Wsbcpa 1B310 Aa

Weld Specification: WSBCPA-1B310-AA
Global Gas Metal Arc Weld, Hybrid Laser-GMAW, and Brazing:

GMAB and Hybrid Laser-GMAB
Part Name: SPEC GAS MTL ARC WLD Part Number: WSBCPA-1B310-AA
LET
FR
LET
FR
Date LET FR Revisions DR CK Reference:
9/26/2012 A Initial Release Notice AC00 E 11261537 444 Approved By
E. Knoy
Prepared/Checked By
Doug Howe/Johnathan Line
Detailed By:
Concurrence/Approval
Signatures:
Design Engineering
Supervisor:
Other Approvals
/Concurrences (as
required):
STA:
Travis Cruzan
Purchasing:
STANDARD NOTES:
FOR CURRENT RELEASE STATUS, SEE THE WERS ENGINEERING NOTICE.
CONTROL ITEM – THE ALSO IDENTIFIES CRITICAL CHARACTERISTICS DESIGNATED BY THE

CROSS FUNCTIONAL TEAMS DEVELOPING THE PRODUCT. THESE, AND ADDITIONAL CRITICAL
CHARACTERISTICS IDENTIFIED BY PROCESS REVIEWS, MUST APPEAR ON THE CONTROL PLANS
ACCORDING TO ISO/TS 16949. THESE CONTROL PLANS REQUIRE PRODUCT ENGINEERING APPROVAL.
Frame 1 of 61 REV A
Global Manufacturing Quality Office

GIS1 Item Number: 25.06
GIS2 Classification: Proprietary
FAF03-150-1 (previously form: 3947-A1) Frame 1 of 61 Version Date: 20100323
Table of Contents:
Subject Frame
I. General
I.1 Scope of Weld Specification, General Statement ………………………….…….………..…... 3
I.2 Welded Sub-Assemblies …………………………………………………….………………… 4
I.3 Process Description ………………………………………………………….………………… 4
I.4 Design Guidelines / Rules …………………………………………………….……………...... 5
I.5 General Design Considerations ……………………………………………………………….. 6
I.6 Welded Seam Identification Symbols…………………………………………………………. 7
I.7 Applicable Materials ……………………………………………………………………..……. 8
I.8 Definitions and Terms ………………………………………………………………………… 12
I.9 Welding Processes ……………………………………………………………….….………… 18
I.10 Operator Qualification …………………………………………………………….….……… 18
I.11 Inspection Personnel ………………………………………………………………..…….….. 18
I.12 Inspection Areas ……………………………………………………………………………... 18
I.13 Weld Identification …………………………………………………………………………... 18
I.14 Weld Classifications / Analysis ………………………………………………………….…... 19
I.15 Inspection Frequencies ………………………………………………………………………. 20
II. Summary of Production Validation and In-process Tests

II.1 Production Validation (PV) ………………………………………………………….….……. 22
II.2 In-process (IP) ………………………………………………………………………….…….. 22
II.3 Summary of ES Tests and Acceptable Parameters ………………………………………....… 22
II.3.1 Inspection Frequencies …………………………………………………………….……….. 22
II.3.2 Weld Quality Evaluations ………………………………………………………………...... 33
III. Test Procedures and Requirements

III.1 Weld Joint Testing – Destructive, Non-destructive, and Functional Testing ………….……. 38
III.2 Applicability of Test Procedures and Requirements ………………………………………… 39
III.3 Weld Parameter Monitoring ……………………………………………………………..…... 40
III.4 Destructive / Non-Destructive and Functional Testing ……………………………………….41
IV. Revalidation Requirements

IV.1 Alteration to Production …………………………………………………………………….. 50
IV.2 Repair Methods ……………………………………………………………………………… 54
IV.3 Process Actions …………………………………………………………………….………. 55
IV.4 Weld Issues – Requalification ……………………………………………………………… 55
V. Instructions and Notes …………………………………………………………….……… 56

V.1 Supplier Data ………………………………………………………………………………..... 56
V.2 Welding Considerations ……………………………………………………………................. 57
VI. Compilation of Reference Documents ………………………………………................ 61
Global Manufacturing Quality

I. General
I.1 Scope of Weld Specification, General Statement

This Engineering Specification harmonizes the requirements globally for Ford Motor Company and is issued to define the
Quality and Reliability design factors, and performance requirements applicable to the weld joining of steel and
aluminium structural and body components using gas metal arc welding (GMAW), hybrid laser-GMAW, and/or brazing,
GMAB and Hybrid Laser-GMAB. It covers manual and automated welding of two sheet metal parts ranging from 0.5 to
20.0 mm of the following Ford Product Development Commodities:
Table I-1 Commodity Areas
Product Development Commodity Area
Vehicle Frames & Suspension (CH)
Body Structures (BS) *
Seat Structures (SS)
Vehicle Closures (VC)
Cross-vehicle beams (CVB)
Front & Rear Axle Housings (AH)
Exhaust (EX)
* As of 2/29/2012 release, Body Structures has not completely aligned with this standard
The terms weld, welding, braze, etc. pertain to GMAW, hybrid laser-GMAW and Brazed (GMAB and Hybrid Laser-
GMAB) joints as the terms are pertinent. This Weld Specification (WS) is a supplement to the released drawing of a given
part, and all requirements herein must be met in addition to all other requirements of the part drawing unless specifically
approved in writing by the responsible Ford Product Development Design and Release (D&R) Engineer & Manager,
Product Development (PD) department welding Subject-Matter Expert (SME)/Design Leader (as appropriate), and
Supplier Technical Assistance (STA) and/or Ford Welding Manufacturing Engineer & Manager. No commercial or other
agreements (e.g., Statement of Works (SOW)) will supersede or exclude the requirements of this specification if
specification is applied to any Ford Motor Company GMAW, hybrid laser-GMAW, GMAB and/or Hybrid Laser-GMAB
joined product. Any approved and signed “Exceptions” to this document should be detailed on the Ford or Supplier Final
Release Detail(s) under the Welding WS callout:
• “Weld/Brazing must conform to WSBCPA-1B310-AA. Except as noted below…”, or
• “Weld/Brazing must conform to WSBCPA-1B310-AA. Exceptions are listed on a Separate Signed Exceptions
Page. See DCP and/or Control Plan."
This Weld 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 PFMEA and Control Plan are the responsibility of the manufacturing source.
The manufacturing source will retain the original Control Plan and any later revisions according to Section 7.3 in FAP02-
001. The PFMEA must be reviewed with, and a copy should be provided to, the design responsible Product Engineering
activity and STA/Weld Manufacturing activity.
Definitions of welding terms, procedures, and discrepancies are generally based on those in the American Welding
Society’s (AWS) publication AWS A3.0:2001 “Welding Terms and Definitions”
It is recommended that the supplier have copies of the applicable publications and references noted in Section V available
in his plant’s Quality Control, Manufacturing, Engineering, and/or Product Testing Offices. Applicable information from
these documents is incorporated into this document to the maximum extent possible. Having copies of these documents is
not required.

In addition, the following documents, or latest version, must be noted on the released drawing or ES when applicable to
avoid any issue(s) between Suppliers and Ford:
• Resistance Spot Welding ESBM5A-1N261-A_
• Projection Welding of Nuts & Bolts ESBM5A-1N265-A_
• Drawn Arc Welding of Studs, Nuts & Brackets ESBM5A-1A332-A_
• Stitch Laser Welding ESBU5A-1B313-A_
• Continuous Laser Welding ESBU5A-1B312-A_
• Specification - Laser Welding of Joints (origin: Global Seats) ES7L1A-7861019-B_X
• Material and Performance Requirements of Weld Bolts WA 960
• Material and Performance Requirements of Weld Nuts WE 960
NOTE: If local Ford Product Development Commodity Activity has an approved specification for use in specific
welding applications, the local requirements supersede the above list.
In case of any conflict between these publications, the following is a list of prioritization from highest to lowest governing
documents:
1) Ford Released Engineering Assembly Detail, then
2) Signed Addendum to this Engineering Specification, then
3) Exception(s) on the Ford Released Engineering Part (Component / Assembly) Detail or Supplier Part Drawing
NOTE: Supplier component details will not take precedence over Ford requirements, then
4) This Engineering Specification: WSBCPA-1B310-AA, then
5) Reference documents.
I.2 Welded Sub-Assemblies
It is the supplier’s responsibility that sub-assemblies must conform to Sections I.1 Scope of Weld Specification, General
Statement, II.3 Summary of ES Tests and Acceptable Parameters, and III. Test Procedures and Requirements. All PIA
welds either produced at the supplier’s facility, or their supplier's are subject to this document and the specifications noted
in section I. 1 Scope of Weld Specification, General Statement.
I.3 Process Description
Gas Metal Arc-Welding (GMAW) is a process where heat generated by an electric arc generated in a protective gas melts
a consumable electrode (filler metal wire) and work pieces together as shown in Figure 1. This also encompasses Metal
Inert Gas welding (MIG).
Hybrid laser-GMAW welding is a process of forming a metallurgical bond where a laser head is used to heat the joint
and/or wire and/or weld the metal pieces together used in conjunction with GMAW weld head. This includes tandem laser
– welding operations.
Brazing (GMAB and Hybrid Laser-GMAB) is a process of forming a diffusion bond where heat generated melts a
consumable electrode (wire) which binds the work pieces together. Laser can be used to supply the heat.

: Sheet Metal
: Fillet
: Filler Metal Wire Feed
: Filler Metal Wire Coil
: Gas Nozzle
: Electrode Contact
: Active/Inert Gas
: Electric Arc
The characteristic parameters of the GMA

Welding process are: Weld Current [A], Arc
Voltage [V], Wire properties, Wire feed [m/min],
Welding Time, Welding Speed [m/min], Filler Wire
Stick Out as well as Gas Flow [l/min], Gas
Composition, Torch Angle, and Work Angle (deg.).
FIGURE 1: Illustration of Gas Metal Arc Welding Operation
• The modes of operation shall be limited to Automatic, Semi-Automatic, or Manual welding / brazing (Ref:
Section II.1.2.1 Welding Types this document). The use of Laser seam tracking devices is permissible when
supported by Metallographic evidence (proof of sustainability through cut and etch). The processes used shall
be limited to the following:
- Gas Metal Arc Welding (GMAW i.e. MIG [Metal Inert Gas])
- Flux Cored Arc Welding (FCAW)
- Submerged Arc Welding (SAW)
- Arc spot welding in conjunction with any of the above processes.
- If used as a burn-through spot weld, a clamping pressure system must be incorporated in the welding gun.
- Hybrid Laser and GMAW
- GMAB and Hybrid Laser-GMAB
• The following are additionally approved for repair only:
- Gas Tungsten Arc Welding (GTAW i.e. HeliArc)
- Shielded Metal Arc Welding (SMAW i.e. STICK Welding) with prior approval by Ford Engineering and
STA.
• Semi-Automatic welding processes shall be subject to these guidelines.
- All welds whose start or terminations are to be held to less than ±3.0 or -0 / +6.0 mm are to be made in a
positive locating fixture to ensure their location.
- Wire feed adjustments and voltages are to be secured and/or controlled so that they cannot be changed,
except by designated personnel.
- The welding control is to be of a design that provides a digital readout of both arc voltage and wire feed
speed.
I.4 Design Guidelines/Rules

Design Rules and Guidelines are important and must be complied with. See the appropriate Technical Specialist / Expert
(e.g., Global Seat Systems Technical Specialist/Joints Design Leader) for all the relevant requirements for your
commodity.
All GMAW and Brazed (GMAB and Hybrid Laser-GMAB) joint designs must be assessed by the responsible Ford
Product Development Engineering Departments (and Manufacturing, where applicable by commodity group) in

conjunction with Ford STA Engineering against existing department-released or department-endorsed requirements (i.e.,
Global Design Rules, Design Rules from another commodity, etc.). All designs must comply with all of the fore-
mentioned requirements or have approved deviations in line with existing Design Rule governance requirements.
I.5 General Design Considerations

