Esbm5a-B 1n261-s Aa RSW

Engineering Specification
FRAME 2 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA
OUTLINE FRAME
I. GENERAL .. 4
I.1 Scope of Engineering Specification, General Statement .. 4
I.2 Process Description ... 5
I.3 Design Guidelines . 5

I.3.1 Governing Metal Thickness
I.3.2 Gauge Ratio Limitations
I.3.3 Weld Diameter
I.3.3.1 Definitions
I.3.3.2 Minimum Weld Diameter
I.3.3.3 Special Cases
I.3.4 Electrode Usage and Flange Dimensions
I.3.5 Weld Pitch
I.3.6 Flatness
I.4 Applicable Materials ... 13

I.4.1 Base Sheet Metal Specification
I.4.2 Standard Base Sheet Metal Coatings
I.5 Weld Identification Symbols . 14
I.6 Weld Classification ........................... 14
I.7 Weld Groups . 14
I.8 Weld Quality Levels, Acceptance Criteria, and Reaction Requirements.... 15

I.8.1 Weld Quality Levels
I.8.2 Acceptance Criteria
I.8.3 Reaction Requirements
II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS... 17
III. TEST PROCEDURES AND REQUIREMENTS .. 22
III.1 Applicability of Test Procedures for PV- and IP-Test Phases .. 22
III.2 Weld Parameter Monitoring ... 23

III.2.1 Introduction
III.2.2 Welding Current over Time [A]
III.2.3 Electrode Force [N]
PD November 28, 2008 EBIW E 12173768 000 Resistance Spot Welding ESBM5A-1N261-AA
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III.3 Inspection of the Visible Part of the Weld ..... 23

III.3.2 Spot Weld Count
III.3.3 Spot Weld Position
III.3.4 Distance from Edges
III.3.5 Surface Characteristics
III.3.5.1 Classes of Weld Finish
III.3.5.2 Surface Indentation and Expulsion
III.3.6 Burn Through
III.3.7 Surface Cracks
III.3.8 Surface Porosity
III.4 Inspection of Section Cuts ....... 27

III.4.2 Nugget Diameter
III.4.3 Weld Penetration
III.4.4 Porosity
III.4.5 Cracks
III.4.6 Inclusions
III.4.7 Hardness Limits
III.5 Destructive, Non-Destructive, and Functional Testing ...... 29

III.5.2 Static Tensile Test
III.5.3 Peel Test
III.5.4 Impact Test
III.5.5 Chisel Test (Destructive)
III.5.6 Destructive Test Using a Machine
III.5.7 Ultrasonic Test
III.5.8 Chisel Test (Non-Destructive)
III.5.9 Durability/Fatigue Test
III.6 Permissible Repair Methods 34

III.6.1 Resistance Spot Welding
III.6.2 Plug Welding
III.6.3 Fusion Fillet Welding
III.6.4 Riveting
III.6.5 Gas Metal Arc Brazing
IV. REVALIDATION REQUIREMENTS . 36
V. INSTRUCTIONS AND NOTES .... 36
VI. COMPILATION OF REFERENCE DOCUMENTS ...... 37
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I. GENERAL
I.1 Scope of Engineering Specification, General Statement
This Engineering Specification is issued to define design factors and performance requirements applicable to the
resistance spot welding of coated, uncoated, and laminated sheet steel
up to a thickness of 3.0 mm for individual sheets,
up to a maximum of 6.0 mm in total joint thickness, and
comprising up to three thicknesses of steel of the same or different gauge
used in the fabrication of assemblies. It harmonizes the requirements globally for Ford Motor Company and is
applicable to new programs.
The design factors and performance requirements apply to both automatic and manual welding applications.
Where manual applications may have an impact on design or performance, the relevant Body and
Manufacturing Engineering departments may agree on deviations.
Resistance spot welds of sheet steel exceeding 3.0 mm for individual sheets and/or exceeding 6.0 mm in total
joint thickness require a case-by-case exemption from the relevant Body and Manufacturing Engineering
departments. Exemptions will only be granted on the basis of a needs assessment.
Resistance spot welds comprising four thicknesses of steel are permissible as non-structural welds only, e.g. as
manufacturing tack welds.
This Engineering Specification also applies to spot welds on steel combinations which include weld sealers,
paint primers, and/or adhesives. Performance requirements of sealers and adhesives themselves are covered in
separate Engineering Specifications.
This Engineering Specification is a supplement to the released drawing part. 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 to this specification.
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.
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.
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I.2 Process Description
Resistance welding is a process in which metals are joined by the heat generated by the resistance of the work to
the passage of electric current. This process involves a coordinated application of current and mechanical
pressure of the proper magnitudes and times. The amount of heat generated depends on three factors defined by
the following formula:
Q = I2*R*t
where:
Q = heat generated, joules
I = current, amperes
R = resistance of the work, ohms
t = duration of current, seconds
Figure 1: Illustration of RSW Process
For resistance spot welding (RSW) in particular, electrodes or weld tips are used to form a nugget of weld metal
at the electrode site. See Figure 1. The characteristic parameters of this process are weld current, time, and
force.
I.3 Design Guidelines
I.3.1 Governing Metal Thickness
Governing metal thickness (GMT) is used throughout this specification for the purpose of establishing design
and manufacturing parameters such as weld flange length, weld pitch, electrode selection, etc. GMT for double
or triple panel welding is defined as:
the thickness of the thinnest sheet in a double panel stackup
the thickness of the second thinnest sheet in a triple panel stackup of unequal thickness
the thickness of one of the equal sheets in a triple sheet stackup having at least two sheets of equal
thickness
I.3.2 Gauge Ratio Limitations
Table I.3.2 outlines the generic gauge ratio limitations applicable to double and triple panel welding of sheet
steels. Ratios are based on the minimum yield strengths and positions of the steels in the stackup.
When one of the outside sheets in a stackup is a dual phase steel (DP) at or above 780 MPa minimum ultimate
tensile strength, transformation-induced plasticity steel (TRIP), martensitic steel (MSW), or boron steel, the
more stringent ratio limitations on the right side shall be used. See Table I.4.1 for relevant material
specifications. All other stackups may use the less stringent ratio limitations on the left side.
Deviations from these sheet metal gauge ratio requirements require the approval of the relevant Body and
Manufacturing Engineering departments. They can be granted on the basis of successful welding trials.
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Ratio for DP
Ratio for MS,
>780, TRIP,
Rule Relationship GMT DR, HSLA, Example Example
MSW, and
and DP <780*
BORON*
1.2 1.2 1.2 1.2
Two Equal Thickness
1 X ~ X Y ~ X Y
(Least Concern Stack-up)
0.8 2.4 0.8 2.0
2 Two Unequal Thickness X X/Y 1/3 X Y X/Y 1/2.5 X Y
1.2 1.2 1.2 1.2 1.2 1.2

