t(e (ard8are. Certain pararap(s o" t(is process speci"ication are a%%reviated re-
statements ta&en "rom t(e applica%le standards and are included (ere "or t(e
clari"ication. T(e remainin pararap(s o" t(is process speci"ication ma$ represent
re4uirements imposed in addition to t(e %asic re4uirements o" t(e applica%le codes
and standards.
All resistance 8eldin s(all %e per"ormed usin 9eldin Procedure Speci"ications
=9PS> t(at (ave %een 4uali"ied in accordance 8it( t(e re4uirements o" Section 3.5.
>#( PR)%ESS2SPE%*F*% RE4.*RE5E0+S
>#(#( WE"D S,S+E5 *0SPE%+*)0 A0D %<E%6 ).+
Prior to t(e start o" eac( 4uali"ication, preproduction, production, or re4uali"ication lot,
and at an$ interval=s> deemed necessar$ %$ t(e operator or enineerin, t(e "ollo8in
items s(all %e addressed and an$ discrepant condition corrected as re4uired. 9eld
circuit interconnections s(all %e inspected to ensure t(at t(e$ are ti(t, clean and
corrosion "ree. +lectrode alinment s(all %e c(ec&ed per t(e 9PS re4uirements and
adBusted. +lectrode tips and contact sur"ace condition s(all %e inspected and
continuousl$ monitored "or conditions 8(ic( ma$ impede 8eldin tec(ni4ues and*or
8eld 4ualit$. T(e electrodes and related essential components s(all %e cleaned,
dressed, or replaced. +lectrodes s(all %e dressed 8it( num%er 300 or "iner rit
a%rasive paper or e4uivalent. +lectrode "orce s(all %e c(ec&ed 4uantitativel$ %$ a
cali%rated "orce aue and adBusted. 7or applications 8(ere eac( electrode is
controlled individuall$ =e.., series 8eldin>, t(e "orce o" eac( electrode s(all %e
determined and adBusted individuall$.
>#2 WE"D 4.A"*F*%A+*)0
A 9eldin Procedure Speci"ication =9PS> s(all %e 4uali"ied "or eac( uni4ue 8eld t$pe
to %e produced %$ con"ormin to t(e re4uirements %elo8, %e"ore t(e production 8elds
are made. An existin 4uali"ied 9PS "or one uni4ue 8eld t$pe ma$ %e used "or a ne8
enineerin dra8in provided t(e resistivit$ determined durin 4uali"ication meet t(e
re4uirements o" t(e ne8 dra8in as applica%le, and it is demonstrated t(at t(e
essential 8eld varia%les 8ill %e met. Demonstration s(all constitute all t(e
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PRC-0009 Rev. D
re4uirements o" Section 3.5.5 except t(at no additional documentation is re4uired
=existin P<R and 9PS records s(all %e accepta%le documentation>.
>#2#( 4.A"*F*%A+*)0 )F WPS
T(e actual 8eldin varia%les, met(ods, practices, speci"ic toolin re4uirements, and
test results used durin 9PS 4uali"ication s(all %e recorded on a Procedure
<uali"ication Record =P<R>.
>#2#2 RE4.A"*F*%A+*)0 )F WPS
Re4uali"ication o" t(e 9PS s(all %e re4uired 8(en an$ o" t(e "ollo8in conditions existA
a> T(e 8eld s$stem (as %een placed on a di""erent external po8er source
except 8(en t(e po8er suppl$ (as a means "or internal po8er
reulation,
%> A 9PS is proposed to %e used on a 8eld s$stem or s$stems ot(er t(an t(at
used "or t(e initial 4uali"ication,
c> 'aBor maintenance (as %een per"ormed on t(e 8eld s$stem. 'aBor
maintenance includes replacement o" t(e po8er suppl$, maBor repair o"
t(e po8er suppl$ re4uirin entrance into t(e controller or trans"ormer
ca%inet, replacement o" t(e 8eld (ead, or replacement or c(ane in
lent( %$ more t(an !0G o" an$ o" t(e interconnectin ca%les,
d> Preproduction 8eld samples do not meet re4uirements and no assina%le
cause "or t(e "ailure can %e determined.