(NOTE: LOCAL COMMODITY DESIGN RULES SUPERCEDE THESE DESIGN CONSIDERATIONS)
I.5.1 Complex Joints
I.5.1.1 Edges of multiple layers, especially where joined on both sides, shall be held per II. 3.2 Weld Quality
Evaluations – Visual and Cross-Sectional (Ref: Figures 2 and 3).
I.5.1.2 Joints with more than one surface of attaching (E.G. a lap joint beside a T joint) must be controlled for
appropriate gaps. If the trim tolerance on the T joint is +/- .25 mm, the lap joint must be held per II. 3.2 Weld
Quality Evaluations – Visual and Cross-Sectional of the T joint surface. (Ref: Figure 3)
I.5.2 Joint Integrity

I.5.2.1 Joints should be designed so the relative angle is 90° +/- 15° to perpendicular except for V and groove welds
(includes tube to tube, tube to flat stock, etc. weld conditions such as those found on seat designs). (Ref:
Figures 4 through 6)
I.5.3 Weld Depiction and Callout (Not measured weld, but for CAD depiction only, including reasonable overlap of
weld start/stops, etc.):
I.5.3.1 All welds are to be depicted including tack and temporary on all Ford CAD models and details (e. g. -5005-
sheet 2) [includes CAD data provided by suppliers]. Welds are to be depicted at minimum length. Weld stops
and starts must be depicted.
I.5.3.2 Weld fill will be depicted as shown (ref: Figures 4 through 9). Depictions reflect actual weld plus a clearance
allowance. See the boxes below Figures 8 and 9.
I.5.3.3 Weld starts and stops are to be depicted using an equilateral triangle ( ).
Gaps per II.3.2 Gaps per II.3.2
Figure 2 Figure 3

R = "A"
90°
R = "A"
90° +/- 15°
+/- 15°
T1
Figure 4 Figure 5 T1
90° R = "A" R= "A"

+/- 15°
T1
"A" + T1
Figure 6
Figure 7
R = "A"
R = "A"
T1
"A" + T1
Figure 8 Figure 9
T1 = Thickness 1 - thinnest (per ES)

T2 = Thickness 2
"A"
MIG, MAG, and GMAB: "A" is the greater of 5.0 mm or T1.
Hybrid Laser GMAW and Hybrid Laser-GMAB – "A" is the greater
of 3.0 mm or T1.
I.6 Welded Seam Identification Symbols
Joint symbols shall be in accordance with Ford Engineering CAD and Drafting Standard D-3 (Welding Symbols and
Specifications):

Figure 10 Weld Callout from CAD Standard D-3
I.6.1 Sizing of Fillet Weld, a- and z- value:
a Two different concepts exist to specify the minimum dimensions of a fillet

weld. The ‘a’ value is not to be used. Use the ‘z’-value (leg).
Note that the throat and leg dimensions are minimum dimensions. In
practice, higher values are often used, especially when welding thin sheet
metal.
Figure 11: Fillet Weld Dimension

I.7 Applicable Materials
To achieve a properly welded joint, the filler and base materials must be metallurgically compatible and in line with
requirements (e. g. Seat Design Rules)
I.7.1 Base Sheet Metal Specification
This Specification covers the use of the following steels categories:
NOTE: material specifications include weldability requirements
Table I-2: Applicable Categories of Sheet Metals Covered By This Engineering Specification
FORD MATERIAL SPECIFICATION NO
CATEGORY TYPES OF MATERIALS CALLOUT
MS Mild Steels, Hot and Cold Rolled, Low Carbon WSS-M1A365-A11 – A15, A20-A23
DR Dent Resistant Steels including Bake Hardening, High WSS-M1A367-A11/A14, A21/A25

Strength IF, Isotropic and Re-phosphorised Steels
HSLA High Strength Low Alloy Steels WSS-M1A367-A33/A39, A44/A49
DP 1) Dual Phase Steels WSS-M1A368-A11/A15, A21/A25, A31/A32,
FB Ferrite Bainite WSS-M1A368-A41/A43

TRIP 1) TRIP Steels WSS-M1A368-A51/A53
CP Complex Phase WSS-M1A368-A61/A62, A71/A72
MSW 1) Martensitic Steels WSS-M1A368-A81-A84, A91-A92
BORON 1) 2) Boron Steels WSS-M1A357-A1-A2, A4; WSS-M1A358-A1-A2, A4

CATEGORY TYPES OF MATERIALS CALLOUT
Stainless Steel See commodity specific materials and designs

Such as 6000 or 7000-series Aluminum Alloys (see
Aluminum
commodity specific materials and designs)
Check commodity material First Pick List(s) for appropriate material usages
Notes:
1) DP, Trip and Boron steels are included in this Engineering Specification within a limited applicability. The use of
these materials needs to be verified with the relevant Engineering Departments on a case-by-case basis.
NOTE: Particular care must be taken for Dual Phase steels grade 780 DP and above as well as TRIP,
Martensitic, and Boron steels due to significant HAZ softening effects relative to base materials and weld
wire strengths.
2) WSS-M99P39-A1/A2/A3/A4 performance specification must be called out with these Boron steels.
3) Seats: Global Seat Engineering materials selections are performed in conjunction with tier 1 and 2 seat
supplier steel strategies due to commercial considerations. However, all steels must meet all static, dynamic,
and durability requirements for life of product (10 years/150k miles)
Any base sheet metal needs the approval from the relevant Materials Engineering, and PD (Core PD is default) Engineering
Departments and as applicable, Manufacturing.
The text of the referenced Ford Material Specifications is available at the following web link:
http://www.mats.ford.com/mats/scripts/spec_by_mtlCat.html, Metals 1A-99A.
I.7.2 Standard Base Sheet Metal Coatings

Table I-3 Welding to Coated Parts
Product Development Commodity Area Welding to Coated Materials
Allowed?
Vehicle Frames & Suspension (CH) Yes (see note below)
Body Structures (BS) Yes (see note below)
Cross-vehicle beams (CVB) (Body Interior) No
Seat Structures (SS) No (no exceptions)
Vehicle Closures (VC) No
Front & Rear Axle Housings (AH) See local procedures
Exhaust (EX) See local procedures
NOTE: Welding applications of coated sheet metal, if allowed per the table above, is permitted as long as the thickness
of zinc coating between overlapping sheets surfaces does not exceed 22 µ m (equal to 80 grams per square meter of
sheet).
Zinc coating between overlapping sheets in excess of 22 µm has a critical influence on process stability resulting in
porosity and overall joint strength. It increases rework of such seams in the plant. Appropriate countermeasures
(Design or Process related) shall be determined individually for each GMA-Welding application during PV testing
within the scope outlined in Section IV. Test Procedures and Requirements.

GMA-Welding supports the following coatings in all combinations:
Table I-4: Standard Base Sheet Metal Coatings
Specification Type Specification No. Coating Type
Hot Dipped Galvanized or Electro-
50G50G GI, EG WSS-M1P94-A
galvanized
Any coating not listed in Table I-4 needs the approval from the relevant Materials Engineering, Manufacturing and PD
(Core PD is default) and/or Body and Manufacturing Engineering Department as applicable.
I.7.3 Filler Metal Wire Specification
Weld wire to comply with AWS 5.18/A 5.18M:2005, AWS A5.28/A5.28M:2005, ISO 14341:2010, ISO 21952:2012 or
ISO 16834: 2006.
-Weld wire choice should align with Table I-5 with respect to the lowest tensile strength (MPa) of the materials being
joined and stresses in the joint. Higher grade weld wire may be used without an exception.
- The use of filler wire other than those meeting the requirements of AWS 5.18/A 5.18M:2005, AWS
A5.28/A5.28M:2005, ISO 14341:2010, ISO 21952:2012 or ISO 16834: 2006 needs the concurrence of the relevant
Product Development Engineer, PD Technical Expert and STA Engineer, and/or Body and Manufacturing Engineering
Department as applicable. (Core PD is default).
Aluminum uses special wires: See Table I-5
GMAB and Hybrid Laser-GMAB wire to comply with WSB-M4A177-A* or ISO 24373:2009 Welding Consumables –
Solid Wires and Rods for Fusion Welding of Copper and Copper Alloys-Classification.
- Wire usage is limited to CuSi3 type wire (AWS) or CU 6560 (ISO). Maximum Si content is 3.0% for corrosion reasons.
NOTE:-
- Use of alternate weld/brazing wire may be acceptable based on analysis and/or test results. Alternate weld/brazing wire
use is to be noted on the part detail. The use of an alternate wire needs the concurrence of the relevant Product
Development Engineer, PD Technical Expert and STA Engineer, and/or Body and Manufacturing Engineering
Department as applicable. (Core PD is default).
I.7.4 GMA-Welding Of HSS/AHSS/UHSS Sheet Metal

Joint strength in HSS/AHSS/UHSS will typically be the same as base metal yield strength up to 700 MPa tensile strength.
Above 700 MPa tensile, the weld wire and/or heat-affected zone (HAZ) can become the weak link in the joints. Weld wire
is to be selected using Table I-5, based on the lowest yield strength material to be joined and stress levels in the joined
area. Use of higher yield strength wire can be minimized through development of the joint geometry i.e. minimizing local
stresses.

Table I-5 Weld Wire Selection
GMAW Weld Wire Selection by Steel Strength
Weld Wire
Minimum Minimum Minimum
Minimum Wire 2/
Tensile Tensile Yield Welding Wire GMAW
Tensile GMAW 2/
Strength Strength Strength Gas 1/ ISO 1/
Strength AWS and
(MPa) (ref) KSI (ref)(MPa)
(KSI) 5042
310 45 230
See
430 62 350
Table I-6 G 2Si,
490 70 400 ER70S-3, G 3Si1 /
70 or 80 ER70S-6 or G 4Si1
550 80 450 ER80S-G or
G 4Mo
620 90 520
690 100 565
760 110 660 90 At least ER90S-G G CrMo2Si

75%
830 120 730 Argon G Mn3Ni1CrMo
110 ER110S-G /
900 130 800 G Mn4Ni2CrMo
1000 145 900

120 ER120S-G
>1000 145 >900
5042, 5052,
Cu 6560 5454
BRAZING ERCuSi-A
(CuSi3)
Stainless Steel 409 or 439 wire
1/
Si content is to be limited to 0.75 % (ER70S-3 / G 2Si) by weight where e-coat is
used. This results in less silicate formation, although it is worse for weld flow
2/
NOTE: Weld wire chemistries must be verified to produce Minimum Tensile Strength.
Other suffixes (e.g. AWS D2) are permissible.
I.7.5 Shielding Gases

Table I-6 Weld Gas Usage
Product Development Commodity Applicable to Ford of Applicable to Ford North America
Area Europe
Advanced Digital Control or Wave
Form Technology (e.g.CMT [Cold All Areas: between 100% CO2 to 75 /25% Argon/CO2
Metal Transfer]; STT)
Body Structures (BS) EN 439 Argon / Carbon Dioxide, with a minimum
content 75% Ar.
Seat Structures (SS) Based on Based on process/product needs
process/product needs
Frames & Suspension (CH) EN 439 Argon / Carbon Dioxide, with a minimum
content 80% Ar *(reduces SiO2 formation)
Vehicle Closures (VC) EN 439 Argon / Carbon Dioxide, with a minimum
content 75% Ar.
Cross-vehicle beams (CVB) EN 439 Argon / Carbon Dioxide, with a minimum
content 75% Ar.
Front & Rear Axle Housings (AH) EN 439 Argon / Carbon Dioxide, with a minimum
content 75% Ar.
Exhausts (EX) tbd 97.5%/2.5% Ar/CO2 or 98%/2% Ar/0xygen
Stainless Steel with a 409 or 439 wire 97.5%/2.5% Ar/CO2 or 98%/2% Ar/0xygen

I.8 Definitions and Terms
I.8.1 Type of Weld Joints
I.8.1.1 Fillet Welds
A fillet weld is approximately triangular in cross section and joins the edge of one member to the surface
of the adjacent member. Examples of acceptable sections for part assemblies are shown below (Figures 12
– 17):
LAP JOINT LAP JOINT T-JOINT
Figure 12 Figure 13 Figure 14

I.8.1.2 Butt Weld/Groove Welds
Figure 15
NOTE: In general, Groove Welds (Flare Bevel / Flare-V) are not considered structural (Evaluate in CAE as if not
present). However, they can be considered structural in Seating applications.
FLARE BEVEL FLARE-V (aka. V-groove, Flare-groove)
Figure 16 Figure 17
I.8.2 Welding Terms (Reference Figures 18 and 19)

I.8.2.1 Welding Types
I.8.2.1.1 Manual (Does not include loading method):
Human held gun, with manual weld wire feed, and/or manual settings of voltage or gas e.g. SMAW (STICK)
or GTAW (TIG).
I.8.2.1.1.1 Manual welding should be avoided on “CC/ ”,"K/KB and ”S" welds to the maximum extent possible.
I.8.2.1.1.2 If Manual welding is required on specific products on "CC/ ". “S”, and/or "K/KB" joints, prior approval is
required from PD Technical Expert, PD Engineering and STA Engineering
I.8.2.1.1.3 Rework performed manually on “CC/ ” weld(s) requires an alert with the quantity affected and repair
procedures described.

