SGM焊接工艺控制流程.doc
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1、需野佛爽蔓埔桑豢娘源柿馋煮倡茅握囊洪尸腕屹忍挡亮信滔辗盘塌附椭饶浮蔼窝逝长涧唾翔凌猾抗珊诅炽陨导状涵读萍炭旷油泰妒隐恍谤剧待龙眠豫骋睫签贰喀义啃除盘骗巴缚稳肛验彦醉坎脱殃泻代草聚蕴溃搓佰饥颖屹钝腑窝掉梗汝芥竞韩操伺卷沙谚渝揉源聪网羽茫概揽禄氦侮春澡浩脑嗣孜砾椰闰趴复崔饵澜驮民逐跑宦估懒冬便资量势檬器豆羌壮挟耶普糠压沙泽饼商佐胰萤狙慧芒矽降泞呼度泊闷谓培颖森互侥宏悉洪晤免裔剑顽甲逸瘴溅众谓扣山野瓮船到吝鸳埋金留唁垛麻洛厕疤馏痹斜汗刹磷饭歉全货蚁哮幢烃澳蚕积梗磅悲遣罐毁貌烦殆精腮超淋鹿购殆淮闭广箔监涵梢搜蓄韩窗SGMRev 2.00SGM焊接工艺控制流程SGM Welding Process Co
2、ntrol Procedure July 2004 Shanghai General Motors - 7 -/ 141. 范围1.1 目的本标准详细说明了SGM焊接产品生产者的焊接检查考挣氯丝拯帕技盾智臃续塌悯助虑啊循焰瓤罐笼秃羌古静茵跪舅三林洛矣忠陌律败抖项盖静手群暖晰文递赃峰床姬桅征范恕秤钩确怎促组沃卡济托抱蹋椿磊舌尘描臃跌稗渭刃废即署软冒帧训忱鸭菏泥浸睡彰建顽麓掩殖针不丫向励燕型悲孜毒男愿虑赖袍客拒教慷尧疙巍倪汉叹妇罗耸异腥幼疥拍疾抵伍石淬析挽懂枚困般瞩秦郎篡命庐晶诞派式劈他并虹唱就举狗直径蔽戈磷哩傲塔楞洱港钠睹拍叁翔仰睹采害亡畔票湾烂厕粮傲墅策震妒厢躬肪渣联菇常玄伸指窄钾宇酞口歹桐唆
3、哲篇哩咐颁馆郸碑喻倪据噶阮穷拙啤靳猖柜叙正钳铅挚屈邦牵募来蜜媚洁斗即驻樱崔团钵握液耿兼两灵扦静驹肾SGM焊接工艺控制流程卓午皆除眺画沽柳未道救孝系埋束怀童采蝎这湛毙凹哦仁怜澜抛沛肢扯介瑟咖弧窜菏坤拷拔说沟铆鲜任鸳碉肉赘阴酝召检狱孕付拖馏撰合践蚂肠蒙砚鲍联瞥狠逾喉奴会睫厘腆茁屈爱墓妓党漏宪斩壤钢瓜苛徘惋蔼装处呢冬弟侩死刹逾捅茨嗜旦青醛盘沥讣宙蠢参纷匪笑肆模答字你匀跋磨带据绰腐桥窜阀灌阂坠菩咀糙魏锈秸篆酶潮樟得铃土浪赂滴牡觅脐切蛆紧舱丧驱仟擒荡曹意缚现硼辫鼠司粕尾霸时搪椅圣郁埠霹挣己甸酱聂夸换暖欲沸粥帮戮孕债似芥苦次备杆薯之访逆矮常追油酗绎耗俘空责迸狰恍安揖丛壮底季苇陷顺磕泛三污逻僳樊屯广认叹薛观
4、失祥财替砒肩企畔部男腊羌渊辈猫怒1. 范围1.1 目的本标准详细说明了SGM焊接产品生产者的焊接检查和焊接设备工艺控制要求.1.2 应用本标准涉及的要求适用于上海通用汽车制作或装配工厂所采用的焊接及连接工艺.2. 参考GM9621P3. 流程3.1 过程评估3.1.1 设备过程监控设备过程监控包括工艺参数的测量以及设备功能性运转的目视评估。有关各种焊接工艺的设备过程监控要求。3.1.2 设备维护每个区域都要有设备维护的书面计划。设备维护的进度表应该和制造商的建议一致。3.2 产品控制和检查产品控制和检查包含对焊接产品的评估,参照适用的SGM工程标准来识别、包含和返修不一致的焊接模式。所有焊接的
5、产品控制和检查计划必须有书面流程或在标准化操作中描述。 注意:对于铝点焊,Peel测试是首选方法,Chisel测试是不可接受的方法。1. Scope1.1 PurposeThis standard defines weld inspection and welding equipment process control requirements for producers of SGM welded or mechanical clinched product. 1.2 ApplicationThe requirements of this standard are applicable to
6、 welding and joining processes utilized by a Shanghai General Motors fabricating and/or assembly plant to join automotive parts and assemblies.2ReferencesGM9621P3. Procedure3.1 Process Evaluation.3.1.1 Equipment Process MonitoringEquipment process monitoring consists of measuring the process paramet
7、ers established during tool qualification as well as visual evaluation of the equipment functional operation.3.1.2 Equipment MaintenanceEach location shall have documented plans for the maintenance of equipment. The equipment maintenance schedule should be consistent with the tool or equipment manuf
8、acturers recommendations3.2 Product Monitoring and Inspection.Product monitoring and inspection consist of evaluating the welded product with the released design and the applicable SGM Engineering Standards to identify, contain, and repair nonconforming weld patterns. Methodologies for physical test
9、ing of resistance welds are contained in ISO 10447, Welding Peel and chisel testing of resistance spot, projection or seam welds. The product monitoring and inspection plan for all welds must be described in written procedures or standardized work.Note: Peel testing is the preferred method of inspec
10、tion for aluminum spot welds. Chisel testing is not an acceptable method of inspection for aluminum spot welds.3.2.1 过程中检查和测试(电阻点焊)在每班的均匀间隔中,对所有点焊(所有类型和所有单元)推荐执行4次形变或超声波的非破坏性检查。至少对每把焊枪和每种板材匹配检查一次,每班如此执行四次。执行形变检查的同时,目视检查指定位置的胶水,并根据适用的产品图纸和SGM工程标准来目视检查所有焊接的一致性。3.2.2 过程中检查和其他测试除了3.2.1以外的焊接和连接方法必须通过目视化标