Re4uali"ication ma$ %e per"ormed 8it( less total test sample re4uirements t(an t(at
re4uired "or an initial 4uali"ication "or a uni4ue 8eld t$pe. 7or re4uali"ication, H total
8eld samples s(all %e produced and su%mitted as a lot. All H samples s(all %e
su%Bected to visual inspection and conductivit$ and destructive peel testin and s(all
meet t(e applica%le re4uirements speci"ied (erein. No re4uali"ication specimens "rom
t(e H su%mitted s(all "ail an$ o" t(e re4uirements as stated (erein. Re4uali"ication
results s(all %e documented on a P<R 8it( a speci"ic notation made indicatin
?re4uali"ication@. 0" t(e re4uali"ication activities result in an$ 8eldin parameter
deviations t(at exceed t(e rane speci"ied in Ta%le ! "or t(at parameter, t(en t(e level
o" testin in 3.5., s(all %e re4uired.
>#2#- ESSE0+*A" &AR*AB"ES
All essential varia%les s(all %e addressed and identi"ied on a 4uali"ied 9PS and t(e
supportin P<R. T(ese essential varia%les are listed in Ta%le ! %elo8. 1t(er
varia%les determined to %e essential to maintainin t(e 4ualit$ o" t(e process output
ma$ %e re4uired to %e controlled, as determined %$ t(e 'KP orani.ation.
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PRC-0009 Rev. D
+AB"E ( ESSE0+*A" WE"D*0/ &AR*AB"ES
0.5BER ESSE0+*A" &AR*AB"ES &AR*AB"E RA0/E
! A c(ane in t(e input line voltae source N1N+
=!>
5 Po8er suppl$ - ma&e and model N1N+
; 9eld (ead - ma&e and model N1N+
, 0nterconnectin ca%le si.e and lent( !0G
H Ta% material t$pe N1N+
3 Ta% material metallurical condition N1N+
6 Ta% material t(ic&ness !0G
: )atter$ material t$pe N1N+
9 )atter$ material metallurical condition N1N+
!0 )atter$ anode t(ic&ness !0G
!! )atter$ cat(ode t(ic&ness !0G
!5 Component lead material t$pe N1N+
!; Component lead metallurical condition N1N+
!, Component lead diameter !0G
!H Sur"ace condition o" %ase materials N1N+
!3 +lectrode R9'A cateor$ or ot(er
classi"ication
N1N+
!6 +lectrode con"iuration K dimensions N1N+
!: +lectrode tip spacin 50G
!9 +lectrode tip contact sur"ace s(ape N1N+
50 +lectrode tip contact sur"ace area !0G
5! Process F a c(ane "rom opposed to
series 8eldin or vice versa
N1N+
55 9eld G po8er or 8att*sec =all pulses> !0G
5; Num%er o" 8eld pulses N1N+
5, 9eld pulse 8idt( N1N+
5H +lectrode tip "orce =pounds> !0G
53 Current t$pe =AC or DC> N1N+
56 DC polarit$ current direction =1pposed
9eldin onl$>
N1N+
=!>
Inless t(e po8er suppl$ (as internall$ reulated voltae capa%ilit$.
>#2#! 4.A"*F*%A+*)0 SA5P"ES
>#2#!#( /E0ERA"
T(e manu"acturin orani.ation is responsi%le "or 4uali"$in t(e 8eldin process.
Actual cat(ode and anode ends "or t(e same ma&e, si.e, and model*t$pe %atter$ used
in t(e desin s(all %e o%tained "or use as 4uali"ication and preproduction control
samples. Actual %atteries ma$ %e also used "or 4uali"ication and*or preproduction
control samples. 9ire*leads o" t(e same material and construction as component
leads, or actual components used in t(e desin, s(all also %e supplied 8(en
appropriate.
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PRC-0009 Rev. D
>#2#!#2 4.A"*F*%A+*)0 5A+ER*A"S
7or eac( uni4ue t$pe o" 8eld to %e produced, a minimum o" !H sample 8elded
connections s(all %e produced "or an initial procedure 4uali"ication and su%mitted as a
lot. 7or eit(er o" t(e "ollo8in 8eld conditions, an additional sample s(all %e produced
and su%mitted "or metallurical examination %rinin t(e minimum total to !3A !> t(e
"a$in sur"aces at t(e 8eld Boint are o" essentiall$ di""erent materials, or 5> 8(ere it is
determined t(at an$ o" t(e %ase materials =plated or not> are &no8n to experience
sini"icant deradation or ot(er pro%lems caused %$ t(e 8eld (eatin. 9eld control
settins s(all not %e varied nor s(all an$ maintenance, except cleanin and*or
polis(in o" electrodes, %e per"ormed on t(e e4uipment durin t(e production o" t(e
4uali"ication samples. T(e num%er o" 8eld spots on eac( 4uali"ication sample
connection s(all not exceed t(e minimum num%er re4uired per t(e enineerin dra8in
or i" not speci"ied s(all %e no reater t(an 5 spots per connection or t(at planned "or
production 8or&. T(e 4uali"ication sample set s(all %e accepta%le to all o" t(e "ollo8in
, levels o" 4ualit$ control as applica%le, "or success"ul 4uali"icationA !> visual
inspection, 5> conductivit$ =resistivit$> testin, ;> destructive peel testin, and ,>
metallurical examination =8(en re4uired>.