I.8.2.2 Semi-Automatic:
Human held gun with automatic wire feed, voltage and gas
I.8.2.3 Automatic:
Fully Robotic with fixed automation.
The following definitions are referenced from American Welding Society publication AWS A3.0-2001, unless otherwise
specified.
I.8.2.4 Fusion Zone:
The area of base metal melted as determined on the cross section of the weld.
I.8.2.5 Gap:
The distance or airspace between two base components at the root of the joint to be welded (Engineering
Specification Definition).
I.8.2.6 Joint Penetration:
The distance the weld metal extends from the weld face into a joint, exclusive of weld reinforcement.
I.8.2.7 Overlap-W (width):
The protrusion of weld metal beyond the toe, or roots of the weld
I.8.2.8 Overlap-L (length):
The portion of the preceding weld nugget remelted by the succeeding weld.
I.8.2.9 Joint Root - (Theoretical):
That portion of a joint to be welded where the members approach closest to each other. In cross section, the
root of the joint may be a point, a line, or an area.
I.8.2.10 Root Penetration:
The distance the weld metal extends into the joint root measured from the theoretical to the weld root (actual).
(Engineering Specification Definition)
I.8.2.11 Skip:
An un-welded portion of a designated weld (ref:AWS D8.8-2007).
I.8.2.12 Spatter:
The metal particles expelled during fusion welding that do not form a part of the weld.
I.8.2.13 Thickness of Welded Parts T1 and T2:
The thinner part has thickness T1 and the thicker part has thickness T2 in a welded joint. (Engineering
I.8.2.14 Throat – Actual Throat
The shortest distance between the weld root and the face of a fillet weld
I.8.2.15 Throat – Effective Throat
The minimum distance from the fillet weld face, minus any convexity, and the weld root.
I.8.2.16 Throat - Theoretical Throat:
The distance from the beginning of the joint root perpendicular to the hypotenuse of the largest right triangle
that can be inscribed within the cross section of a fillet weld. This dimension is based on the assumption that
the root opening is equal to zero.
I.8.2.17 Weld Back (Ref.: V.2.3 Weld Past / Weld By / Weld Back)
Welding direction reversed and overlapped at the end of the weld to effectively increase the weld penetration
locally.
I.8.2.18 Weld Face:
The exposed surface of a weld on the side from which welding was done.
I.8.2.19 Weld Leg (L1, L2 in Figures 18 and 19) :
The distance from the Joint Root (theoretical) to the toe of the weld not including the gap (Engineering
I.8.2.20 Weld Past (Weld By) Ref.: V.2.3 Weld Past / Weld By / Weld Back:
Welding continued beyond the point of adjacency of the pieces being welded together.
I.8.2.21 Weld Length:
The length of weld between the beginning of a weld start to the end of a weld stop; the visual portion of a
weld. This is also the length of the weld per the CAD callout.
I.8.2.22 Weld Length (effective):
The length of weld between a start and stop throughout which the correctly proportioned cross-section exists.
The minimum length of a structural weld is typically 25.0 mm (10.0 mm on thinner parts (T1 < 1.0 mm), which
gives an effective weld length of about 13.0 -15.0 mm ( 4.0 – 6.0 mm) A weld of less than 25.0 (10.0 mm on
thinner parts) is typically considered a tack weld (this may be modified by specific commodity Design Rules).
I.8.2.23 Weld Root - (Actual):
The points, as shown in cross section, at which the back of the weld intersects the base metal. (Engineering
I.8.2.24 Weld Toe:
The junction between the weld face and the base metal welded surface.

Root
Penetration Actual and
Effective Throat
Toes
T1
Gap
L1
Weld Root
L2 T2
Theoretical Theoretical
Root Throat
FIGURE 18
Effective Throat
L1
Actual
Z1 Throat
T1
Gap
T2
Face
Z2 Penetration
L2
FIGURE 19
I.8.3 Weld Length Defects (Reference Figures 20 to 25)
Definitions are from American Welding Society publication AWS 3.0-2001, unless otherwise stated. Types of
defects are:
I.8.3.1 Arc Strike:
A discontinuity resulting from an arc, consisting of any localized re-melted metal, heat-affected metal, or
change in the surface profile of any metal object.
I.8.3.2 Burn Thru:
Holes burned completely through the weld joint and/or base metal. (Engineering Specification definition).
I.8.3.3 Cracks: Surface Cracks, End Crater Cracks
Cracks are fracture type discontinuities characterized by a sharp tip and high ratio of length to width. They
typically result from an non-homogeneous heat distribution in the joint and a subsequent uncontrolled
solidification of molten filler metal.
I.8.3.4 Crater:
A depression at the termination of a weld bead(s) or in the molten weld pool. (Ref: AWS D8.8-2007).
I.8.3.5 Inclusions:
Shall be considered and judged as being porosity (Ref: AWS D8.8-2007).
I.8.3.6 Meltback:
This occurs where the base metal melts back from the edge but does not become part of the weld. This
condition leaves a void between the weld deposit and the base metal. (Ref: AWS D8.8-2007).
I.8.3.7 Melt Thru:
The protrusion of metal through the base metal surface opposite the weld joint location. (Engineering
Specification definition).
I.8.3.8 Notching:
Gouging of the parent metal at the ends or edge of the welded joint (Ref: AWS D8.8-2007).
I.8.3.9 Porosity:
Cavity type discontinuities formed by gas entrapment during solidification or in a thermal spray deposit. (Ref:
AWS D8.8-2007).
I.8.3.10 Spatter
Spatter is defined as filler metal particles that are expelled during the welding operation and do not form a part
of the seam. Spatter - to a certain degree - is considered process typical and cannot be avoided entirely.
However, the occurrence of spatter shall be reduced to an absolute minimum by adjusting the welding process
parameters during the definition of the job characteristic curve in PV-testing. Shielding must be used when
depicted on the part detail.
I.8.3.11 Undercut:
A groove melted into the base metal adjacent to the weld toe or weld root and left unfilled by weld metal.
Figures 20 through 25 below: some defect types

NOTCHING
UNDERCUT
WELD -
TRAVEL
ANGLE
WELD -
WORKING
MELT-THROUGH ANGLE
FIGURE 20 FIGURE 21

Maximum notching is
T1 - 1.6 mm per Maximum undercut
dimension shown (sheet is T1 in 1st /last 13
metal thickness [T1] = mm (1.6 mm in example)
1.6 mm).
Notching along this

axis is also
limited to T1. –
1.6 mm (sheet metal
thickness [T1] = 1.6 mm)
Figure 22
Good weld; notching is less than T1 Bad weld – notching is greater than T1 (1.6 mm in example)
FIGURE 23 FIGURE 24
UNDERCUT
INSUFFICIENT ROOT
PENETRATION
FIGURE 25

I.9 Welding Processes
I.9.1.1 The mode of operation shall be limited to Automatic, Semi-Automatic, or Manual welding (Ref: I.8.2.1
Welding Types this document). The use of Laser seam tracking devices is permissible when supported by
metallographic evidence (cut and etch) and path tracking. The welding processes used shall be limited to the
following:
— Gas Metal Arc Welding (GMAW i.e. MIG [Metal Inert Gas]), Advanced GMAW with Digital Control
or Wave Form Technology e.g. Cold-Metal Transfer, "Micro-MIG"
— Flux Cored Arc Welding (FCAW)
— Hybrid Laser - GMAW
— Submerged Arc Welding (SAW)
— Arc spot welding in conjunction with any of the above processes.
The following are additionally required and approved for repair only:
• If used as a burn-through spot weld, a clamping pressure system must be incorporated in the welding
gun.
• Gas Tungsten Arc Welding (GTAW)
• Shielded Metal Arc Welding (SMAW i.e. STICK Welding) with prior approval by Ford Engineering
and STA.
I.9.2 Semi-Automatic welding processes shall be subject to the guidelines noted in Section I.3. Process Description.
I.10 Operator Qualification

• All welders or operators permitted to weld on a part shall be first qualified by both test and training.
• Qualification and training of welders and welding operators according to AWS, DIN (ref: EN 287-1), ISO, or
other applicable documents shall apply. It is required that the welder shall be qualified on the thinnest material
to be welded.
• Supplier shall submit his program for welder qualification and training to the relevant PD (Core PD is default),
STA and as appropriate, Manufacturing, Materials Engineering Departments.
• The training program shall include the theory of the welding, the welding processes to be used, definitions,
cause of welding defects, and Ford’s expected level of weld quality as defined in this specification.
I.11 Inspection Personnel

The personnel responsible for compliance with Section II.3.2, Weld Quality Evaluations – Visual and Cross Sectional
shall administratively report to the supplier’s Quality Control Department and/or the Weld Process Engineer. While
sectioning may be performed by other activities, the results shall be reported to the appropriate quality control activity.
Personnel involved in weld inspection shall be certified by the supplier as receiving adequate formal training on the
recognition of weld defects, their cause, and effect on the product. Training shall consist of a minimum aggregate of 40
hours. Appropriate visual aids of actual welds should be available for this program and in the inspection area.
I.12 Inspection Areas

Suppliers are to provide an appropriate environment for weld section inspection inclusive of, but not limited to,
appropriate lighting, fixtures, and magnification lenses.
I.13 Weld Identification
I.13.1 For all identified part welds (“CC/ ”,”S”, “K”, “KB”), the supplier will perform weld section and etch analysis
(or root bend or crush for "KB" class welds) to demonstrate compliance with Section II.3.2 Weld Quality
Evaluations – Visual and Cross-Sectional. The section locations are identified and numbered on the part assembly
drawing as follows:
N-CC/ -L/R where:
N Identifies individual number of weld section. "CC/ " welds should be identified and numbered first,
followed by "S", “K”, and "KB" class welds in order of ‘priority’.
CC/ , S, K, KB Designates Classification as "CC/ ", "S", "K", "KB" or "U" (if designated) per I.14.1 through
I.14.6 Weld Classifications / Analysis. Must be present for "CC/ ", "S", "K", or "KB" class welds. Not
required for "U" class welds
L/R/B May be used to designate if only left side [L] and/or right side [R] of part weld section and/or both [B] weld
sections are required. If not called out, assumed to be both sides of the part where geometry is symmetrical.
Where multiple sides are called out, each weld will have a unique weld number.
—-- or Bar or section line (with arrows pointing to side of weld section to be reviewed) drawn thru weld
where section cut is to be performed.
I.14 Weld Classifications / Analysis