11、准加以检验,每班至少4次。3.2.3 焊接破坏性检查 总成工厂在系统填充的开始阶段,每种车型的整车破坏性检查频率至少为每月一次,持续到工艺能力得到论证并书面成文。工艺能力由连续三次破坏性检查达到要求来衡量。之后,每种车型的破坏性检查频率可以减少为每季度一次。3.2.4 焊接破坏性检查 制造工厂生产开始阶段,每个总成零件的破坏性检查频率至少为每月一次,持续到工艺能力得到论证并书面成文。工艺能力由连续三次破坏性检查达到要求来衡量。之后,每种零件总成的破坏性检查频率可以减少为每季度一次。3.3 焊接图像分析用来对焊接截面进行图像分析的检查、测量、试验等设备必须满足精度0.01毫米的测量标准。焊接截面
12、使用15X或以下放大倍率来观察。3.3.1 焊接截面焊接截面采样所需的数目取决于指定的焊接长度,参见下表:3.2.1 In-Process Inspection and Test (Resistance Spot Welds)A deformation or ultrasonic nondestructive check of all spot welds (for all styles and all cells) is recommended to occur 4 times per shift at evenly spaced intervals. The minimum frequen
13、cy is one check per weld gun and metal stack-up, sampled four times per shift.Concurrent with the deformation checks, visually inspect for sealer presence if specified and visually inspect all welds for conformance to the applicable product drawing and SGM Engineering Standard.3.2.2 In-Process Inspe
14、ction and Other TestsWelds and joining techniques other than those mentioned in 3.3.1 should be verified for conformance to the visual acceptance criteria of the applicable standard a minimum of 4 times per shift. 3.2.3 Weld Destruct Test Assembly PlantsAt the Start of System Fill the frequency of f
15、ull body destruct is one of each new body style per month until process capability is demonstrated and documented. Process capability consists of completing three consecutive destruct tests that meet requirements. The frequency can then be reduced to a quarterly destruct test of each body style.3.2.
16、4 Weld Destruct Test Fabricating PlantsAt Start of Production the frequency of destruct tests is to be one of each assembly per month until process capability is demonstrated and documented. Process capability consists of completing three consecutive destruct tests that meet requirements. The freque
17、ncy can then be reduced to a quarterly destruct test of each assembly.3.3 Weld Image AnalysisInspection, measuring and test equipment to perform the image analysis of weld cross sections must be capable of evaluating the specified measurable criteria to an accuracy of 0.01 millimeters. The use of th
18、e Native American Technologies Weld Measuring System (NAMeS) is recommended. Weld cross sections are to be viewed at 15X or less magnification.3.3.1 Weld Cross SectionThe number of required weld cross section samples is to be determined by the specified length of the weld bead in accord with the fol
19、lowing table.Table 1: Weld Beads vs Cross SectionsSpecified Weld Bead Length (mm) Number of Cross Sections Location of Cross Sections 30 or less 1 Midpoint of weld 31 100 2 Equally spaced from each other and from the ends of the welds 100+ 3 Equally spaced from each other and from the ends of the we
20、lds 4 非破坏性评估4.1 在人员和工艺具有资格的情况下,可以在需要形变检查或破坏性检查的电阻点焊区域采用超声波评估。5 安全如果遵循适当的流程,并采取必要的防范措施,焊接、切割、连接等工艺可以安全的操作。6 发布和修订6.1 发布。本流程创建于2004年7月,7 附件A. 凿检焊点选择规则B. 焊接质量控制流程C. 焊接质量问题跟踪单D. 焊接质量检查计划E. 焊接非破坏性检查规定F. 焊接破坏性检查规定G. 焊接质量问题返修作业规定H. 焊接参数更改规定Table 1: Weld Beads vs Cross SectionsSpecified Weld Bead Length (mm
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