>#2#!#- &*S.A" *0SPE%+*)0 A0D E"E%+R*%A" %)0D.%+*&*+, +ES+*0/
All 8eld specimens s(all %e visuall$ inspected per 6.; and tested "or electrical
conductivit$ =resistivit$>. T(e resistivit$ o" eac( connection s(all meet t(e dra8in
re4uirements or i" not speci"ied %$ t(e dra8in, s(all measure less t(an !.0 m. 0" an$
o" t(e individual samples "rom t(ose su%mitted "ail to pass t(e visual or resistivit$
re4uirements, an additional sample s(all %e allo8ed to %e 8elded and su%mitted to
replace it, one time onl$. 0" more t(an 5 samples "rom t(e oriinal lot "ail t(e visual or
resistivit$ re4uirements "urt(er 8eld parameter development or process anal$sis to
determine t(e cause "or t(e reBection=s> is re4uired prior to su%mittin anot(er lot o"
samples "or testin to t(e re4uirements o" t(is speci"ication.
>#2#!#! DES+R.%+*&E PEE" +ES+*0/
7i"teen =!H> 8eld samples s(all %e peel tested. T(e edes o" a spot 8elded sample
connection s(all %e ripped and pulled apart to "ailure. T(e 8elded connection =lap
Boint> s(all %e pulled in tension at an approximate 90
0
anle to t(e plane o" t(e "a$in
Boint sur"aces. See 7iure ;. T(e lent( o" t(e rip sections on t(e samples s(all %e
lon enou( to preclude an$ inter"erence o" t(e rippin (ard8are 8it( t(e 8elded
connection. 7or a procedure 4uali"ication or preproduction veri"ication sample set to %e
considered accepta%le, t(e result o" t(e peel test must %e a plu pull-out in a minimum
o" 6HG o" t(e total num%er o" individual spots in t(e sample set "or connections 8it( ,
or more spots, :HG "or connections 8it( ; spots onl$, and !00G "or connections 8it( 5
or less spots. 0" an$ o" t(e individual samples "rom t(e !H peel tests "ail to result in at
least 5 plu pull-outs "rom t(e total num%er o" 8eld spots on t(e individual connection,
5 additional 8elded sample connections ma$ %e 8elded and su%mitted "or inspection
and testin as part o" t(e initial sample set, one time onl$. T(ese 5 samples s(all t(en
%e "actored into t(e a%ove acceptance criteria. 0" more t(an 5 samples "rom t(e oriinal
lot "ail t(e peel test as descri%ed a%ove, "urt(er 8eld parameter development or
process anal$sis to determine t(e cause "or t(e "ailure=s> is re4uired prior to su%mittin
anot(er !3 samples "or testin to t(e re4uirements o" t(is speci"ication. 0" t(e minimum
plu pull-out re4uirement "or t(e total num%er o" individual spots in t(e sample set =i.e.,
6HG, :HG, or !00G "or t(e respective condition> can not %e met as descri%ed a%ove,
"urt(er 8eld parameter development or process anal$sis to determine t(e cause "or t(e
&erify correct version before use#
Pae !0 o" !9
PRC-0009 Rev. D
"ailure is re4uired prior to su%mittin anot(er lot o" samples "or testin to t(e
re4uirements o" t(is speci"ication.