Ford: Concept of “Control Welds”
"Control welds" for GMA-Welding are defined as welds that are important for structural integrity, safety, or
Federal compliance. They shall be identified jointly between Engineering (Core and Vehicle Program) and as
applicable, the Attribute Teams (Crash, Durability and/or NVH) on the basis of the relevant Critical
Characteristic Requirement Team's (CCRT), Design-FMEAs, CAE-analysis and physical verification testing.
I.14.1 "CC/ " – CC / Inverted Delta welds are those where the DFMEA severity ranking is 9 or 10 (YC). Each weld is
evaluated independently. If multiple weld failures are required for failure, the welds may be classified other than
"CC/ "."CC/ " welds must be evaluated using cut and etch procedures.
I.14.2 "S" Welds – Sensitive welds must be evaluated using cut and etch procedures.
I.14.2.1 "S" welds will be selected based on information from, but is not limited to (if multiple welds are used to
maintain a connection, each weld may be analyzed independently):
I.14.2.1.1 Welds as determined through CAE assessment as needing special considerations including:
I.14.2.1.1.1 During a strength event, the parent metal stress cannot exceed 95% of the ultimate strength of the base and/or
weld materials which would be an indicator of potential weld nugget separation, or
I.14.2.1.1.2 Weld fatigue as determined using the FESafe Verity Weld Fatigue Tool with CAE performance less than
100%, or other Ford approved software with CAE fatigue performance less than 200% of the weld seam
target, or
I.14.2.1.1.3 High stress areas, exceeding 75% of material yield, as defined by CAE Analysis and/or test, proving
grounds, or field failures. Perform a sensitivity analysis using the FESafe Verity Weld Fatigue Tool, where
each end of the effective weld length is shortened and lengthened by the lesser of 9 to 12 mm (as determined
by CAE grid size) or 5% of the total weld length, but not to be shortened and lengthened by more than a total
of 12 mm. If test validation proves shortened and lengthened welds are capable of passing appropriate tests
in adequate sample sizes (absolute minimum of three), the weld may be classified "K" or "KB"
I.14.3 "K" Welds - Key welds must be evaluated per:

I.14.3.1 "KB" Welds - Some portion (subset) of "K" welds may be designated "KB". “K” welds are to be evaluated using
cut and etch procedures. A portion of the evaluations of each "K" weld (up to 80%) may be verified through
bend and peel and/or crush testing [must be designated as “KB” welds] :
I.14.3.2 "K" and "KB" welds will be selected based on information from but is not limited to the following (if multiple
welds are used to maintain a connection, each weld is to be analyzed independently):
I.14.3.2.1 Welds as defined through the DFMEA / CCRT review as requiring special considerations (e.g. Severity of
Effects rating 5 to 8, with final PFMEA Occurrence Ratings greater than 3), or
I.14.3.2.2 Weld experience based on test, proving ground field failures, history or engineering judgment.
I.14.4 For symmetrical or mirror image welds, if one weld is to be classified “CC/ ", ”S”, "K" or "KB" by above
analysis, the opposite weld will also be classified “CC/ ", ”S”, "K" or "KB". e.g. if a weld to the point three
bracket on the left side is classified "S" per above analysis, then the symmetrical or mirror weld on the point three
bracket on the right side is to be classified "S" also, or
I.14.5 Welds which cannot be viewed or repaired after assembly (closed out welds) are to be considered for “CC/ " or
"S” classification. There must be a method to insure weld presence.
I.14.6 "U" welds: Unclassified – welds that are not classified "CC/ ", "S" or "K / KB".
I.15 Inspection Frequencies
I.15.1 Inspection frequencies and quantities detailed below in Section II.3 Summary of ES Tests and Acceptable
Parameters are based on a high volume assembly line (about 60 units per hour, 16 to 20 hours per day (2, 8 to 10
hour shifts), and 5 days per week). Frequencies may be increased or decreased when agreed to at by least two of
STA, Product Engineering, and/or Manufacturing based on the quantity of parts produced, and the frequency of
part inspections and analysis (batch / batch size). For “CC/ ” or “S” welds, it is highly desired that inspection
and analysis are completed prior to the supplier shipping the batch that the sample is verifying. Only with STA
and Product Engineering approval, completion of inspection of the batch may be revised such that inspection is
completed prior to assembly of a vehicle or a sub-assembly (module) at the assembly / manufacturing facility
{when applicable}, or at the latest assembled at a Ford facility. Inspection and analysis for “CC/ ” or “S” welds
is not to be reduced such that completed units can be moved beyond the final Ford assembly plant's control prior
to completion of inspection and analysis of the batch.
I.15.2 For Seats reference Section II.3.1.3 Seat Structures Commodities (SS) Frequency and Sample Requirements
below for inspection frequencies and quantities. Note the specific commodity instructions below in Section II.3.
I.15.3 For Body, comply with VOPSSN 008 / VOPQUE 612.
I.15.4 Completion of weld section analysis: Weld section analysis must be completed prior to the end of the next same
scheduled shift; root bend or crush before end of current shift. Sections may be obtained from completed or partial
(front, mid or rear stub) part assemblies as appropriate. Weld sections may be taken from full or partial assemblies
that have been scrapped from the current day’s production for various reasons other than section(s) being
checked.
I.15.5 Inspection frequencies may be adjusted. Appropriate data must be presented reflecting maintenance of an
Occurrence of Cause rank of 2 or less based on 120 calendar / 85 production days of data (or 90 calendar / 60
production days for "S" and "K / KB" welds). The occurrence rating shall be determined by dividing the number
of defects produced by the number of parts manufactured over the 120 calendar / 85 (or 90 / 60) production day
period of time as described in the AIAG FMEA manual, 4th Edition (ref Figure 26, below). The result of this
calculation is occurrence per thousand. The result shall then be cross referenced to the table below.
I.15.5.1 The frequency of inspection of "CC/ ", "S", and "K / KB" welds can be reduced with proof of sustainability
after phase III PSW, for individual lines, if IP-1 level of quality has been established and:
• If supported through a review of the DFMEA, PFMEA, and Control Plan, and
• After more than 120 calendar / 85 production days for "CC/ "; 90 calendar / 60 production days for "S"
and/or "K / KB" welds experience at production rate, and. appropriate data is provided to obtain both Ford
STA and Product Engineering concurrence. This is to be documented through a SREA or other acceptable
written method.
I.15.5.2 "CC/ " weld inspection frequency may be reduced to the “S”, or "K / KB" level, but the classification cannot
be changed on the part detail or any other document.
I.15.5.3 "S" and "K / KB" class weld inspection frequency may be changed to a lower level of inspection, and also may
be reclassified to “K / KB" or "U" respectively. Each reduction in the classification must be addressed
separately.
Figure 26: Occurrence Evaluation Table (ref AIAG FMEA Manual)

.

II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS
II.1 Production Validation (PV) tests are used to obtain an initial estimate of the process potential or sustainability
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). These tests must be completed successfully
using initial parts from production tooling and processes 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 line
with this specification. Note specific commodity frequency and sampling requirements for inclusion in Weld Control
Plans.
In addition, tests can be performed 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 (defined as Design Verification (DV) and pre-
Design Verification (pre-DV) testing. Note specific commodity frequency and sampling requirements for these phases
for inclusion in Weld Control Plans).
II.2 In-Process (IP) tests are used to further understand the relationship between significant design and process
characteristics, exhibit sustainability, 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 in line with this specification. Note specific commodity frequency and
sampling requirements for inclusion in Weld Control Plans. When the process is found to be trending or out of control or
the test acceptance criteria are not met, the reaction plan approved in the Control Plan shall be invoked.
Welded joints 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 IV.2 Repair Methods.
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, ISO/TS 16949:2002.
II.3 Summary of ES Tests and Acceptable Parameters

II.3.1 Inspection Frequencies:
II.3.1.1 Definitions:
II.3.1.1.1 Line: Combination of Operations that results in the production of a part
II.3.1.1.2 Operation: A Table, or a conjunction of more than one Table.
II.3.1.1.3 Fixture or Station: Location which holds one assembly (builds one part)
II.3.1.1.4 Pallet: A stand where several fixtures are installed
II.3.1.1.5 Table: A bench where several pallets are incorporated.
II.3.1.1.6 Line# – Line number
Table Pallet Fixture or Station
c
L

The following diagrams are to be used for clarification of the weld inspection frequencies:
Line 1
Part Flow
Operation1 Operation 2 Operation 3
a L
a a
b b
b
c c c
FIGURE 27: Welding Operations (1)

Depicted above: 3 Operations on one, Line; 6 Fixtures on Tables 1 and 3, 3 Fixtures on Table 2, 9 Pallets (3 per table),
and 15 Fixtures or Stations.
6 parts in operations 1 and 3, 3 parts in operation 2.
Inspections (assumption – 1 CC weld per part in Operation 1,1 CC weld per part on Operation 2, 2 S welds per part on
Table 3) = > 6 weld inspections in Operation 1, 3 in Operation 2, and 6 (on 3 parts) in Operation 3 = 15 weld inspections
to be performed on 6 parts per day.
Perform as many weld inspections as possible on the same part so as to minimize the number of parts to be destroyed. An
additional operation does not mean an additional part needs to be destroyed, as the additional inspection is to be
performed on the same part.
NOTES: Where multiple tables with multiple fixtures make up a line, inspected parts are to be rotated so as to evaluate
each fixture and combination of fixtures at an equal rate.
Where the same tools are used for multiple shifts, part inspections are to be rotated so that each parts from each shift are
inspected at the same frequency e.g. every other day for two shift operations.

Line 2
Part Flow
Operation 1 Operation 2
.
b a
c
b
a
c
c a
a b
c
b
FIGURE 28: Welding Operations (2)

Depicted above: 2 Operations on one Line, 6 parts per Table, 5 Tables, 15 Pallets (3 per table), and 30 Fixtures or Stations
Frequency of inspection 1 CC weld in operation 1 on each part, 1 S weld in operation 2 on each part =>
18 weld inspections in operation 1 + 12 in operation 2 = 30 weld inspections evaluated, on 18 parts. Weld fixtures
evaluated in operation 2 must be rotated every other day so as to capture all weld combinations at the same rate.
NOTE: Where multiple tables with multiple fixtures make up a line, inspected parts are to be rotated so as to evaluate
each fixture and combination of fixtures at an equal rate.
Perform as many weld inspections as possible on the same part so as to minimize the number of parts to be destroyed. An
additional operation does not mean an additional part needs to be destroyed, as the additional inspection is to be
performed on the same part.