Three Equal Thickness
3 X ~ X Y Z ~ X Y Z
(Least Concern of 3t Stacks)
1.2 0.8 3.0 1.2 0.8 2.4
Three Unequal Thicknesses,
4 X X/Z 1/2.5 X Y Z X/Z 1/2 X Y Z
Lightest Gage in Center
0.8 2.4 2.0 0.8 2.0 1.6
Three Unequal Thicknesses, X/Y 1/3 X/Y 1/2.5
5 Z X Y Z X Y Z
Heaviest Gage in Center X/Z 1/2.5 X/Z 1/2
0.8 1.2 2.0 0.8 1.2 1.6
Three Unequal Thicknesses,

6 Medium Gage in Center Y X/Z 1/2.5 X Y Z X/Z 1/2 X Y Z
(Highest Concern of 3t Stacks)
2.4 0.8 2.4 2.0 0.8 2.0

Two Equal Thicknesses and a
7 Lighter Gage in Center X Y/X 1/3 X Y Z Y/X 1/2.5 X Y Z
(Low Concern 3t Stack-up)
0.8 2.4 0.8 0.8 2.0 0.8
8 X X/Y 1/3 X Y Z X/Y 1/2.5 X Y Z
Heavier Gage in Center
0.8 2.0 2.0 0.8 1.6 1.6
9 Y X/Y 1/2.5 X Y Z X/Y 1/2 X Y Z
Lighter Gage on Outside
0.8 0.8 2.0 0.8 0.8 1.6
10 X X/Z 1/2.5 X Y Z X/Z 1/2 X Y Z
Heavier Gage on Outside
* See Section I.3.2 for additional description of rules for ratio limitations.
Table I.3.2: Gauge Ratio Limitations for Double and Triple Panel Welding
I.3.3 Weld Diameter
I.3.3.1 Definitions
The nugget diameter dL is the diameter of the fused material measured in a section cut as shown in
Figure 2.
Figure 2: Weld Nugget Diameter Figure 3: Weld Button

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The weld diameter dp is the diameter of the fused material measured in a destructive test. Figure 3
shows a button pulled out of one of the welded components. The fracture mode from a destructive test
may not always be a full button, as described below in Figures 4 through 6.
NOTE: For the purposes of this specification, dp defines the weld diameter, regardless of fracture type.
The permissibility of the partial plug or interfacial fracture is specified in Section III.5.5, Chisel Test
(Destructive).
o For pure plug fracture, the weld diameter dP is the average diameter of the surface area of the
exposed button as shown in Figure 4.
Figure 4: Full Plug Fracture ("Button") Diameter
o For partial plug fracture, the weld diameter dP is the average diameter of the surface area of the
exposed button including the interfacial fracture zone as shown in Figure 5.
Figure 5: Partial Plug Fracture Diameter
o For pure interfacial fracture, the weld diameter dP is the average diameter of the fractured surface
without the adhesion ring zone as shown in Figure 6.
adhesion ring zone
Figure 6: Interfacial Fracture Diameter
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I.3.3.2 Minimum Weld Diameter
For double panel welding, the minimum weld diameter is determined by using the thickness of the
thinnest sheet.
For triple panel welding (defined as a single functional weld consisting of two double panel
combinations), the minimum weld diameter at each interface is determined using the thickness of the
thinnest sheet (GMT for a double panel condition). See Figure 7 for an example.
Weld diameter for this interface shall be

based on sheet thickness of 0.7 mm.
t1 = 0.7 mm
t2 = 1.0 mm
t3 = 1.3 mm
Weld diameter for this interface shall be

based on sheet thickness of 1.0 mm
Figure 7: Determination of Weld Diameters in a Triple Panel Combination
Table I.3.3.2 lists the minimum weld diameter measured following a teardown test, as described in III.5.3,
III.5.5, or III.5.6. The minimum weld diameter is the relevant dimension for joint design and weld layout. The
sheet metal thickness referenced in the table refers to the nominal thickness of the thinnest sheet at each weld
interface, as outlined on the engineering drawing or in the CAD model.
Thinnest Sheet Metal Minimum Satisfactory Minimum Undersized

Thickness at Weld Interface Weld Diameter Weld Diameter
[mm] [mm] [mm]
0.50 0.79 3.5 2.6
0.80 1.24 4.0 3.0
1.25 1.99 5.0 3.8
2.00 3.00 6.3 4.7
Table I.3.3.2: Minimum Weld Diameter
I.3.3.3 Special Cases
Manufacturing Welds
The following spot welds are considered manufacturing welds outside the regular spot weld pattern
supporting the Body Construction assembly process:
o spot welds executed as tack welds
o spot welds on toy tabs
o spot welds on hemmed flanges
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These manufacturing welds can be executed as 2T, 3T, or 4T welds that do not need to comply with the
requirements listed in Table I.3.3.2 and do not need to be repaired. However, they do need to be
identified on engineering drawings and agreed upon by Body Engineering. The minimum weld
diameter requirements need to be determined during PV phase testing.
Laminated Steel
The minimum weld diameter is equivalent to that of homogeneous steel with a thickness equal to the
total thickness of the laminated steel. The weld button as described above must be pulled from all layers
of the laminated steel.
I.3.4 Electrode Usage and Flange Dimensions
Tables I.3.4-1 and -2 define standard electrodes and associated minimum values for flange overlap and flange
width for double and triple panel welding. A design radius of 3 mm is assumed for all flange width values.
Other activities may have additional requirements for flange widths. Reductions to these standard values require
the approval of the relevant Body and Manufacturing Engineering departments.
Double Panel Welding

Electrode/Face Flange Dimensions
GMT
Diameter, D/d Lfo Lwe 3) Lww 3)
[mm]
[mm] [mm] [mm] [mm]
16/6 10.5 17.0 23
0.50 - 0.79
13/5 1) 10.5 15.5 21.5
0.80 - 1.24 16/6 11.5 17.5 23.5
1.25 - 1.99 20/8 14 20.5 26.5
2.00 - 3.00 20/8 16.5 22 28
Table I.3.4-1: Standards for Double Panel Welding
Triple Panel Welding

Electrode/Face Flange Dimensions
GMT
Diameter, D/d Lfo Lwe 3) Lww 3)
[mm]
[mm] [mm] [mm] [mm]
16/6 12 18.0 24.5
0.50 - 0.79
13/5 1) 12 16.5 22.5
0.80 - 1.24 16/6 13 18.5 24.5
20/8 15 21.5 27.5
1.25 - 1.99
16/6 or 16/8 2) 15 19.5 25.5
2.00 - 3.00 20/8 18 23 29
Table I.3.4-2: Standards for Triple Panel Welding
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1) The use of 13/5 mm electrodes to achieve shorter flanges requires approval from the relevant Body and
Manufacturing Engineering departments.
2) In triple panel combinations, the 20/8 mm electrode may be replaced by a 16 mm electrode if the
thinnest sheet is 0.8 mm or less. Depending on the specific application, Manufacturing will determine
whether a 6 mm or 8 mm face is required.
3) The overall flange width dimensions Lwe shown in Figures 9 and 10 and Lww shown in Figure 10
consider the compensation of the relevant manufacturing tolerances and ensure the minimum clearance
between electrode and wall(s). They must be maintained in design as the minimum dominating
dimensions.
NOTE: The sum of Lfo and the design radius may be greater than the values for Lwe or Lww shown in
Tables I.3.4-1 and I.3.4-2. In such cases, Lwe or Lww must be increased to match that sum.
D D D
R R
d d d R
Lfo Lfo Lfo