Direction o"
Tension
#oint 7a$in
Sur"ace
Ta%*9ire*Cead
Direction o"
Tension
~90
O
Ta%*9ire*Cead
Component
=e.., )atter$>
#oint 7a$in
Sur"ace
Figure - 2 Peel +est E?amples
~90
O
Figure ! 2 5etallurgical Sectioning Re7uirements
9eld Spot Pair 7rom
Series 9eldin C$cle
on Ta% to )atter$ or Ta%
to ot(er 7lat Sur"ace
=L>
=-> =L>
=->
9eld Spots Sectioned
90
o
7rom +ac(ot(er on
9ire * Cead to Ta% or Cead
or 1t(er Component
>#2#!#; 5E+A"".R/*%A" E=A5*0A+*)0
9(en re4uired, one =!> o" t(e !3 samples su%mitted s(all %e cross-sectioned,
mounted, polis(ed, and etc(ed "or metallurical examination. 7or samples involvin a
8ire or component leads, one eac( 8eld spot on t(e connection 8ill %e cross sectioned
transverse to t(e 8ire diameter and lonitudinal to t(e 8ire diameter axis and "or Series
9elded samples, cross sections o" %ot( 8eld spots produced %$ one 8eld c$cle =8elds
produced under eac( electrode contact> s(all %e ta&en. See 7iure ,.
T(e 8elds s(all %e "ree o" crac&s or voids open to an$ exterior sur"ace. Pore and voids
contained 8it(in t(e 8eld .one %ut not open to an exterior sur"ace, and are not
determined to (ave s(arp notc( li&e c(aracteristics, s(all %e accepta%le. 9(en
examinin 8elds intended "or %atter$ cells, an$ anomal$ 8(ic( is determined to %e a
&erify correct version before use#
Pae !! o" !9
PRC-0009 Rev. D
potential "or %reac(in or deradin t(e %atter$ (ousin and t(ere"ore potentiall$
causin a lea&, s(all %e cause "or reBection. 0n addition, a metallurical "usion %ond
s(all %e visi%le at eac( 8eld spot inter"ace. 0" t(is criteria cannot %e met, "urt(er 8eld
parameter development or process anal$sis to determine t(e cause "or t(e reBecta%le
condition, is re4uired prior to su%mittin anot(er lot o" samples "or testin to t(e
re4uirements o" t(is speci"ication. P(otomicrorap(s s(all %e ta&en o" t(e prepared
samples and retained 8it( t(e P<R.
@# PR)%ESS &ER*F*%A+*)0
Process veri"ication s(all consist o" visual examination and*or nondestructive
inspection, as descri%ed "urt(er in sections 6.! to 6.;. 0n addition, at t(e appropriate
time durin t(e "a%rication activities, t(e manu"acturin activit$ s(all assure t(e
"ollo8in itemsA
a> T(e operator is certi"ied "or t(e speci"ic 8eldin operation,
%> A valid 9PS exists,
c> T(e essential varia%le ranes "or t(e 9PS are %ein ad(ered to.
@#( PREPR)D.%+*)0 WE"D*0/ &ER*F*%A+*)0
Prior to t(e start o" a production run, a minimum o" ! preproduction 8eld sample "or
eac( uni4ue t$pe o" 8eld s(all %e prepared usin t(e appropriate 4uali"ied 9PS.
Actual %atteries and component leads or simulated ones, as descri%ed in section
3.5.,.!, s(all %e used "or t(is preproduction 8eld sample. T(e sample s(all %e visuall$
inspected, in accordance 8it( Section 6.;, and peel tested, in accordance 8it( Section
3.5.,.,. T(e preproduction sample s(all %e made and tested %e"ore t(e 8eldin o" t(e
production 8elds and under t(e "ollo8in conditionsA
a> At t(e start o" a production s(i"t or t(e c(ane o" production s(i"ts,
%> Ipon replacement o" eit(er or %ot( o" t(e 8eldin electrodes,
c> 7ollo8in metal expulsion or severe metal deposits on t(e electrode "ace=s>,
d> 7ollo8in t(e mis"ire or no 8eld condition 8(ere a 8eld (as %een attempted %ut not
made and no assina%le cause can %e determined,
e> 7ollo8in a dela$ in 8eldin o" more t(an , (ours and 8(ere t(e 8eldin s$stem
8as re4uired to %e po8ered do8n durin t(is period,
"> 9(ere a di""erent operator 8as assined to t(e 8or&station to continue a Bo%.
Di""erent 9PSs ma$ %e alternated 8it(in a production 8eldin session provided t(e
a%ove re4uirements are met.
@#2 WE"D &ER*F*%A+*)0
Prior to encapsulation, pottin, or an$ process 8(ic( 8ould preclude inspection o" t(e
8elds, all 8elds and 8or&mans(ip s(all %e inspected "or con"ormance to t(e
re4uirements o" t(is standard and t(e enineerin dra8in. 0" a noncon"ormance is
identi"ied it s(all %e documented appropriatel$. 0" t(e 8elds o" a completed 8elded
module or assem%l$ cannot %e inspected a"ter t(e assem%l$ is complete, t(e module or
assem%l$ must %e inspected at selected points durin assem%l$ to assure inspection o"
eac( 8eld in t(e module.