II.3.1.2 Frame & Suspension Commodities (CH) Frequency and Sampling Requirements (Section II.3.1.2 and Tables II-1 through II-4 below)
[NOTE: applies to all commodities Except Seats (SS)]
Table II.-1 General Vehicle Weld Inspection Frequency Table – Frame & Suspension Commodities (CH), etc. – Except: For Seats, see table II.-5 below
W eld Length and Quality Inspection Section and Etch Bend and Peel
Evaluations per weld seam Evaluations per weld seam
appearance, dimensional
Weld LengthandQuality
andlength-> II.3.1.2.1.1
Inspection-> II.3.1.2.1.2
100%Visual check for
per fixture (operation)

weldpresence and
Section and Etch
BendandPeel
per operation
per model*
per model*
per model*
per month
per month
per month
per fixture
per fixture
per week
per week
per week
II.3.1.2.3
II.3.1.2.3
per shift
per shift
per shift
per line
per line
per day
per day
per day
Remarks
Prototype - to PV
1 / 10 or
CC/ , S, K, 1/50
100% 100% - - - X X X - - - - - - - - - - - - - - - -
& KB 2/100
3/150 …
1/) 2/)
PV to IP: From Run at Rate to Production proveout (10 /5 days of consecutive samples)
1) Each weld / weld segment
CC/ 100% 3 - - - X X X - 1
1) - - X - X X X - - - - - - - - for 10 consecutive
to be analyzed individually.
days w/o failure
Only welds that do not
2)
S 100% 3 - - - X X X - 1
2) - - X - X X X - - - - - - - - for 5 consecutive show sustainablity must
days w/o failure continue be analyzed until
2) sustainability is
K & KB 100% 3 - - - X X X - 1
2) - - X - X X X - - - - - - - - for 5 consecutive
demonstrated for the
days w/o failure
appropriate period of time.
2)
Unclassified 100% 3 - - - X X X - 2) - - X - X X X - - - - - - - - for 5 consecutive
1
days w/o failure
In Production
3/
Semi-Automatic and
5/ 3/ Manual: Section and Etch -
CC/ 100% 3 - - - X X X - 1 - - X - X - - - - - - - -
additional inspection per
shift
per two days
S 100% 3 - - - X X X - 1 - - - - X - - - - - - - - -
4/
K 100% 3 - - - X X X - 1 - X - - - X X - - - - - - - - Some portion of K weld
sectioning (e.g.8/10) can
be replaced by Bend or
KB 100% 3 - - - X X X - 4/ - X - - - X X 4/ - X - X X X -
1 1 Peel (K B) weld analysis
greater II.3.1.2.2
of 1 /
Unclassified 100% 3 - - - X X X month 1 - - - - X - - - - - - - - -
or 1 /
30,000
5/
= rotating per shift (all robotically applied)
* Model: Substantial difference, e.g. FWD vs AWD, wheelbase, unique welds
II.3.1.2.1 Visual and/or Automated Inspection,
II.3.1.2.1.1 All parts: Dimensional, and Weld Length Inspection, on or offline:
• 100% Visual check for weld presence and appearance
II.3.1.2.1.2 Formal Weld Inspections – offline: 3 per operation / per shift /per fixture:
• Weld length inspection: (III.4.1: III.4.1.1 and III.4.1.2 Inspection of the Visible Portion of Weld)
• Weld check for weld quality, comply with II.3.2. Weld Quality Evaluations – Visual and Cross-Sectional
(visual (v) items)
II.3.1.2.2 Unclassified welds: Inspect the greater of one part per fixture per month or one part per 30,000 from each
table via cut and etch, or bend and peel / crush. 1 / 30,000 inspections are to be rotated so that parts from all
fixtures will be evaluated at the same frequency.
II.3.1.2.3 "CC/ ", "S" , "K / KB", and “U” weld inspections:
II.3.1.2.3.1 Prototype: Prior to and including TT

All prototype welds are to be inspected per section III. 4.1.4 Cut and Etch (Cross Section and Etch) inclusive,
per the following frequencies:
Table II.-2 Prototype Section and Etch Frequency
Number of Minimum Number Specific Instructions
Parts Ordered of Parts to Be Weld
Inspected
A 1 to 9 1 Can reduce to 0 with engineering agreement
B 1 to 50 1 One within first 7
C 51 to 100 2 One within first 7, plus one between numbers 51 to 100
D 101 to 150 3 One within first 7, plus one between numbers 51 to 100,
plus one between numbers 101 to 150
E 151 up 4 and up One within first 7, plus one between numbers 51 to 100,
plus one between numbers 101 to 150, plus one
additional part per 100, within the range of 100 1/.
1/
e.g. if order is for 151 to 250 parts, four parts are to be evaluated, three of which will be in the first
150 built per rows B, C, and D, and. in addition, one additional part will be evaluated between numbers
151 and 250. For 251 to 350 parts, five will be inspected, four as described in the previous sentence and
one additional part will be evaluated between the 251st and 350th parts built.
II.3.1.2.3.2 PV (Production Validation): after TT to Job #1 (Run at Production Rate)
II.3.1.2.3.2.1 After M1 is approved, a part with all welds shall be high gloss painted black, e-coated or black anodized.
This part shall have all welds outlined in red for “CC/ ", light green for "S", and white for “K” / "KB"
class welds with their lengths annotated. Additionally, the outlined welds will have the agreed to
sectioning areas marked in yellow, with the weld numbering scheme relating back to the part detail
identifying the areas of weld cross sectioning. Interior welds, including in-accessible and “closed out”
welds, shall also be marked on the exterior or the part (E.G. weld plates, nuts, interior reinforcements,
etc.).
II.3.1.2.3.2.2 Weld analysis via section and etch shall be each weld, per day, per model, per fixture, per shift.
Inspections will be performed until each section passes all criteria for a minimum of 10 production days
for “CC/ ” class welds, or 5 production days for "S", "K / KB " and Unclassified welds, and concurrence
from Ford engineering and STA is received to proceed to IP sampling per Section II 3.1.2.3.3. Where
there are multiple fixtures, inspection will be alternated between fixtures so that each is inspected at the
same frequency; a minimum of one part per fixture every other day.
II.3.1.2.3.2.3 Any alteration, change in process – mechanical, assembly, material, etc., weld wire (inclusive of size of
wire, or solid to cored, etc.), changes in weld position or angle, creates a new weld that must be evaluated
per IV.1 Alteration to Production.
Table II.-3: PV Sampling

Test Test Name Performed Frequency Test Requirement Data Delivery
Method type Time
By Where
A Visual and/or Qualified In-line Per Per Pass/fail Attribute Prior to the
Automated Operators and off- II.3.1.2.1 II.3.1.2.1 next
Inspection - and / or line scheduled
Dimensional, Quality dedicated weld joint
and Weld Technician position quality
Length per I.10 inspection.
Inspection and I.11
B1 Cross- Quality Off-line Per Per Pass/fail Attribute Before end of
section and Technician dedicated II.3.1.2.3.2.2 III.4.1.4 next
etch position scheduled
shift I.15.4
II.3.1.2.3.3 IP (In Production): After PV is approved and at Production Rate

IP Sampling commences once full production is agreed to (ref. II.3.1.2.3.2.2) with concurrence from Ford
Engineering and STA.
An agreed to part (from PV) shall be reviewed. If there are any changes from PV, a part shall be high
gloss black painted, e-coated or black anodized. This part shall have all welds outlined in red for “CC/ ",
light green for "S", and white for “K / KB" welds with their lengths. Additionally, the outlined welds will
have the agreed to sectioning areas marked in yellow, with a weld numbering scheme relating back to the
part detail identifying the areas of weld cross sectioning Interior welds , including in-accessible and
“closed out” welds, must also be marked on the exterior the part (E.G. weld plates, nuts, interior
reinforcements, etc.). If agreed to in advance, only changed welds need to be marked as described.
II.3.1.2.3.3.1 "CC/ " (YC in DFMEA) (ref appropriate inspection chart for your commodity below):
Cross-section and etch, one part per line, per fixture per day (6 parts in operation 1 (Figure 27) above).
Inspections are to be rotated so that parts from all fixtures will be evaluated at the same frequency. For
semi-automatic and manual welds, the inspection frequency will be one part per line, per fixture, per day,
per shift.
II.3.1.2.3.3.2 "S" Welds

Cross section and etch, one part per line, per fixture every 2 days (3 parts per day on Line1 (Figure 27)
above). Rotate inspections so that parts from all fixtures will be evaluated at the same frequency.
II.3.1.2.3.3.3 "K/KB" welds:

One part per fixture per week, per model (6 parts per week on Line1 (Figure 27) example above).
Inspections will be cut and etch. For semi-automatic and manual welds, the inspection frequency will be
one part per fixture per week per shift. For KB welds, up to 80% of the weekly inspections of each weld
may be replaced with bend and peel and/or crush with engineering and STA concurrence. Inspections are
to be rotated so that parts from all fixtures will be evaluated at the same frequency.
II.3.1.2.3.4 Any alteration in part design, change in material (or source), change in manufacturing process, or change in
weld process (e.g. wire inclusive of -size of wire, or solid to cored, etc.) changes in a weld position, or
angle, that could affect part function, performance, durability, or appearance creates a new weld that reverts
back to the PV weld sampling plan or as agreed to with Ford engineering and STA - until capacity
sustainability is re-established. Costs for any Ford engineering change that results in a new weld, or an
existing weld reverting back to PV weld sampling may be included in the quote for the change. Quality
actions will not incur any additional costs to Ford.
NOTE: during any weld quality issue(s) any of the above sampling plans can or may be reverted back to.
Weld sections shall be taken from the area or areas that have demonstrated a failure or questionable weld
(customer issue - plant or dealer). The fall back to a higher weld sampling frequency is the supplier's
quality responsibility. It is between Ford Motor Company Engineering, STA, and the Supplier to
recognize when this is enforced and for STA and Engineering to determine when this higher weld
sampling frequency is returned to the normal sampling plan(s). Depending on the severity of the
concerns, a higher sampling frequency may be required to reach IP status.
Table II.-4: IP Sampling Summary

Test Test Name Performed Frequency Test Requirement Data Delivery
Method type Time
By Where
A Visual and/or Qualified In-line Per II.3.1.2.1 Per Pass/fail Attribute Prior to the
Automated Operators and off- II.3.1.2.1 next
Inspection. and / or line scheduled
Dimensional, Quality dedicated weld joint
and Weld Length Technician position(s) quality
Inspection per I.10 inspection.
and I.11
B1 Cross-section Quality Off-line Per Per Pass/fail Attribute Before end
and etch Technician dedicated II.3.1.2.3.3.1 III.4.1.4 of next
position scheduled
shift I.15.4
Possible Alternative (with written Ford Engineering and STA concurrence)
B2 Root Bend Quality Off-line Per Per Pass/fail Attribute Before end
Alternative test - Technician dedicated II.3.1.2.3.3.3 II.4.4.1 of same
may be position as required shift I.15.4
performed in lieu per control
of cross-section plan
and etch
B3 Crush Quality Off-line Per Per Pass/fail Attribute Before end
Alternative test- Technician dedicated II.3.1.2.3.3.3 II.4.4.2 of same
may be position as required shift I.15.4
performed in lieu per control
of cross-section plan
and etch

II.3.1.3 Seat Structures Commodities (SS) Frequency and Sample Requirements
Table II.-5 Seat Structures Commodities (SS) Weld Inspection Frequency Table – General. See Table II-1 for other commodities
Section Inspection
Functional Testing
Destructive, Non-
Visual Inspection
destructive, and
(Cut & Etch)
per shift/lot
per shift/lot
per shift/lot
per month
per month
per month
per fixture
per fixture
per fixture
per week
per week
per week
per table
per table
per table
per day
per day
per day
Additional Requirements Instructions/Comments/Remarks
Pre-DV phase
Weld Types
CC/∇ x x x x x x x x x Per pre-DV prototype lot (every 4 hours)

K 100% x x x 3 x x x 3 x x x Minimum time-separated consecutively-tested assemblies (i.e., first,
U x x x x x x x x x middle, and last assembly of lot)
DV Phase
Weld Types
CC/∇ x x x x x x x x x Per DV prototype lot (every 4 hours)

PV Phase
Weld Types
CC/∇ x x x x x x x x x Per PV pre-production/PSW lot (every 4 hours)

IP-1 Phase
CC/∇ x x x x x x x x x Per IP-1 lot (every 4 hours); sustainability requires min. 10 days w/o failure
Weld Types
K x x x x x x x x x If/when sustainability achieved, sample and frequency will be reduced