Lwe Lwe
Lww
Fig. 8: Flat Overlap Fig. 9: Wall-To-Edge Fig. 10: Wall-To-Wall
I.3.4.1 Target Locations
Flat Overlap Condition Wall-To-Edge Condition

The center of the spot weld shall be located as The center of the spot weld shall be located
close as possible to the centerline of the parent Lfo / 2 away from the outer edge of the
sheet metal overlap Lfo as shown in Figure 11(a). flange as shown in Figure 11(b).
Lfo
Lfo /2
Lfo/2
(a) (b)
Figure 11: Distance of Weld from Edge for Flat Overlap (a) and Wall-to-Edge (b) Condition
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I.3.4.3 Reduced Flange Width for Bending Angles 120
Figure 13 shows the electrode positioned in a joint condition with a large bending angle .
Lfo
Lwe
Figure 13: Electrode Position for Large Bending Angles
Depending on the bending angle , the flange width dimension Lwe outlined in Tables I.3.4-1 and I.3.4-2 (see
Figures 9 and 10) is reduced as follows:
Electrode/Face Angle Permissible

Diameter, D/d [] Reduction of Lwe
[mm] [mm]
13/5 120 < 150 0.5
150 < 180 2.0
16/6 120 < 150 1.0
150 < 180 2.5
20/8 120 < 150 1.0
150 < 180 2.5
Table I.3.4.3: Permissible Flange Length Reduction, ISO 5821 B-Type Electrode
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I.3.5 Weld Pitch
The weld pitch is the distance between the centers of two adjacent spot welds as shown in Figure 14. The
minimum weld pitch values are listed in Table I.3.5 and must be maintained in order to reduce the risk of a
shunt effect.
NOTE: When a double panel weld is next to a triple panel weld, the minimum weld pitch based on the triple
panel GMT must be used.
GMT Minimum Weld Pitch, S

[mm] [mm]
0.50 - 0.79 20
S
0.80 - 1.24 25
1.25 - 1.99 30
2.00 - 3.00 35
Table I.3.5: Minimum Weld Pitch Fig. 14: Spot Weld Pitch S
Deviations from these pitch requirements require the approval of the relevant Body and Manufacturing
Engineering departments.
I.3.6 Flatness
The area to be welded should be flat and smooth to ensure proper electrode-to-metal and metal-to-metal contact.
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I.4 Applicable Materials
I.4.1 Base Sheet Metal Specification
This Engineering Specification covers the use of the following steels categories in uncoated and coated
condition:
FORD MATERIAL SPECIFICATION NO

CATEGORY TYPES OF STEEL Applicable to Applicable to
Ford of Europe Ford North America
MS Mild Steels, Hot and Cold WSS-M1A344-A1/A2 WSD-M1A333-A1/A2/A3/A4
Rolled, Low Carbon WSS-M1A345-A1/A2/A3/A4
DR Dent Resistant Steels WSS-M1A341-A1/A2/A3/A4/ WSS-M1A341-A1/A2/A3/A4/
including Bake Hardening, A5/A6/A7/A8/ A9/A10 A5/A6/ A7/A8/A9/A10
High Strength IF, Isotropic
and Rephosphorised Steels
HSLA High Strength Low Alloy WSS-M1A346-A1/A2/A3 WSB-M1A215-E1/F1
Steels WSS-M1A347-A1/A2/A3
DP 1) Dual Phase Steels WSS-M1A348-A1/A2/A3/A4/ WSS-M1A348-A1/A2/A3/A4/
A5/A6/A7/A8/A9 A5/A6/A7/A8/A9
TRIP 1) TRIP Steels WSS-M1A351-A1/A2/A3 WSS-M1A351-A1/A2/A3
MSW 1) Martensitic Steels TBD WSS-M1A183-D
BORON 1) Boron Steels WSS-M1A322-A3 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.
2) WSS-M99P39-A1/A2/A3/A4 performance specification must be called out with these Boron steels.
Table I.4.1: Applicable Categories of Base Sheet Steels Covered by this Specification
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.
New steel types are under constant development. In the case of steel types not covered by Table I.4-1 the
relevant Body and Manufacturing Engineering departments shall be contacted.
I.4.2 Standard Base Sheet Metal Coatings
Resistance spot welding supports the following coatings in all combinations:
Specification Type Specification No. Coating Type

60G60G EL, 50G50G EL WSS-M1P94-A Electro-galvanized
55A55A HD WSS-M1P94-A Galvannealed
60G60G HD, 50G50G HD WSS-M1P94-A Hot Dip Galvanized
AlSi coating WSD-M1A295-A2 Hot Dip Aluminized
Table I.4.2: Standard Base Metal Coatings Covered by this Specification
The use of coatings not listed in Table I.4-2 requires the approval of the relevant Body and Manufacturing
Engineering departments.
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I.5 Weld Identification Symbols

The weld symbols shall be in accordance with Ford Engineering CAD and Drafting Standard D-3 (Welding
Symbols and Specifications), available from http://www.fecds.ford.com
I.6 Weld Classification

"Control welds" for resistance spot welding are defined as welds that are important for structural integrity,
safety, or Federal compliance (North America). They shall be identified jointly between Body Engineering
(Core and Vehicle Program) and the Attribute Teams (Crash, Durability and, if applicable, NVH) on the basis of
the relevant Design-FMEAs, CAE-analysis and physical verification testing.
"Control welds" are identified by Control / V. This designation is attached to specific welds in the relevant
CAD files. Welds not designated as "control welds" are considered "common welds".
I.7 Weld Groups

A weld group is defined as a set of spot welds that join the same combination of sheets ("stackup"). In general,
all welds in a stackup will be in one group. A metal condition change (e.g. when a tailor-welded part is in the
stackup) requires designation of a new group. Because individual control welds may be identified as described
in Section I.6, a group may contain both common and control welds. This situation is described further in
Section I.8.
A group size of one is not permitted. If the weld is essential, the joint should be redesigned to
incorporate a redundant weld or a mechanical fastener.
A group size of two is not recommended. If both welds are essential, the joint should be redesigned to
incorporate a redundant weld or a mechanical fastener. If a second weld was added as noted above to
avoid a one-weld group, a note can be added to the engineering drawing to allow one discrepant weld in
the group. This requires approval of the relevant Body and Manufacturing Engineering departments.
I.8 Weld Quality Levels, Acceptance Criteria, and Reaction Requirements
I.8.1 Weld Quality Levels
For this Engineering Specification, Table I.8.1 defines three distinct levels of quality for spot welds:
Satisfactory Undersized Discrepant
A spot weld that meets the A spot weld that meets at least A spot weld that is below
minimum weld diameter 75% of the minimum undersized or does not meet all the
requirements at each interface satisfactory weld diameter at relevant requirements of Section III.
(Table I.3.3.2) and all the each interface (Table I.3.3.2)
relevant requirements of and all the relevant Note: A missing spot weld is
Section III. requirements of Section III. classified as discrepant.
Table I.8.1: Levels of Spot Weld Quality
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I.8.2 Acceptance Criteria
Table I.8.2 defines the requirements for determining weld group effectiveness based on the quantity of welds
designated, the quantity of satisfactory welds, and the quantity of satisfactory and undersized welds combined.
Number of Minimum Number of Minimum Number of Maximum Number of