&erify correct version before use#
Pae !5 o" !9
PRC-0009 Rev. D
@#- &*S.A" *0SPE%+*)0
All 8elds s(all %e inspected visuall$ at a mani"ication o" ;0M. T(e 8elds s(all
con"orm to t(e "ollo8in visual inspection criteriaA
a> %racAed Weld - An$ 8eld t(at ex(i%its a crac& in t(e 8eld .one s(all %e reBected.
%> Pitted1Deformed Weld - An$ 8eld t(at ex(i%its pits, (oles or voids open to t(e
sur"ace, in eit(er o" t(e materials %ein s(all %e reBected. Sur"ace de"ormation
or upset "rom electrode contact s(all not %e considered unless t(e area in
4uestion ex(i%its s(arp notc( li&e c(aracteristics, severe oxidation due to
over(eatin, or 8(ere eit(er o" t(e elements (as %een de"ormed*upset %$ more
t(an H0G o" t(e material t(ic&ness.
c> 5etal E?pulsion - An$ 8eld t(at ex(i%its metal expulsion 8(ere t(e molten metal
(as %ecome separated "rom t(e 8eld area s(all %e reBected.
d> Electrode Deposit - Sini"icant deposits o" t(e electrode tip %ein le"t on t(e 8eld
sur"ace s(all %e reBected. Topical s(allo8 deposits and super"icial mar&s s(all
not %e considered.
e> )pen Weld - An open 8eld s(all %e reBected. An open 8eld is one in 8(ic( a 8eld
(as %een attempted %ut no %ondin (as occurred.
"> 5issed Weld - An$ 8eld t(at (as %een speci"ied on t(e dra8ins %ut (as %een
overloo&ed %$ t(e 8eldin operator s(all %e identi"ied and 8elded to meet t(e
dra8in re4uirements.
@#! WE"D REPA*RS A0D REW)R6
An$ 8eld t(at (as %een indicated as (avin a de"ect =8it( t(e exception o" an 1pen
9eld or a 'issed 9eld> as listed in 6.;, or as not meetin t(e re4uirements speci"ied
on t(e dra8in, ma$ %e re8elded no more t(an ! time at t(e same location 8(ere t(e
oriinal 8eld 8as attempted. An 1pen or 'issed 9eld s(all %e re8or&ed to provide an
initial 8eld per t(e enineerin dra8in. 0" a re8eld attempt is unsuccess"ul, unless a
mis"ire condition occurs, a discrepanc$ report s(all %e enerated and s(all re4uire
dispositionin %$ t(e responsi%le enineerin orani.ation. T8o unsuccess"ul re8eld
attempts s(all re4uire dispositionin %$ t(e 'aterial Revie8 )oard ='R)>. T(e level o"
documentation o" repair 8elds s(all, at a minimum, %e consistent 8it( t(at re4uired "or
t(e oriinal production 8eld. All re8elds s(all %e per"ormed usin t(e 9PS used "or
t(e oriinal 8eld or a speci"ic 4uali"ied 9PS "or t(at repair and s(all meet all o" t(e
re4uirements o" t(e oriinal dra8in and an$ additional re4uirements t(at are
documented in t(e 9PS.
B# PR)%ESS D)%.5E0+A+*)0 RE4.*RE5E0+S
T(e 9PS, P<R, and 91P< s(all %e prepared and retained as a permanent record
and made availa%le upon re4uest to t(e NASA*#SC 'KP orani.ation "or revie8.
T(ese procedures must contain, at a minimum, all o" t(e essential 8eldin parameters,
an identi"ication o" t(e 8eldin e4uipment, and include an$ pertinent toolin
in"ormation. 1ne cop$ o" t(e 9PS s(all %e maintained in t(e vicinit$ o" t(e 8eldin
station and s(all %e readil$ accessi%le %$ t(e 8elders, inspectors, supervision, and*or
enineerin.