100% 4 4
Kb x x x x x x x x x with PD and STA Weld Technical Experts and responsible PD/STA
U x x x x x x x x x Engineer(s) approvals (recommend min. 1 sample/shift) - see IP-2 Phase
Minimum time-separated consecutively-tested assemblies
(i.e., 2 first & 2 last assembly of lot)
IP-2 Phase
CC/∇ x x x x x x x x x Per IP-1 lot (every 4 hours); sustainability requires min. 10 days w/o failure
Weld Types
K x x x x x x x x x If/when sustainability achieved, sample and frequency will be reduced

100% 1 1
Kb x x x x x x x x x with PD and STA Weld Technical Experts and responsible PD/STA
U x x x x x x x x x Engineer(s) approvals (recommend min. 1 sample/shift)
If weld quality issues occur, ICA/PCA/PR is required and mfg. location
returns to IP-1 Phase requirements above until sustainability re-established
II.3.1.4 Ford Manufacturing/Assembly Plant Weld Inspection Frequency Notes (Body)- General
For Ford Plants (body), minimum Sample Size and Frequency are 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://wiki.ford.com/display/QOS/VOPQUE-
612+Uniform+Test+and+Evaluation+Program+for+Welding+and+other+joining+Operations
• Ford North America: Document VOPSSN-008, available at http://www.vo.ford.com/ss/procedures/procd-
files/ssn008c.pdf
II.3.1.5 Welding Parameter Monitoring – for automated GMA-Welding applications only

Certain process parameters will have a significant influence on the Welded joint quality. The control plan, as
defined in Ford ISO/TS 16949:2002, is an essential part of a quality product. Some recommended process
variables to include in the control plan are:
• Job Characteristic Curve defined by: Current [A], Voltage [V], and Wire Feed [m/min]
• Wire Feed Motor Current [A]
• Welding Speed [m/min]
• Flow of Shielding Gas [l/min]
II.3.1.6 Procedure for weld lot quality inspection deduction

Determine the start of deficient parts by: evaluating the batch in 50% steps (1/2, 3/4, 7/8, 15/16 …) until a
deficient part is found. When a deficient part is found select the next part, in a 50% step forward. If a
deficient part is found, move by a 50% step forward (toward the first part), and if a good part is found,
move by a 50% step rearward. Continue this process until the start of the deficiency can be determined.
Then check one more part(s) forward and one or more part(s) rearward to reinforce that the start of the
deficiency has been determined.
Example:
1. Select a part in the middle of the batch (1st 50% step). It is ok,
2. Select another part in the 3rd quarter of the batch (2nd - 50% step), it is ok
3. Select another part 7/8ths of the way in the batch (3rd 50% step),
Continue process until the start of the deficiency can be determined. Then check at least one more part
forward and one part rearward to reinforce that the start of the deficiency has been determined.

Table II. -6 Summary of ES Tests and Acceptable Parameters
NOTE: See Table IV-1
Test Test Characteristic Low Tolerance Limit Target Value Upper Tolerance Minimum Minimum
Number Limit Sample Size Sample
Frequency
Controllable Parameters
III.3.3.1. Current [A] -5% of nominal Nominal as determined in +5% of nominal see 1) 100 % 2/
PV testing
III.3.3.2. Voltage [V] -5% of nominal Nominal as determined in +5% of nominal see 1) 100 % 2/
PV testing
III.3.3.3. Wire Feed Speed [m/min] -10% of nominal Nominal as determined in +10% of nominal see 1) 100 % 2/
PV testing
III.3.3.4. Wire Feed Motor Current -25% of nominal Nominal as determined in +25% of nominal see 1) 100% 2/
(amps) PV testing
III.3.3.5. Welding Speed [m/min] -10% of nominal Nominal as determined in +10% of nominal see 1) 100 % 2/
PV testing
III.3.3.6. Flow of Shielding Gas -15% of nominal As at PPAP +15% of nominal see 1) 100 % 2/
[l/min]
Arc length (if available) As determined in PV As at PPAP As determined in PV see 1) 100 % 2/
testing 3/ testing
Polarity As determined in PV As at PPAP As determined in PV see 1) 100 % 2/
testing 3/ testing
CTWD (Contact to work As determined in PV Nominal as determined in As determined in PV see 1) 100 % 2/
distance) testing PV testing testing

Transfer mode As determined in PV As at PPAP As determined in PV see 1) 100 % 2/
testing 3/ testing
Stick out length 0 As at PPAP 3.2 mm see 1) 100% 2/
Dwell (arc on time [sec]) As determined in PV Nominal as determined in As determined in PV see 1) 100 % 2/
testing 3/ PV testing testing

Equipment Settings:
III.3.3.7. Torch and Travel Angle [°]
Travel Angle [°] -10 horizontal, -2 vertical Nominal as determined in +10 horizontal, +2 vertical see 1) see 1)
PV testing
Work Angle [°] -2.5 horizontal or -2.0 Nominal as determined in +2.5 horizontal or +2.0 see 1) see 1)
vertical PV testing vertical
III.3.3.8 Welding Direction As determined in PV Nominal as determined in As determined in PV see 1) see 1)
Test Test Characteristic Low Tolerance Limit Target Value Upper Tolerance Minimum Minimum
Number Limit Sample Size Sample
Frequency
Controllable Parameters
I.7.4 Shielding gas type & As determined in PV Nominal as determined in As determined in PV see 1) see 1)
mixture testing 3/ PV testing testing
Filler wire diameter As determined in PV Nominal as determined in As determined in PV see 1) see 1)
I.7.3 Filler wire type As determined in PV As determined in PV As determined in PV see 1) see 1)
testing 3/ testing testing
Wave form As determined in PV As determined in PV As determined in PV see 1) see 1)
Torch oscillation As determined in PV As determined in PV As determined in PV see 1) see 1)
Joint Preparation Settings
Gap & fixturing As determined in PV Per Table II-7 Weld As determined in PV see 1) see 1)
testing 3/ Quality Requirements testing
Cleanliness As determined in PV As determined in PV As determined in PV see 1) see 1)
Joint width for welding As determined in PV Nominal as determined in As determined in PV see 1) see 1)
1
/ Reference Commodity-specific frequency and sampling requirements sections and tables
2/
100% verification through process monitoring or startup check sheet verification of running within the parameter window.
3/
See Table IV-1 Weld Changes / Actions
NOTE: Weld parameters must be submitted as part of the PPAP package.

II.3.2 Weld Quality Evaluations – Visual and Cross-Sectional
Table II-7 Weld Quality Requirements
V = visual
T1 (min) Gauge Range:
inspection T1 (min) Gauge Range:
Test >1.5 mm
I = section 0.7 to 1.5mm Visual Aids
inspection
Characteristics (based on governing metal thickness, T1
(based on governing metal thickness, T1 (min)
V/I = both (min)
Lap-Joints: Lap-Joints:
100% tmin or
t1 leg angle t1 face fusion
Leg penetration: All legs must achieve a penetration Leg penetration: All legs must achieve
depth of 0.1 x T1 ≤ maximum penetration depth ≤ T2 penetration depth of 0.1 x T1 ≤ maximum
with a nominal target of 0.3*T2 penetration depth ≤ T2 with a nominal target
of 0.3 x T2
Target: ≥0.3*t2
Leg length fusion: (min. range
100% t2 faying
1) T1 (L1) fusion (leg length must consider max gap Leg length fusion: surface plane fusion
≥0.1*t2)
conditions noted below): 100% T1 leg length (fusion 1) T1 (L1) fusion (leg length must consider
along face) max gap conditions noted below): min. 70%
T1 leg length (fusion along face)
2) T2 (L2) fusion: 100% T1 leg length (fusion along
faying surface plane) 2) T2 (L2) fusion: min. 70% T1 leg length
(fusion along face)
Root Penetration (reference specific schematics
for lap-joint, t-joints, flare-bevel/flare-V/flare- Root Penetration (reference specific
groove/V-groove & butt-joints): schematics for lap-joint, t-joints, flare-
Minimum ==> T1 L1 leg < 70˚ angle relative to faying surface bevel/flare-V/flare-groove/V-groove & butt-
Penetration/ (fusion zone) joints): 0.1 x T1 at nominal target of 0.3 x T1 *
I Depth of Fusion & ==> I f >70˚ to 90˚, confirm root fusion and gap - or use '< 1.5mm GMT methodology' to left
Minimum Actual confirm with Ford PD, Mfg, STA Engineering
Throat ==> I f >90˚, not acceptable Actual Throat: a ≥ 0.7 x T1
Actual Throat: a ≥ 0.7 x T1
T-Joints:
Leg penetration: All legs must achieve penetration depth of 0.1 x T1 ≤ penetration depth ≤ T2 at nominal
target of 0.3 x T2
Leg length fusion:

1) T1 (L1 ) fusion (leg length must consider max gap conditions noted below):
* minimimum of 70% T1 leg length (fusion along face)
2) T2 (L2 ) fusion:
* minimum of 70% T1 leg length (fusion along face)

V = visual
Test >1.5 mm
inspection
V/I = both (min)
T-Joints (cont):
Root Penetration (reference specific schematics for lap-joint, t-joints, flare-bevel/flare-V/flare-
groove/V-groove & butt-joints):
* minimum of 0.1 x T1 at nominal target of 0.3 x T1
Actual Throat: a ≥ 0.7 x T1
Flare-bevel/Flare-V/Flare-groove/V-groove: Flare-bevel/Flare-V/Flare-groove/V-groove:
Leg penetration: All legs must achieve penetration Leg penetration: All legs must achieve
depth of 0.1 x T1 ≤ penetration depth ≤ T2 at nominal penetration depth of 0.1 x T1 ≤ penetration
target of 0.3 x T2 depth ≤ T2 at nominal target of 0.3 x T2
Minimum
Penetration/ Leg length fusion: Leg length fusion:
I Depth of Fusion & 1) T1 (L1) fusion (leg length must consider max gap 1) T1 (L1) fusion (leg length must consider
Minimum Actual conditions noted below): 100% T1 leg length (fusion max gap conditions noted below): min. 70%
Throat along face) T1 leg length (fusion along face)
2) T2 (L2) fusion: 100% T1 leg length (fusion along 2) T2 (L2) fusion: minimum 70% T1 leg length
face) (fusion along face)
Root Penetration: Evidence of root fusion Root Penetration: Evidence of root fusion
Butt-Joints ("Groove Weld"):
Leg Penetration/Depth of fusion: All legs must achieve leg fusion depth of 0.1 x T1 ≤ maximum
fusion depth ≤ T1 at nominal target of 0.3 x T1
Root penetration and joint fusion (Weld size dimension): ≥ 0.85 of joint contact surface
h-excessive or
incomplete fill Butt-Joints ("Groove Weld"):
V/I
(top and bottom Not to exceed 0.2 mm + 0.2 x T1 or 2.0mm, whichever is greater
as depicted)
Linear Butt-Joints ("Groove Weld"):
V/I
Misalignment 0.2mm + 0.2 x T1 or 5 mm, whichever is smaller
V = visual
Test >1.5 mm
inspection
V/I = both (min)
Top bead convexity

"weld toe" angle
Bead concavity & Top & Lower bead convexity: weld toe ≥ 125˚ relative to T1 top surface plane and T2 lower surface
I
convexity plane
Lower (Root)
convexity "weld toe"
angle
V/I Burn Through None Permitted

V/I Cracks None Permitted
Crater - Open End

V Permitted but no cracks
Crater
V Discontiuities No burnt off wire, fishhooks, or any similar sharp protrusion that exceed 5.0 mm in height
V/I Fusion - Lack of See penetration above and in addition maintain maximum gap specification control conditions Above
Gap target = 0 mm
Gap target = 0 mm Max. allowable: < 0.7 x T1, or 175% electrode
Max. allowable: G <0.5 x T1 (never exceed 1.0 mm) diameter, whichever is smaller (never to
I Gaps Special Note: Max. allowable for Dual Phase and exceed 1.5 mm for thick stack-ups)
UHSS steels (Tensile strength 780 MPa or more): ≤ Special Note: Max. allowable for Dual Phase
0.4 mm and UHSS steels (Tensile strength 780 MPa or
more): ≤ 0.4 mm
I Weld leg See penetration above and in addition maintain maximum gap specification control conditions Above
V = visual
Test >1.5 mm
inspection
V/I = both (min)
Transverse Hardness is Mandatory for the Seats Commodity

Others: optional at engineer’s discretion
Assess hardness transverse/micro-hardness (see Tables III-1 Test Characterization and

I Hardness III-2 Applicability of Test Procedures and Requirements for frequencies, etc.)
Note: Especially important for Dual Phase and other UHSS applications
(Tensile strength 780 MPa or more)
V Melt Back - Edge Must not exceed stock thickness and to decrease to zero at or before the root of the weld.
I Melt Through max. 1.1 x T1
V/I Notching None Permitted Not to exceed 1 x T1 Ref: Figures 21 - 24
V/I Overlap - W Not permitted
Overlap such as stop/start of two welds along

V/I Overlap - L Permitted unless otherwise noted in CAD
length of part.
Target: none present

Porosity, Target: none present Pinholes separated by minimum of own
Inclusions single pore: max 0.4 x T1 diameter & other scattered porosity ok.
V/I
(surface and max. 0.2 of projected section cut for multiple pores pinholes: d ≤ 1.5 mm each.
internal) pinholes not permitted p (sum of diameters) ≤ 6 mm in any 25 mm
weld length.