Spot Welds in Satisfactory Satisfactory + Undersized Discrepant Welds
Group Welds Required Welds Required Allowed (For Reference)
2 1 2 0
3 2 2 1
4 3 A 3 1
5 4 4 1
6 4 N 5 1
7
8
5
6 D 6
6
1
2
9 6 7 2
N>9 70% based on common 80% based on common 20% based on common
rounding rules rounding rules rounding rules
Table I.8.2: Permissible Number of Discrepant and Undersized Spot Welds in a Group
NOTE: Both "Minimum Satisfactory" AND "Minimum Satisfactory + Undersized" criteria from Table I.8.2 must be met in
order to have an effective group.
Examples for a group size of 6 welds:

o 3 satisfactory welds, 2 undersized welds, and 1 discrepant weld does not pass because "Minimum
Satisfactory" is not met.
o 4 satisfactory welds and 2 discrepant welds does not pass because "Minimum Satisfactory +
Undersized" is not met.
o 4 satisfactory welds, 1 undersized weld, and 1 discrepant weld passes because both "Minimum
Satisfactory" and "Minimum Satisfactory + Undersized" are met.
I.8.3 Reaction Requirements
Reaction plans for containment and repair according to local weld control plans shall be executed in any one of
the following cases:
the criteria in Table I.8.2 are not met
a single control weld is discrepant
adjacent welds are discrepant, even if they are from different groups (for example, if G1 and G2 in
Figure 15 had adjacent discrepant welds, reaction would be required)
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Group G1,
8 spot welds
Group G2,
Control welds 3 spot welds
as assigned Group G3,
by Body 4 spot welds
Engineering
Control
3 Thickness
2 Thickness Weld
Group G4,
10 spot welds G = Group
Figure 15: Weld Grouping Illustration
Examples of how to consider control welds in group testing, using Figure 15:
o Group G1 follows the requirements of Table I.8.2 for a group of eight spot welds, but none of the
control welds shown above are allowed to be discrepant.
o Group G4 follows the requirements of Table I.8.2 for a group of 10 spot welds, but the control
weld shown above is not allowed to be discrepant.
NOTE: Start or end welds of groups relevant to attribute performance may be identified as control
welds, as shown in this example.
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II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS
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 at production rates). 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.
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.
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.
Welds 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.6.
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.
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II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS (cont.)
Weld Parameter Monitoring
Test Test Characteristic Lower Tolerance Target Value Upper Tolerance Minimum Minimum
Number Limit Limit Sample Size Sample
Frequency
III.2.2 Welding Current over Time [A] As determined in As determined in As determined in see 1) see 1)
PV testing PV testing PV testing
III.2.3 Electrode Force [N] As determined in As determined in As determined in see 1) see 1)
PV testing PV testing PV testing
1)
Ford
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
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Inspection of the Visible Part of the Weld
Frequency
III.3.2 Spot Weld Count As defined in Table As specified on the No additional spots see 1) see 1)
I.8.2 engineering drawing or allowed
relevant CAD model
III.3.3 Spot Weld Position 10.0 mm from target As specified on the Not applicable see 1) see 1)
position engineering drawing or
relevant CAD model
III.3.4 Distance From Edges As defined in III.3.4 As defined by the spot Not applicable see 1) see 1)
weld position
III.3.5 Classes of Weld Finish, See Section III.3.5 for See Section III.3.5 for See Section III.3.5 for see 1) see 1)
Surface Indentation, and details details details
Expulsion
III.3.6 Burn Through Not applicable Not present Not applicable see 1) see 1)
III.3.7 Surface Cracks Not applicable Not present Not applicable see 1) see 1)
III.3.8 Surface Porosity Not applicable Not present Not applicable see 1) see 1)
1)
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Inspection of Section Cut
Frequency
III.4.2 Nugget Diameter 85 % of required Matching Not applicable see 1) see 1)
minimum weld minimum weld
diameter (Table diameter (Table
I.3.3.2) I.3.3.2)
III.4.3 Weld Penetration See Section III.4.3 Not applicable See Section III.4.3 see 1) see 1)
for details for details
III.4.4 Porosity Permitted in center of Not present Not applicable see 1) see 1)
weld at individual or
cumulative size of
25% of weld area.
III.4.5 Cracks Permitted in center of Not present Not applicable see 1) see 1)
cumulative length of
20% of nugget
diameter.
III.4.6 Inclusions Permitted in center of Not present Not applicable see 1) see 1)
cumulative length of
20% of weld area.
III.4.7 Hardness Limits See Section III.4.7 See Section III.4.7 See Section III.4.7 see 1) see 1)
for details for details for details
1)
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Destructive, Non-Destructive, and Functional Testing
Test Test Characteristic Lower Tolerance Limit Target Value Upper Minimum Minimum
Number Tolerance Limit Sample Size Sample
Frequency
III.5.2 Static Tensile Test As determined by Body Not applicable Not applicable see 1) see 1)
Engineering
III.5.3 Peel Test Minimum weld diameter dP Not applicable Not applicable see 1) see 1)
as outlined in Section I.3.3.2
III.5.4 Impact Test See Section III.5.4 for details See Section III.5.4 for See Section see 1) see 1)
details III.5.4 for details
III.5.5 Chisel Test Minimum weld diameter dP Not applicable Not applicable see 1) see 1)
(Destructive) as outlined in Section I.3.3.2
III.5.6 Destructive Test Minimum weld diameter dP Not applicable Not applicable see 1) see 1)
Using a Machine as outlined in Section I.3.3.2
III.5.7 Ultrasonic Test Not applicable See Section III.5.7 for Not applicable see 1) see 1)
details
III.5.8 Chisel Test Not applicable No separation of sheets in Not applicable see 1) see 1)
(Non-Destructive) stackup
III.5.9 Durability/Fatigue Not applicable No cracks in weld or HAZ and Not applicable see 1) see 1)
Test no separation following
completion of full vehicle
PASCAR Phase 1 and 50 % of
PASCAR Phase 2 testing
according to CETP 00.00-
R310
1)
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III. TEST PROCEDURES AND REQUIREMENTS
III. 1 Applicability of Test Procedures for Production Validation (PV) and In-Process (IP) Test Phases
Test Test PV-Test Phase IP-Test Phase