&erify correct version before use#
Pae !; o" !9
PRC-0009 Rev. D
B#( WE"D*0/ PR)%ED.RE SPE%*F*%A+*)0
A 9eldin Procedure Speci"ication =9PS> is a 4uali"ied 8ritten 8or&in procedure t(at
must %e developed %e"ore %einnin production "or eac( uni4ue 8eld t$pe to %e
produced. <uali"ication support documentation in t(e "orm o" a Procedure <uali"ication
Record =P<R> s(all %e maintained on "ile to s(o8 proo" o" process*procedure capa%ilit$
usin t(e 9PS. T(e 9PS s(all %e tracea%le %$ means o" seriali.ed nomenclature and
s(all s(o8 tracea%ilit$ to t(e applica%le P<R=s>. T(e 9PS used "or production 8eldin
s(all meet t(e re4uirements o" t(is process speci"ication and s(all %e certi"ied %$ t(e
responsi%le 'KP orani.ation at t(e operatin "acilit$, prior to use in production.
Appendix ) is an example o" a 9eldin Procedure Speci"ication (o8ever, an$ "ormat is
considered accepta%le provided all t(e in"ormation and data necessar$ to success"ull$
per"orm t(e 8eldin activit$ is availa%le and displa$ed clearl$.
B#2 PR)%ED.RE 4.A"*F*%A+*)0 RE%)RD
A Procedure <uali"ication Record =P<R> is documentation to support t(e 8eldin
procedure speci"ication to s(o8 proo" o" process*procedure capa%ilit$. A P<R s(all %e
uni4ue and tracea%le, %$ means o" seriali.ed nomenclature. T(e P<R s(all %e process
speci"ic and speci"ic to a uni4ue 8eld t$pe. Data re4uired in t(e P<R s(all include
detailed descriptions o" t(e test coupon con"iurations and Boint desins, all pertinent
material speci"ications, all pertinent essential process varia%les used, all destructive
and nondestructive test results "rom t(e 4uali"ication sample set, and all re4uired
certi"ications "rom t(e approvin orani.ation. T(e P<R s(all %e approved %$ t(e
responsi%le 'KP orani.ation at t(e operatin "acilit$. Appendix A is an example o" a
Procedure <uali"ication Record (o8ever, an$ "ormat is considered accepta%le provided
all t(e in"ormation and data necessar$ to accuratel$ document t(e process is made
availa%le and displa$ed clearl$.
B#- WE"D*0/ )PERA+)R PERF)R5A0%E 4.A"*F*%A+*)0
A 9eldin 1perator Per"ormance <uali"ication =91P<> is documentation t(at s(o8s
t(at a 8elder (as %een tested in accordance 8it( t(is PRC and s(o8n competent to
produce a sound 8eld "or a speci"ic 8eldin process*%ase material*e4uipment
com%ination. An$ "ormat is considered accepta%le provided all t(e in"ormation and
data necessar$ to accuratel$ document t(e operator-s per"ormance 4uali"ication is
made availa%le and displa$ed clearl$.
B#! DE&*A+*)0S A0D WA*&ERS
An$ deviations or 8aivers reardin t(e use o" t(is process speci"ication s(all %e
re4uested in 8ritin %$ t(e outside vendor. T(is re4uest s(all %e directed to t(e
NASA*#SC 'KP orani.ation 8it( t(e appropriate Busti"ication and rationale. A 8ritten
response 8ill %e provided upon suc( a re4uest.
&erify correct version before use#
Pae !, o" !9
PRC-0009 Rev. D
3# +RA*0*0/ A0D %ER+*F*%A+*)0 )F PERS)00E"
3#( +RA*0*0/
At #SC, i" 8eldin operator trainin is considered necessar$ prior to
4uali"ication*re4uali"ication o" existin #SC 8eldin operator personnel or t(e initial
4uali"ication o" ne8 (ires, it s(all %e conducted in accordance 8it( T0-0000-0,. 7or an
outside #SC vendor, 8eldin operator trainin =8(en necessar$> s(ould consist o"
practice usin t(e "acilit$ 8eldin e4uipment 8it( a speci"ic 9PS to demonstrate
pro"icienc$, under t(e supervision o" a 4uali"ied*certi"ied 8eldin operator or
desinated trainin personnel. Speci"ic development o" an appropriate trainin
proram s(all %e t(e responsi%ilit$ o" t(e vendor. RS9 is a potentiall$ (a.ardous
Boinin process %ecause o" t(e (i( eneries involved. Trainin s(all include ade4uate
exposure to all spot 8eldin e4uipment manu"acturer-s instructions and applica%le
industr$ standards relatin to sa"et$ and 8(ere applica%le, to t(e speci"ic (a.ards
related to %atteries. All #SC orani.ations and t(eir contractors 8(o enae in
(andlin %atteries s(all %e trained in all approved uidelines and procedures "or
8or&in 8it( and (andlin %atteries. Sa"et$ related documents listed in Section ,.0 o"
t(is PRC "orm a part o" t(ese sa"et$ precautions and notes to t(e extent speci"ied
(erein.