V = visual
Test >1.5 mm
inspection (based on governing metal thickness, T1 (min)
V/I = both (min)
min. -6mm in longitudinal direction
max. +6mm in longitudinal direction
V Position of weld
meet min. a or s-value in transverse direction
(wp) Designates Weld Past (V.2.3)
Length in CAD/Drawing is minimum length (see Weld Symbol call-out)

V Weld length Length tolerance is -0 / +6 on each end of the weld
Total length must include min. 5mm run-in, 5mm run-out considerations
Only 1 defect, < 9mm long permitted in any ≥

100mm length of weld
V/I Skips Weld discontinuity: none no skips in any weld < 100 mm
no skips within 25 mm from ends of effective
weld lengths
Acceptance criteria for spatter depends on the class of surface finish as follows
(ref: ESF75B-11007-AA):
• Ford Class 1 Finish: Spatter shall not be detectable.
• Ford Class 2 Finish: Spatter shall not be detectable. Individual exemptions can be agreed between
Manufacturing, Engineering and Craftsmanship.
V Spatter
• Ford Class 3 Finish: The minimum occurrence of spatter – as determined during the definition of
the job characteristic curve in PV-testing - is acceptable unless the drawing indicates that spatter is
prohibited.
Spatter on threads of weld nuts and bolts shall be avoided - employ protective shields while
welding.
V Slags & Oxides None present on surfaces requiring electro-static coatings
max. 0.1 x T1 (first/last 13mm)

V/I Undercut
max. 0.2 x T1

III.TEST PROCEDURES AND REQUIREMENTS
III.1 Weld Joint Testing – Destructive, Non-destructive, and Functional Testing

Table III. -1 Test Characterization
Test Test Low Tolerance Target Value Upper Minimum Minimum
Number Characteristic Limit Tolerance Sample Size Sample
Limit Frequency
III.4.1 Visual / Per Table II-7 Per Table II-7 Per Table II-7 Per Section Per Section II.3.1
Dimensional II.3.1
Inspections of
Welds
III.4.14 Cut and Etch Not applicable Refer to weld (characteristics) inspection table Not applicable see 1) see 1)
III.4.2 Transverse Develop weld joint hardness (base/HAZ/weld see 1) see 1)
Hardness Test matrix/HAZ/base) profile to understand heat effects in weld
zone at engineer’s discretion.
III.4.3 Durability/ Not applicable No lack of compliance following completion of full vehicle No cracks see 1) see 1)
Fatigue Test durability per ARL 18-0001.
III.4.4.1. Bend & Peel Test Tensile Strength of Sample to separate in base sheet metal or in HAZ but not in Not applicable see 1) see 1)
lowest strength weld bead
material in stack
III.4.4.2 Crush Test Tensile Strength of Sample to separate in base sheet metal or in HAZ but not in Not applicable see 1) see 1)
lowest strength weld bead
material in stack
II1.4.4.3 Static Tensile Not applicable Sample to separate in base sheet metal or in HAZ but not in Not applicable see 1 see 1)
Test weld bead
III.4.4.4 Chisel Test Not Applicable Sample to separate in base sheetmetal or in HAZ but not in Not applicable see 1)
(Destructive) weld bead
III.4.4.5 Chisel Test Not applicable No partial or complete separation of welded joint Not applicable see 1) see 1)
(Non-Destructive)
III.4.5 Impact Test Not applicable Welded joint integrity in either component and/or Not applicable see 1) see 1)
subassembly testing; test set up and test conditions to be
agreed with responsible Safety Attribute Team
1) Reference Commodity-specific frequency and sampling requirements sections and tables

III.2 Applicability of Test Procedures and Requirements
Table III.-2: Applicability of Test Procedures and Requirements
Test Test DV/PV-Test Phases IP-Test Phase
Number Characteristic
III.3 Welding Parameter Monitoring
III.3.3 Welding Parameters Mandatory Mandatory
Automated GMA-Welding Applications: Automated GMA-Welding Applications:
Definition of joint-specific welding process window. Checks to verify compliance of running production with the
Manual GMA-Welding Applications: GMA-Welding process window determined during PV-Testing
Definition of joint-specific set of "jobs". Manual GMA-Welding Applications:
Checks to verify compliance of running production with these
"jobs" determined during PV-Testing
III.4.1.1 – Inspection of the Mandatory Mandatory
III.4.1.3 Visible Part of the Recommended: Dye Penetration Test to further analyze the Dye Penetration Test recommended to further analyze the
Weld occurrence of surface cracks and porosity occurrence of surface cracks and porosity
III.4.1.4 Cut and Etch (Cross Mandatory -- for control " CC/ ”; "S", "K”, and “U” class" joints, Mandatory: for the Seats Commodity
Section and Etch) - Optional -- for uncontrolled welds
Inspection of Recommended for
• Any joint that has a classification, i.e. "CC/ ", "S”, "K / KB", or “U”.
• root cause analysis in case of discrepancies and weld quality evaluation as part of the requalification (Section I.15)
III.4.2 Transverse and/or Optional: Engineer’s Discretion, Mandatory: for the Seats Commodity
Micro-Hardness Optional: DV, PV and Annual PPAP re-certification
Evaluations Optional: IP phases (recommended as on-going Quality Control for validation of base parent metal and weld interface
robustness)
III.4.4 Weld Bead Strength Optional: Functional Engineering to decide applicability
Tests
III.4.6 New Material Weld Optional: Functional Engineering to decide applicability: Mandatory -- for control " CC/ -class" joints
Analysis (Cold Drop Optional -- for normal welds
Test) Recommended for
• Any joint that has a classification, i.e. "CC/ ", "S"
and "K / KB"
• root cause analysis in case of discrepancies and
weld quality evaluation as part of the revalidation (Section IV)
NOTE: For Body and Manufacturing: Engineering expert departments to decide whether the following tests are required: Static Tensile Test (III.4.4.3), Bend & Peel Test
or Crush Test (III.4.4.1 and/or 4.4.2), Impact Test (III.4.5), Durability /Fatigue Test (III.4.3), Destructive Chisel Test (III.4.4.4), Non-Destructive Chisel Test (III.4.4.5):
Non-destructive chisel test (typically for unknown GMA-Welding applications only).
III.3 Weld Parameter Monitoring
III.3.1 Automated GMA-Welding Applications

Each automated welding application requires an individual set of fixed equipment settings as well as controllable
process parameters as outlined below - the ’job’: characteristic curve. It consists of target values as well as the upper
and lower tolerance limits and shall be determined in Production Validation tests individually for each GMA-Welded
joint.
GMA-Welding equipment used for the assembly of components according to this Engineering Specification shall be
equipped with a built-in memory unit capable of storing individual job characteristic curves for the relevant welding
jobs. This unit shall be capable of adjusting the parameters within the parameter window and monitoring compliance of
the welding operation with the job characteristic curve in order to ensure a weld of high quality that meets the
requirements outlined in this Engineering Specification.
The job characteristic curve shall be captured and maintained by the manufacturing source and applied on the basis of a
100 % sampling rate in IP-conformance testing. Special provisions (e.g. robot issuing a failure message) are required to
identify those joints that were welded with parameters outside the tolerance limits of the job-characteristic curve.
III.3.2 Manual GMA-Welding Applications

Manual GMA-Welding applications are defined on the basis of joint-specific "jobs" that shall be determined
individually for each application during the PV-test phase. The following parameters define a manual "welding job":
• welding direction
• type of drawn-arc (short-arc, pulse, etc.)
• one lead dependent parameter; either welding current [A] or wire feed [m/min]
• shielding gas flow [l/min]
These parameters shall be captured and maintained by the manufacturing source, and be used during IP-phase for
running production
III.3.3 Welding Parameters

III.3.3.1 Current [A]
The welding current characteristic is a measure of the energy input into the welded joint. During IP-monitoring
(automated GMA-Welding application only), it shall stay within 5% of the process window of the job characteristic
curve as defined in PV-testing individually for each welded joint application.
III.3.3.2 Voltage [V]
The welding voltage is proportional to the length of the electric arc and thus controls the energy input into the welded
joint. During IP-monitoring (automated GMA-Welding application only), it shall stay within 5% of the process window
of the job characteristic curve as defined in PV-testing individually for each welded joint application.
III.3.3.3 Wire Feed Speed [m/min]
The filler metal wire feed determines the amount of filler material that is available for the actual welding operation in
conjunction with the speed of the gun (welding speed). Typically, the wire feed is proportional to the welding current
and voltage and is set during PV-Phase jointly with the welding speed as one element of the job characteristic curve.
During IP-monitoring (automated GMA-Welding application only), the wire feed shall stay within 10% of the process
window of the job characteristic curve as defined in PV-testing individually for each welded joint application.

III.3.3.4 Wire Feed Motor Current (System Dependent) [A]
If possible, the wire motor current shall be monitored to ensure that a blocked wire in the wire guide can reliably be
detected during the welding operation. The wire feed signal is typically picked from the transporting wire feed roll,
which may slip while still sending o.k.-wire feed signals to the controller. During IP-monitoring (automated GMA-
Welding application only), the wire feed motor current shall not increase by more than 25%, or exceed the maximum
value as defined in PV-testing individually for each welded joint application.
III.3.3.5 Welding Speed [m/min]
During IP-monitoring (automated GMA-Welding application only), the welding speed shall stay within 10% of the
process window of the job characteristic curve as defined in PV-testing individually for each welded joint application.
III.3.3.6 Flow of Shielding Gas [l/min]
One of the main criteria for a quality-welded joint is the constant flow of shielding gas. Therefore, a gas sensor shall
continuously monitor whether or not a proper flow of gas is delivered to the welding torch. The gas flow rate shall not
change by more than 15%
III.3.3.7 Torch and Travel Angle [°]
During the IP-phase, the torch and the travel angle of the welding torch shall be within the parameters of the table
below.
III.3.3.8 Welding Direction
During the IP-phase, the welding direction of the gun (forehand, backhand) shall be as determined during PV-testing
individually for the relevant welded joint application.
III.4 Destructive, Non-Destructive and Functional Testing

Welds shall be inspected for discrepancies using the following inspection methods. The applicability of the relevant test
methods is defined in Section III.2 Applicability of Test Procedures and Requirements.
III.4.1 Visual/Dimensional Inspections of Welds.