Number Characteristic
III.2 Welding Parameter Mandatory to establish target values and tolerance Mandatory
Monitoring limits.
III.3 Inspection of the Mandatory Mandatory

Visible Part of the
Weld
III.4 Inspection of Section Optional Body and Manufacturing Engineering Optional may be used for root cause analysis.
Cuts departments must decide whether section cut analysis is
required (e.g. for unknown sheet metal combinations).
III.5 Destructive, Non- Mandatory Destructive Chisel Test (III.5.5) and/or Mandatory At least one Destructive and one Non-Destructive
Destructive, and Test Using a Machine (III.5.6) Test method according to local weld control plans.
Functional Testing
Optional Body and Manufacturing Engineering
departments to decide whether Static Tensile Test
(III.5.2), Peel Test (III.5.3), Impact Test (III.5.4), and/or
Durability/Fatigue Test (III.5.9) is required (e.g. for
unknown sheet metal combinations).
Table III.1: Applicability of Test Procedures and Requirements
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III.2 Weld Parameter Monitoring
Resistance spot welding equipment used for the production of parts according to this Engineering Specification
shall be equipped with a built-in weld parameter control and monitoring unit. The target values and the upper
and lower tolerance limits for the parameters below shall be determined in Product Validation (PV) tests
individually for each spot welding application. They shall be included in the process control plan and later be
applied on the basis of a 100 % sampling rate during In Process (IP) conformance testing. Non-conforming
welds should be identified and processed for additional inspection and possible rework.
III.2.2 Welding Current over Time [A]
During IP-monitoring, the welding current over time shall stay within the welding current window as defined in
PV-testing individually for each spot welding application.
III.2.3 Electrode Force [N]
During IP-monitoring, the electrode force shall stay within the force window as defined in PV-testing
individually for each spot welding application. Note that 100% sampling may only be possible if the weld gun is
equipped with a load cell or transducer.
III.3 Inspection of the Visible Part of the Weld
Visual inspection shall be performed without the aid of magnification to detect obvious discrepancies on the
surface of the weld. The intent of this type of inspection is also to verify that the number and location of the
welds is as outlined on the engineering drawing or relevant CAD model.
Dimensional compliance shall be checked using a caliper gauge, scale, or a template where applicable.
III.3.2 Spot Weld Count
Lower Tolerance Limit Target Value Upper Tolerance Limit

Missing welds are The number of spots No additional spots allowed.
classified as discrepant made shall be as
welds. The tolerance specified on the NOTE: In cases where more spots than specified
limit for discrepant welds Engineering drawing are required in production, the extra spots shall be
is defined in Table I.8.2. or the CAD model. agreed by the responsible design department.
Table III.3.2: Target Value and Tolerance Limits for Spot Weld Count
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III.3.3 Spot Weld Position
Spot welds shall be placed as specified on engineering drawings or relevant CAD models. Figure 17 shows the
permissible deviation of the spot weld location (center of weld) from its nominal position. Note that
discrepancies such as Edge Condition UA1 described in III.3.4 may override this positional tolerance.
Nominal Position
(Center of Weld)
Range for Welding
20 mm
Figure 17: Tolerance Range for Spot Weld Position
NOTE: The weld pitch shall not be reduced below the minimum pitch (see Section I.3.5).
III.3.4 Distance from Edges
The distance-to-edge requirements outlined below overrule the positional requirements.
Acceptable Conditions - The following two distance-from-edge conditions are considered to be acceptable
under the described restrictions and do not represent a discrepant weld:
Condition A1: Describes a position where both the inner (A) and outer (B) diameter of the visible
electrode indentation (ISO 5821 Type B electrode) remain inside the trim edge without causing trim
edge deformation. This condition is acceptable for ALL types of flanges.
Condition A2: Includes the effect of trim edge deformation. It is acceptable provided diameter A stays
within the projected trim edge as shown. This condition is acceptable only for Class 2 and Class 3
flanges that are not classified as functional flanges1).
B B
A A
Figure 18: Condition A1 Figure 19: Condition A2
1) Flanges are classified as functional if they carry a secondary function such as the attachment of a seal
against water ingress (e.g. the door opening flange). See Section III.3.5 for the definitions of surface
classes.
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Unacceptable Conditions - The following distance-from-edge conditions are considered to be unacceptable and
represent a discrepant weld:
Condition UA1: Describes a position where the inner diameter A of the visible electrode indentation
(ISO 5821 Type B electrode) extends beyond the trim edge. This condition is not acceptable and
represents a discrepant weld.
Condition UA2: Describes a case where the trim edge has been smashed. This condition is not
acceptable and represents a discrepant weld.
B
A
Figure 20: Condition UA1 Figure 21: Condition UA2
III.3.5 Surface Characteristics
The weld finish requirements described below are based on the requirements for surface quality per Engineering
Specification ESF75B-11007-AA, available from http://forddoc.secure24.ford.com/.
III.3.5.1 Classes of Weld Finish
Weld Finish on Class 1 Surfaces

Spot welds on these surfaces should be avoided and require the approval of the relevant Body and
Manufacturing Engineering departments, as well as Craftsmanship.
This weld finish classification covers sheet metal surfaces that must be free from surface markings or
imperfections after metal finishing to the extent that they are not apparent after painting and within the
limits as described below. Spot welds for subsequent metal finish to a Class 1 metal surface should be
held to the least possible marking on the surface to be metal finished. Weld marking must not exceed a
depth such as can be removed by metal finishing. Metal finishing shall not remove more than 10 % of
the surface thickness, meaning a marking in excess of 10 % of surface sheet thickness must be filled
prior to metal finishing. No surface expulsion of metal will be acceptable.

This weld finish classification covers a minimal marked welded surface and shall be used where a
minimum amount of metal displacement is acceptable. Outside surface sheet metal assemblies in which
this weld finish is required will be governed by approved specific visual samples. Outside Surface
Sheet Metals are defined as those surfaces that are visible from the outside of the vehicle in its normal
running condition (including when doors, tailgates, or hoods are open).
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This weld finish applies to surfaces which, after final assembly, are always covered.
III.3.5.2 Surface Indentation and Expulsion
The term surface indentation describes the geometry of the depression caused by the electrodes. The key
dimensions as shown in Figure 22 are:
Indentation I, expressed as a percentage of the thickness of the outer sheet and
Minimum remaining total thickness X, expressed as a percentage of overall stackup (t1 + t2 + t3)
I t1
t2
X
t3
Figure 22: Surface Indentation over the Spot Weld

The term surface expulsion describes the height of the annular rim and/or weld burr caused by the ejection of
molten metal from the electrode-to-sheet metal interface. The term "metal spatter" or "flash" describes the
ejection of molten metal which gets deposited on a sheet metal surface, either from the electrode-to-sheet metal
interface or the sheet metal-to-sheet metal interface.
Surface Lower Target Value Upper Tolerance Limit