3#2 WE"D*0/ )PERA+)R 4.A"*F*%A+*)0
Resistance spot 8eldin o" %atter$ and related electronic assem%lies s(all %e
per"ormed %$ a 8eldin operator 4uali"ied and certi"ied in accordance 8it( NASA*#SC
PRC-0009. Su""icientl$ detailed records s(all %e maintained %$ t(e manu"acturin
orani.ation executin t(e process=es>. T(ese records s(all %e made availa%le to t(e
NASA*#SC 'KP orani.ation upon re4uest. 'inimum re4uirements "or
4uali"ication*certi"ication s(all %e demonstrated %$ eit(er o" t(e "ollo8inA
a> t(e operator must (ave success"ull$ per"ormed a P<R 4uali"ication or
re4uali"ication to a 8ritten 9PS per t(is speci"ication, or
%> t(e operator must (ave %een Buded competent in t(e process and use o" t(e
e4uipment, %$ t(e responsi%le 'KP enineerin representative, %$ success"ull$
demonstratin t(e application o" a 4uali"ied 9PS. T(is s(all include demonstration
to t(e 4uali"ier =certi"$in representative>, mac(ine operation, sc(edule*parameter
selection, electrode setup, and 8eld c$cle execution.
&erify correct version before use#
Pae !H o" !9
PRC-0009 Rev. D
APPE0D*= A
C$ndon ). #o(nson Space Center
NR+S0STANC+ SP1T 9+CD0N2O PR1C+DIR+ <IAC070CAT01N R+C1RD =P<R>
E4.*P5E0+ *DE0+*F*%A+*)0
E"E%+R)DE %)0F*/.RA+*)0 A0D SE+.P
DateAPPPPPPPPPPP 0nitial <uali"ication Re4uali"ication P<R No. PPPPPPPPPPPPPPPPP
E"E%+R)DES
)$A
)$A
DateA
DateA
PA/E ( of -
9e certi"$ t(at t(e statements and p(otomicrorap(s in t(is data s(eet
are correct and t(e test 8elds 8ere 8elded and tested in accordance
8it( #SC PRC-0009. T(e p(otomicrorap(s s(all "orm a part o" t(is
P<R to t(e extent speci"ied in #SC PRC-0009, RevisionPPPPPPPPPPP.
&AR*AB"ES
No. o" 9eld C$cles Per Cocation A
Polarit$, 7irst C$cle A
Polarit$, Second C$cle A
Pulse 9idt( A
Num%er o" Pulses A
Total +lectrode Tip 7orce =l%s> A
Ce"t +lectrode Tip 7orce =l%s> A
Ri(t +lectrode Tip 7orce =l%s> A
7irin 7orce Settin A
Approx Av Pea& Amperae
Response =re"erence onl$> A
18ner * Cocation A
Po8er Suppl$ * 'odel A
Serial Num%er A
9eld Head * 'odel A
Serial Num%er A
0nterconnectin Ca%le Si.e * Cent(A
5A+ER*A"S
BA++ER,
'anu"acturer A
T$pe * Si.e A
'aterial T$pe * 'etallurical Cond A
Anode T(ic&ness A
Cat(ode T(ic&ness A
Sur"ace Condition A
'anu"acturer A
T$pe * Temper A
Heat Num%er A
T(ic&ness * 9idt( A
Sur"ace Condition A
Component Cead 'aterial A
Component Cead 2ae A
%)00E%+*0/ 1 %)5P)0E0+ 5A+ER*A"S
R9'A Cateor$ A
1t(er Cateor$ * Descip A
Distance )et8een +lectrode Tips A
+lect Tip Con"i * Si.e A
Contact Tip Sur"ace S(ape A
+lectrode )od$ Dimensions A
1t(er A
Pulse ! A
Pulse 5 A
8att seconds
8att seconds
G po8er or
G po8er or
&erify correct version before use#
Pae !3 o" !9
PRC-0009 Rev. D
C$ndon ). #o(nson Space Center
CRES*S+A0%E SP)+ WE"D*0/D PR)%ED.RE 4.A"*F*%A+*)0 RE%)RD 8P4R9
DateAPPPPPPPPPPP 0nitial <uali"ication Re4uali"ication P<R No. PPPPPPPPPPPPPPPPP
)$A
)$A
DateA
DateA
Peel Test
Sample %athode or &isual Resistivity Peel +est ITS =l%s.>
0umber Anode Results 8m2ohms9 E Plug Pull )uts 1 +otal =Re"erence 1nl$>
!