Class Tolerance
Ford Limit
Class 1 Not Spot welds for subsequent metal I = 10%. Weld marking must not
(Spot Welds Applicable finish to this class should be held to exceed a depth such as can be removed
Should Be the least possible marking on the by metal finishing.
Avoided) surface to be metal finished.
Surface expulsion and metal spatter
are not acceptable.
Class 2 Not A minimum amount of indentation I = 15 %. Surface expulsion is a
Applicable is acceptable. maximum of 10 % of sheet thickness.
Surface expulsion and metal spatter
are not acceptable.
Class 3 Not A minimum amount of indentation X = 60 % unless stated differently.
Applicable is acceptable. Surface expulsion Surface expulsion or metal spatter shall
and metal spatter should be avoided be removed if required (for example, if
(example shown in Figures 23 and weld is designated as "flash free or
24). spatter free"); excessive indentation in
the outer sheet as shown in Figures 25
and 26 is not acceptable
Table III.3.5.2: Target Value and Tolerance Limits for Surface Indentation and Expulsion
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Figure 23: Top View of Weld Figure 24: Section Cut with Acceptable
with Acceptable Indentation Indentation (Same Weld as Fig. 23)
Figure 25: Top View of Weld Figure 26: Section Cut with Unacceptable
with Unacceptable Indentation Indentation (Same Weld as Fig. 25)
III.3.6 Burn Through
A spot weld shall be classified as discrepant if it shows any sign of a hole through the weld.
III.3.7 Surface Cracks
A spot weld shall be classified as discrepant if it shows any sign of surface cracks.
III.3.8 Surface Porosity
A spot weld shall be classified as discrepant if it shows any sign of surface porosity.
III.4 Inspection of Section Cut
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 may be analyzed to detect the discrepancies described below.
In addition, section cut analysis could be used for root cause analysis in case of discrepancies during the IP-
phase. Section cuts shall be made through the center of the weld, perpendicular to the sheets.
NOTE: Relevant expert departments shall be consulted in case these acceptance criteria cannot be met.
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III.4.2 Nugget Diameter dL
Measured in a section cut, the nugget diameter, dL, shall be at least 85 % of the minimum weld diameter as listed
in Table I.3.3.2.
Figure 28 shows the relevant diameter dL for a double panel welding condition.
Nugget
t1
p1
p2
t2
dL
Figure 28: Nugget Diameter and Weld Penetration Double Panel Welding
In the case of section cut analysis on triple welding conditions, dL1 and dL2 are measured to determine
compliance with the minimum nugget diameter requirements, as shown in Figure 29.
dL1 Nugget
p1
t1
t2 p2
p3
t3
dL2
Figure 29: Nugget Diameter and Weld Penetration Triple Panel Welding
III.4.3 Weld Penetration
The weld penetration, p, shall be measured in a section cut as shown in Figures 28 and 29. The upper and lower
tolerance limits listed below serve as guidelines:
p1 p
Double Panel Welding: 0.4 0.8 and 0.4 2 0.8
t1 t2
p1 p2 p
Triple Panel Welding: 0.3 0.8 and = 1 and 0.3 3 0.8
t1 t2 t3
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III.4.4 Porosity
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 cumulative size of 25% of the weld area.
III.4.5 Cracks
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 nugget diameter (dL for double panel or dL1 for triple panel welding).
III.4.6 Inclusions
Inclusions are foreign solid materials such as impurities entrapped in the weld. Inclusions should not be present,
but are permitted in the center of the weld at an individual or cumulative size of 20% of the weld area.
NOTE: The relevant Body and Manufacturing Engineering departments shall be consulted in case that the
imperfections described in III.4.4, III.4.5, or III.4.6 occur off the center of the weld and/or in case more than
one discrepancy occurs in a single weld.
III.4.7 Hardness Limits
Hardness testing shall be performed according to ISO 14271 (Europe) on spot weld section cuts to determine the
Vickers hardness (low load range, HV 1) of the weld nugget, the heat affected zone, and the parent sheet metal.
Initial Parent Sheet Hardness In Table III.4.7 lists the permissible increase in
Metal Hardness Weld Nugget hardness based on the initial parent sheet metal
[HV 1] [HV 1] hardness.
< 120 < 350
The material used and the welding techniques
> 120 < 200 < 450
employed shall be such that the hardness of the
> 200 < 300 < 550 weld nugget and the heat-affected zone do not
> 300 < 600 exceed the limits listed in Table III.4.7.
Table III.4.7: Hardness Increase Limits
NOTE: The relevant expert department shall be consulted in case that these limits cannot be met.
III.5 Destructive, Non-Destructive, and Functional Tests
Weld strength tests are performed as PV- and IP-tests to ensure that the weld joint meets the individual
performance requirements in terms of static and dynamic loads. Fracture or separation during a test is supposed
to occur in the base metal or the heat-affected zone (HAZ), but not in the weld. For non-destructive tests, the
applied test method shall indicate the presence of a weld.
Note: Non-destructive tests are not suitable to determine compliance with the minimum weld diameter
requirements outlined in Section I.3.3.2.
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III.5.2 Static Tensile Test
The static tensile test shall be performed in accordance with one of the following:
ISO 14273, Specimen Dimensions And Procedure For Shear Testing Resistance Spot, Seam And
Embossed Projection Welds (Europe).
AWS D8.9M:2002 Recommended Practices for Test Methods for Evaluating the Resistance Spot
Welding Behavior of Automotive Sheet Steels (North America).
The test specimen shall be manufactured using base sheet metal identical to production conditions in terms of
material specification, gauge and base sheet metal coating. The weld diameter shall be as indicated in Section
I.3.3.2. The test specimen shall be loaded gradually and continuously until separation occurs. Figure 30 shows
the test setup and loading direction. Table III.5.2, as a reference, lists typical minimum shear strength values for
two sheets of Mild Steel in equal thickness combinations.
Sheet Thickness Ultimate Shear

[mm] Strength [kN]
0.5 1.5
0.8 2.6
1.0 3.2
1.25 4.8
1.5 5.1
2.0 7.8
2.5 10.6
Figure 30: Static Tensile Test, DIN EN ISO 14273 Table III.5.2: Ultimate Shear Strength
Additional strength data for other steel combinations may be available from relative Body and Manufacturing
Engineering departments or from active databases such as Join-NET at
http://gbwux014.gothenburg.vcc.ford.com/mtdatab/joinnet/.
III.5.3 Peel Test
The static peel test shall be performed in accordance with one of the following:
ISO 14270, Specimen Dimensions And Procedure For Mechanized Peel Testing Resistance Spot, Seam
And Embossed Projection Welds (Europe).
AWS D8.9M:2002 Recommended Practices for Test Methods for Evaluating the Resistance Spot
Welding Behavior of Automotive Sheet Steels (North America).
The test specimen shall be manufactured using base sheet metal identical to production conditions in terms of
material specification, gauge and base sheet metal coating. The weld diameter shall be as indicated in Table
I.3.3.2. The test specimen shall be loaded gradually and continuously until separation occurs. Separation is
acceptable in the base sheet metal or in the HAZ, but not in the weld.
III.5.4 Impact Test
Impact tests shall be performed with those welded joints that are subjected to loads at high speeds to verify
integrity of the welded joint.
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The test set up and test conditions shall be agreed upon with the relevant Safety Attribute Team taking into
consideration the location and loading condition of the relevant joint on the vehicle. Testing can be performed
on either components or subassemblies (e.g. sled testing, drop testing) that contain the welded joint.
III.5.5 Chisel Test (Destructive)
Destructive chisel testing requires separating the base sheet metal adjacent to the weld using a chisel. The chisel
test can be applied on a subassembly or complete body. It is performed to validate adequate fusion by
measuring weld diameter and comparing it against the minimum weld diameter requirements as outlined in
Section I.3.3.2. The chisel according to ISO 10447 is shown as an example in Figure 26 for Europe. Figure 27
shows the chisel used in North America.
40
R 70
All edges to be
15 free of burrs
24 9 12.5
For button diameter < 8.0
Figure 26: Chisel According to ISO 10447 (Europe)
Figure 27: Destructive Test Chisel Used in North America (ref. tool # 5ZF-15063)
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Permissibility of Partial Plug and Interfacial Fractures
Figure 6 in Section I.3.3.1 illustrates a typical interfacial fracture face. It is characterized by a lack of a
button. The occurrence of the interfacial fracture or partial plug fracture is acceptable for the
combinations listed below provided there is evidence of good metal bonding at the weld, i.e. the fracture
face is crystalline and there is metal distortion in the parent metal around the weld.
o All Steel Categories
An interfacial fracture typically occurs in conjunction with combinations of thick sheets (for
example 2.0 mm GMT).
o HSS/UHSS Steel Categories
A partial plug or interfacial fracture may occur on spot welded joints involving homogenous and
heterogeneous combinations of the sheet steel categories DP, TRIP, MSW and BORON, even at
lower gauges. The permissibility of these fractures shall be determined during PV testing.
The occurrence of a partial plug failure or interfacial fracture is permissible for these combinations
only on the basis of compliance with the weld penetration requirements as outlined in Section
III.4.3.
NOTE: The relevant expert departments shall be consulted in case partial plug failures or
interfacial fractures occur on combinations other than those listed above.
III.5.6 Destructive Test Using a Machine
A peel testing bench (weld teardown machine), tensile machine, and/or hydraulic tool ("jaws of life") may be
utilized in lieu of a chisel for destructive inspection. Welds are evaluated using the same criteria.
III.5.7 Ultrasonic Inspection
Spot welds can be evaluated by reading the echo from an ultrasonic probe. Some of the conditions that may be
observed during ultrasonic inspection are small nugget size, lack of fusion, poor penetration, burnt welds (too
hot), voids, and pores. These are considered discrepancies if they exceed the limitations defined in other
sections of this specification. For triple panel welding, the nugget diameter at the two-sheet interface with the
smaller GMT, defined as dL1 in Section III.4.2, is the dominating dimension in ultrasonic testing.
Ultrasonic inspection requirements shall be included in the weld control plan.
III.5.8 Chisel Test (Non-Destructive)
In a non-destructive chisel test, a chisel or pry bar is used as shown in Figure 32 to separate the steel sheets
between adjacent spot welds. The chisel is driven with a hammer until the sheets start to separate at the sides of
the weld nugget. The purpose is to apply enough force to deform the material and show the sheets are fused, but
not completely separate the sheets. Sheets that separate with no evidence of fusion indicate a discrepant weld
condition. If a button is accidentally pulled during this test, the sheets must be brought back together and the
weld must be repaired.
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Figure 31: Pry Bar Chisel Used in North America (ref. tool # 5ZF-12236)
Figure 32: Chisel Test Illustration
Following are specific rules that apply to non-destructive chisel testing:

The chisel shall not be directed straight onto the weld.
The test shall not be performed on two adjacent welds.
The test should not be performed on Class 1 or Class 2 welds.
In the case of triple panel joints, the two-joint layers shall be tested on separate welds.
Welds in adhesively-bonded joints should not be non-destructively chisel tested since the chisel may
wipe away the adhesive. As an alternative, the spot may be tested ultrasonically.
The test shall not be applied when sufficient deformation cannot occur, for example when:
o Both sheets are 2.0mm or greater
o Design section is stiff
o Both sheets have a minimum ultimate tensile strength of 600 MPa or greater
o Any combination of the above exists
Following the tests, sheet deformation shall be restored by straightening the sheets with a hammer.
NOTE: This is especially important for functional flanges (Section III.2.4).
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III.5.9 Durability/Fatigue Test
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 joints and no lack of compliance to full vehicle PASCAR Phase 1 and
completion of half of PASCAR Phase 2 testing.
III.6 Permissible Repair Methods
Spot welds that do not meet the acceptance criteria of this Engineering Specification may be repaired by one of
the following methods. The preferred method is resistance spot welding. Specific permission must be obtained
from Product Development Engineering to use other methods, but agreements may be made to cover general
situations.
III.6.1 Resistance Spot Welding
An additional effective spot weld shall be placed as close as possible to the actual position of the discrepant spot
weld without interfering with it. If spacing allows, it shall be placed half way between the discrepant and the
next existing spot weld.
III.6.2 Plug Welding
A plug weld using gas metal arc welding as described in specification ESBM5A-1B310 may be used as a repair
for a single spot weld or two plug welds for two adjacent spot welds. That specification includes the wire type
to be used.
The plug weld is made on the side of the thinnest metal, so the hole drilled for the weld shall be in the thinnest
outer metal. The hole is made with a specially ground drill so that the heavy metal backup thickness is left
essentially intact after drilling completely through the thinner metal(s). The following table shows required hole
sizes for plug welds.
Minimum Sheet Minimum Hole Size

Metal Thickness for Plug Welding
[mm] [mm]
0.50 1.24 10.0
1.25 3.00 13.0
Table III.6-1: Minimum Plug Weld Repair Hole Size
In a plug weld repair, the entire hole, including the periphery of the hole, must be fused to the heavy metal part.
Weld build-up that is detrimental to the dimensional integrity, appearance, or function must be made nearly
flush by grinding (grinding completely flush may reduced the strength of the weld).
Note: For triple panel welding, the thinnest permissible backup metal thickness which is not drilled is 2.0mm.
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III.6.3 Fillet Fusion Welding
Fusion fillet welding as described in the latest version of the gas metal arc welding specification ESBM5A-
1B310 may be used as a repair for suspected discrepant welds. That specification includes the wire type to be
used. The following table shows the required fusion weld length for each discrepant spot weld.
Minimum Sheet Minimum Length of

Metal Thickness Fusion Fillet Weld
[mm] [mm]
0.50 1.69 9.5
1.70 3.00 13.0
Table III.6-2: Minimum Fusion Weld Length Repair
A suitable sealer shall be applied over all fusion welds that are used to repair missing spot welds located in areas
of the product that are vulnerable to water and dust leaks.
III.6.4 Riveting
One suspected discrepant spot weld may be repaired by replacement with one blind rivet per the following table.
Total Metal Nominal Rivet Maximum Recommended Ford Standard