5
;
,
H
3
6
:
9
!0
!!
!5
!;
!,
!H
!3
!6
!:
!9
50
5!
55
5;
5,
5H
53
56
5:
59
;0
*0SPE%+*)0 A0D +ES+*0/ RES."+S
9e certi"$ t(at t(e statements and p(otomicrorap(s in t(is data s(eet
are correct and t(e test 8elds 8ere 8elded and tested in accordance
8it( #SC PRC-0009. T(e p(otomicrorap(s s(all "orm a part o" t(is
P<R to t(e extent speci"ied in #SC PRC-0009, RevisionPPPPPPPPPPP.
PA/E 2 of -
&erify correct version before use#
Pae !6 o" !9
PRC-0009 Rev. D
C$ndon ). #o(nson Space Center
CRES*S+A0%E SP)+ WE"D*0/D PR)%ED.RE 4.A"*F*%A+*)0 RE%)RD 8P4R9
DateAPPPPPPPPPPP 0nitial <uali"ication Re4uali"ication P<R No. PPPPPPPPPPPPPPPPP
)$A
)$A
DateA
DateA
5E+A"".R/*%A" +ES+*0/ RES."+S
9e certi"$ t(at t(e statements and p(otomicrorap(s in t(is data s(eet
are correct and t(e test 8elds 8ere 8elded and tested in accordance
8it( #SC PRC-0009. T(e p(otomicrorap(s s(all "orm a part o" t(is
P<R to t(e extent speci"ied in #SC PRC-0009, RevisionPPPPPPPPPPP.
PA/E - of -
&erify correct version before use#
Pae !: o" !9
PRC-0009 Rev. D
APPE0D*= B
C$ndon ). #o(nson Space Center
CRES*S+A0%E SP)+ WE"D*0/D WE"D*0/ PR)%ED.RE SPE%*F*%A+*)0 8WPS9
E4.*P5E0+ *DE0+*F*%A+*)0
18ner * Cocation A
Po8er Suppl$ * 'odel A
Serial Num%er A
9eld Head * 'odel A
Serial Num%er A
5A+ER*A"S
%)00E%+*0/ 1 %)5P)0E0+ 5A+ER*A"S
E"E%+R)DE %)0F*/.RA+*)0 A0D SE+.P
9e certi"$ t(at t(e statements in t(is speci"ication s(eet
are correct and t(e test 8elds 8ere 8elded and tested in
accordance 8it( #SC PRC-0009, RevisionPPPPPPPPPPP.
)$A
)$A
DateA
DateA
RS9 Procedure Speci"ication Num%er A
Applica%le #SC P<R Num%er=s> A
Date 0n +""ectA
RevisionA
BA++ER,
'anu"acturer A
T$pe * Si.e A
'aterial T$pe * 'etallurical Cond A
Anode T(ic&ness A
Cat(ode T(ic&ness A
Sur"ace Condition A
PA/E ( of (
'anu"acturer A
T$pe * Temper A
T(ic&ness * 9idt( A
Sur"ace Condition A
Component Cead 'aterial A
Component Cead 2ae A
+ES+*0/
Detailed test results are documented in t(e "ollo8in
Procedure <uali"ication Record=s> =P<R>A
No. o" 9eld C$cles Per Cocation A
Polarit$, 7irst C$cle A
Polarit$, Second C$cle A
Pulse 9idt( A
Num%er o" Pulses A
Total +lectrode Tip 7orce =l%s> A
Ce"t +lectrode Tip 7orce =l%s> A
Ri(t +lectrode Tip 7orce =l%s> A
7irin 7orce Settin A
Approx Av Pea& Amperae
Response =re"erence onl$>A
Pulse ! A
Pulse 5 A
G po8er or A
G po8er or A
8att seconds
8att seconds
&AR*AB"ES
E"E%+R)DES
R9'A Cateor$ A
1t(er Cateor$ * Comp A
Distance )et8een +lectrode Tips A
+lect Tip Con"i * Si.e A
Contact Tip Sur"ace S(ape A
+lectrode )od$ Dimensions A
&erify correct version before use#
Pae !9 o" !9