Thickness Diameter Length Hole Size Part Number
(mm) (mm) (mm) (mm)
1.50 to 3.50 6.5 13.7 6.7/6.9 W707638-S437
2.80 to 4.80 6.5 15.0 6.7/6.9 W702512-S437
4.80 to 6.80 6.5 17.0 6.7/6.9 W708777-S437
Table III.6-3: Rivet Size Requirements
The type of repair rivet used is to be a domed head steel rivet with a steel mandrel. To insure discrepant spot
weld repairs are leak free, apply a suitable sealer over all rivet repairs that are vulnerable to water and dust leaks.
Blind rivets must not be used in the proximity of fuel tanks, fuel lines, brake lines or emission lines.
Note: To determine the Total Metal Thickness for applications using laminated steel, the total thickness of
the laminated steel should be used.
III.6.5 Gas Metal Arc Brazing
This repair is only allowed if agreed upon between Body and Manufacturing Engineering. The repair is limited
to double panel welding with a GMT up to 1.2mm and must follow the appropriate brazing guidelines described
in the latest version of the gas metal arc brazing specification ESBM5A-1A336. A plug braze repair could also
be executed and would following the requirements of III.6.2 above.
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IV. REVALIDATION REQUIREMENTS
Any of the following conditions that affect the welding operation require a re-run of Production 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:
o New, different, relocated, or rehabilitated production machinery or equipment
o Any change in subcontracted products or services including the use of engineering-approved
alternate materials
o Changes to rework methods
o Changes in the sequence of operations
o 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:
o A switch from mild steel to high strength steel with a yield strength > 260 MPa
o 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.
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
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 recommended process variables to include in the control
plan are:
Welding current over time [A]

Electrode force [N]
V. INSTRUCTION AND NOTES
Control Plans address all significant design and process characteristics, which include all ES tests and Control
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 that, with their sample sizes and
frequencies, will be performed in order to:
Confirm whether the process is being managed effectively.
Further identify significant process characteristics.
May92
3947a2e
Evaluate performance of marginal processes.

Better anticipate the customer effect of proposed process improvements.
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 Design activity for review. This Product Engineering activity
has flexibility to honour business relationships with suppliers having proprietary processes.
Examples of formats for Control Plans are shown in Quality System Requirements, QS-9000.
VI. COMPILATION OF REFERENCE DOCUMENTS
A. QS-9000, Quality System Requirements

B. Ford Material Specifications available at http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html,
Metals 1A-99A.
C. Welding Symbols and Specifications: http://www.fecds.ford.com
D. Ford Engineering Specification - Sheet Metal Surfaces and Edges (ESF75B-11007-AA) available at
http://forddoc.secure24.ford.com/
E. ISO 10447:1991, Welding Peel & Chisel Testing Of Resistance Spot, Projection & Seam Welds
F. DIN EN ISO 14273:2001, Specimen Dimensions & Procedure For Shear Testing Resistance Spot, Seam &
Embossed Projection Welds
G. JoinNet Database http://gbwux014.gothenburg.vcc.ford.com/mtdatab/joinnet/
H. ISO 14271:2000, Vickers Hardness Testing Of Resistance Spot, Projection & Seam Welds
I. Vehicle Operations Operating Procedure VOPSSN-008, Weld Quality Program, available at
http://www.vo.ford.com/ss/procedures
J. Vehicle Operations Operating procedure VOPQUE-612, Uniform Test and Evaluation Program for Welding
and other joining Operations; available at
https://www.ekbbooks.ford.com/ekbbooks/bookmark.html?objectId=0b000c5180744ffb
K. ISO 5821:1979, Resistance spot welding electrode caps
L. AWS Welding Handbook, Volume 2, Eighth Edition
May92
3947a2e

Esbm5a-B 1n261-s Aa RSW

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Engineering Specification

FRAME 2 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

I.1 Scope of Engineering Specification, General Statement .. 4

I.2 Process Description ... 5

I.3 Design Guidelines . 5

I.4 Applicable Materials ... 13

I.5 Weld Identification Symbols . 14

I.6 Weld Classification ........................... 14

I.7 Weld Groups . 14

I.8 Weld Quality Levels, Acceptance Criteria, and Reaction Requirements.... 15

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS... 17

III. TEST PROCEDURES AND REQUIREMENTS .. 22

III.1 Applicability of Test Procedures for PV- and IP-Test Phases .. 22

III.2 Weld Parameter Monitoring ... 23

FRAME 3 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

III.3 Inspection of the Visible Part of the Weld ..... 23

III.4 Inspection of Section Cuts ....... 27

III.5 Destructive, Non-Destructive, and Functional Testing ...... 29

III.6 Permissible Repair Methods 34

IV. REVALIDATION REQUIREMENTS . 36

V. INSTRUCTIONS AND NOTES .... 36

VI. COMPILATION OF REFERENCE DOCUMENTS ...... 37

FRAME 4 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

I.1 Scope of Engineering Specification, General Statement

This Engineering Specification is intended to evaluate specific characteristics as a supplement to normal

FRAME 5 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

I.2 Process Description

Figure 1: Illustration of RSW Process

I.3 Design Guidelines

I.3.1 Governing Metal Thickness

I.3.2 Gauge Ratio Limitations

FRAME 6 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

2 Two Unequal Thickness X X/Y 1/3 X Y X/Y 1/2.5 X Y

1.2 1.2 1.2 1.2 1.2 1.2

Three Unequal Thicknesses,

2.4 0.8 2.4 2.0 0.8 2.0

I.3.3 Weld Diameter

Figure 2: Weld Nugget Diameter Figure 3: Weld Button

FRAME 7 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

Figure 4: Full Plug Fracture ("Button") Diameter

Figure 5: Partial Plug Fracture Diameter

adhesion ring zone

Figure 6: Interfacial Fracture Diameter

FRAME 8 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

I.3.3.2 Minimum Weld Diameter

Weld diameter for this interface shall be

Weld diameter for this interface shall be

Figure 7: Determination of Weld Diameters in a Triple Panel Combination

Thinnest Sheet Metal Minimum Satisfactory Minimum Undersized

I.3.3.3 Special Cases

FRAME 9 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

I.3.4 Electrode Usage and Flange Dimensions

Double Panel Welding

1.25 - 1.99 20/8 14 20.5 26.5

2.00 - 3.00 20/8 16.5 22 28

Table I.3.4-1: Standards for Double Panel Welding

Triple Panel Welding

Table I.3.4-2: Standards for Triple Panel Welding

FRAME 10 OF 37 REV. LET. PART NO. ESBM5A-1N261-AA

Lfo Lfo Lfo

Fig. 8: Flat Overlap Fig. 9: Wall-To-Edge Fig. 10: Wall-To-Wall

I.3.4.1 Target Locations

Flat Overlap Condition Wall-To-Edge Condition