Test Equipment – Scales, calipers, gages, templates, lamps, magnifying lenses, workmanship samples, visual aids, and
laser vision and or vision cameras as required.
Visual inspection will be used only as a check for weld location, total weld length, surface finish, visual discrepancies
(cracks, burn-through, surface porosity, undercut and gaps), correct number of welds and specified spacing as called out
in the weld manual.
Distortion that occurs as a result of the welding process must be controlled to fall within the tolerances as shown on the
engineering drawing.
The visible part of the weld shall be inspected for discrepancies using the following three inspection methods.
III.4.1.1 Bare Eye Inspection

Visual inspections shall be performed (naked eye inspection) to detect those obvious discrepancies outlined in this
Section. Scales or caliper gauges are required to verify dimensional compliance.
III.4.1.2 Position of Weld

Weld position and length shall be as outlined on the assembly drawing or in the CAD-system. The upper tolerance limit
is +/- 3 mm in longitudinal direction, while in transverse direction compliance with the minimum ‘z’ value is mandatory.

III.4.1.3 Dye Penetrant Testing
A dye penetrant test shall be performed to further analyze the following discrepancies:
- Surface Cracks, End Crater Cracks see Section I.8.3.3; Table II-7 pg. 35 and
- Surface Porosity, see Section I.8.3.9; Table II-7 pg. 36.
III.4.1.4 Cut and Etch (Cross Section and Etch)

Weld Section and Etch is the primary test. This specification requires analysis of identified production welds using
Weld Section and Etch with minimum frequency as summarized in Section II. 3. 1. Inspection Frequencies, unless
otherwise designated on the part detail.
Sectioning not associated with normal daily production requirements may be supplemented with the weld bead strength
tests below (III.4.4) only with prior written approval from Ford Engineering and STA, or if designated on the part weld
detail (KB). Model for weld analysis is to be defined by the program engineer(s) based on commonality and documented
on the part assembly detail. Unclassified welds shall be tested at a minimum frequency per II. 3. 1. Inspection
Frequencies, using weld section and etch unless specific prior authorization is provided in writing by Ford Engineering
and STA to use other of the testing procedures in this document.
FIGURE 29: Example of a Weld Section and Etch Report

• Welds samples will be tested in location as identified on the detail
• Welds will be measured for proper size, contour and other visual acceptance criteria. Visual inspections are to be
enhanced with magnifiers of the standard 10x (e. g. handheld magnifiers).
• Cross-sectioned welds will be polished, etched and evaluated at 5 to 10 x magnifications depending on field of view,
with magnification documented with picture or file.
(Ref. Macroscopic Examination of Metals, Principles of Metallographic Laboratory Practice, Geo. Kehl).
Minimal acceptable conditions for Cross-section and Etch Test:
-Welds must show positive evidence of fusion from the root to the toes and must meet the minimum size and throat as
defined in this specification section II.3.2. Weld Quality Evaluations, or the Engineering Assembly Detail. The last
listed will govern over all prior.
-There shall be no evidence of weld metal overlap and/or incomplete root penetration per II.3.2. Weld Quality
Evaluations.
Note: The depth to which the base metal has melted during welding is the "Depth of penetration/fusion". Adequate
fusion is characterized by torn base metal. Lack of fusion is characterized by a straight "line” which is the unfused edge
or surface of base metal that did not melt or become a part of the admixture.
III.4.2 Transverse and/or Micro-Hardness Evaluations

Method Overview
• Hardness checks performed about every 1 mm across the parent materials, heat-affected zones, and weld zones
to determine if some kind of material softening has occurred through the weld joint due to the heating
• Typically using RHb and RHc, Brinell, or Vickers scales which correlate to material strength (MPa) at that point.
• This method is a good indication of whether the heat input is excessive and whether the materials are at the
correct mechanical property levels.
Examples of Output from Studies:

Test Output Graphs:
FIGURE 30

FIGURE 31
Weld Cross-section of "Micro" or "Transverse" Hardness Test
FIGURE 32
Weld Testing Information On-line for Micro-Hardness Testing:
From http://www.angelfire.com/my/welding/test.html :
"13-24. HARDNESS TESTS
a. General. Hardness may be defined as the ability of a substance to resist indentation of localized displacement. The
hardness test usually applied is a nondestructive test, used primarily in the laboratory and not to any great extent in the
field. Hardness tests are used as a means of controlling the properties of materials used for specific purposes after the
desired hardness has been established for the particular application. A hardness test is used to determine the hardness of
weld metal. By careful testing of a welded joint, the hard areas can be isolated and the extent of the effect of the welding
heat on the properties of the base metal determined.
b. Hardness Testing Equipment.

(1) File test.

The simplest method for determining comparative hardness is the file test. It is performed by running a file
under manual pressure over the piece being tested. Information may be obtained as to whether the metal
tested is harder or softer than the file or other materials that have been given the same treatment.
(2) Hardness testing machines.
(a) General. There are several types of hardness testing machines. Each of them is singular in that its
functional design best lends itself to the particular field or application for which the machine is intended.
However, more than one type of machine can be used on a given metal, and the hardness values obtained
can be satisfactorily correlated. Two types of machines are used most commonly in laboratory tests for
metal hardness: the Brinell hardness tester and the Rockwell hardness tester.
(b) Brinell hardness tester. In the Brinell tests, the specimen is mounted on the anvil of the machine and a
load of 6620 lb (3003 kg) is applied against a hardened steel ball which is in contact with the surface of the
specimen being tested. The steel ball is 0.4 in. (10.2 mm) in diameter. The load is allowed to remain 1/2
minute and is then released, and the depth of the depression made by the ball on the specimen is measured.
The resultant Brinell hardness number is obtained by the following formula:
It should be noted that, in order to facilitate the determination of Brinell hardness, the diameter of the
depression rather than the depth is actually measured. Charts of Brinell hardness numbers have been
prepared for a range of impression diameters. These charts are commonly used to determine Brinell
numbers.
(c) Rockwell hardness tester. The principle of the Rockwell tester is essentially the same as the Brinell
tester. It differs from the Brinell tester in that a lesser load is impressed on a smaller ball or cone shaped
diamond. The depth of the indentation is measured and indicated on a dial attached to the machine. The
hardness is expressed in arbitrary figures called "Rockwell numbers." These are prefixed with a letter
notation such as "B" or "C" to indicate the size of the ball used, the impressed load, and the scale used in
the test. "

Table III-3 Hardness Conversion Numbers

Recommended Facilities with Expertise (not exhaustive):
• Stork Materials Technology: http://www.storksmt.com/16123/Welding_Engineering_Services.html
• AET Integration in Wixom, MI (Jack Sang & Cindy Jiang) - utilized by Ford (Seats and Research & Advanced
Engineering team) for welding fatigue, transverse ("micro") hardness testing, etc. http://www.aet-int.com/
III.4.3 Durability / Fatigue Test

Full vehicle durability testing according to ARL 18-0001 and any applicable SDS requirements 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.
See appropriate SDS for acceptance criteria
III.4.4 Weld Bead Strength Tests
Weld bead strength tests are performed to ensure that the joint meets the individual performance requirements in terms
of static and dynamic loads. The applicability of the relevant test methods is defined in Section III.2 Applicability of
Test Procedures and Requirements. The acceptance criteria are based on the theory that the application of the welding
process shall not weaken the integrity of the joint in any way.
III.4.4.1 Bend and Peel

The static peel test shall be performed in accordance with:
• ISO 14270, Specimen Dimensions And Procedure For Mechanized Peel Testing Resistance Spot, Seam And
Embossed Projection Welds or
• Auto/Steel Partnership Test Procedures (North America).
The test specimen shall be manufactured using base sheet metal as well as filler metal wire identical to production
conditions in terms of material specification, gauge and base sheet metal coating. The length of the bead shall be as
indicated on the assembly drawing. 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 bead.
III.4.4.2 Crush Test
Force
Force
Figure 33 Figure 34
Mechanical testing such as crush test may be used to supplement root bend and chisel testing. Process/procedure and
method of testing will be documented, and the method, frequency, and location will be documented in the Weld Control
Plan.
Minimal acceptable conditions for Crush Test:
Evidence of fusion from the root to the toes

No evidence of metal overlap and/or incomplete root penetration.
Adequate fusion is characterized by torn base metal, and/or fracture face with ductile features.
III.4.4.3 Static Tensile and Torque Strength Test (or local procedure depending on loading of component.)
The static tensile or torque strength test shall be performed in accordance with:
• ISO 14273, Specimen Dimensions And Procedure For Shear Testing Resistance Spot, Seam And Embossed
Projection Welds or
• Auto/Steel Partnership Test Procedures for North America

The test specimen shall be manufactured using base sheet metal as well as filler metal wire identical to production
conditions in terms of material specification, gauge and base sheet metal coating. The length of the seam shall be as
indicated on the assembly drawing. 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 bead.
III.4.4.4 Chisel Test (Destructive) [Optional – Not to be used as a primary validation process, but can be used in
conjunction with other verification methods].
Minimum acceptable conditions for the destructive chisel test are:
• the base metal tears out with weld or
• the weld separates through the throat (in metal thickness over 3mm) – root fusion must be evident and visible.
The chisel test can be applied on subassembly or complete bodies. It is performed to validate the evidence of fusion for
the entire weld.
Destructive chisel testing requires separating the base sheet metal adjacent to the weld in the direction parallel to the
weld using a chisel. The chisel according to ISO 10447 is shown as an example in Figure 35 for Europe. Figure 36
shows the chisel used in North America.
40
R 70
All edges to be
15 free of burrs
24 9 Ø 12.5
FIGURE 35: Chisel According to ISO 10447
FIGURE 36: Spot Test Chisel Used in North America (ref.: tool # 5ZF-15063)

III.4.4.5 Chisel Test (Non-Destructive) [Optional – Not to be used as a primary validation process, but can be used in
conjunction with other verification methods]
The non-destructive chisel test can be applied to exclude the risk of a lack of fusion. The operator - in contrast to the
destructive chisel test – should apply the load gradually and exercise care to avoid permanent damage to the panels.
There shall be no partial or complete joint separation.
The non-destructive chisel test can also be used to verify the integrity of joints that were welded with parameters outside
the job characteristic curve which do not display imperfections in a visual inspection (Section III.3 Weld Parameter
Monitoring).
III.4.5 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.
The test set up and test conditions shall be agreed upon with the relevant PD Technical Expert (and/or STA
Expert/Engineer and/or Body and Manufacturing Engineering Department as applicable) 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.4.6 New Material Weld Analysis (NOTE: This cold test is Ford responsibility):
For materials classified as described in V.2.1 Introduction: below for welding or subjected to welding that is not
customary for the known material, weld tests must be conducted that comply to FLTM (Ford Laboratory Test Method)
BA 113-08 “Spot Weld Test Criteria for Bare and Coated (Zn & Zn/Fe) Low Carbon and Medium Strength Steel Sheet"
or applicable industry standard(s), e.g. AWS D-8.9 M: 2002 (basis for BA-113-08).
The general Ford vehicle minimum temperature test requirement is - 40° C (-40° F), but welding components of
materials not common to the selected welding process may result in weldments that may be subjected potential
environmental temperatures of -54° C (-65° F) or lower. It is strongly recommended that these component weldments be
subjected to metallurgical evaluation and weld analysis (Charpy Impact, cut - mount – polish – etch - microstructure
analysis, chisel, peel, crush, or similar evaluation(s)), after a cold soak to a minimum of - 54 °C (- 65° F) (min of 3
samples). Actual components, or surrogate parts of the same mass, material weld stack up and thicknesses, may be used
for these tests:
Mechanical Test Verification: If the materials fall into the classes of materials mentioned in V.2.1 Introduction:,
verification should consist, at a minimum, of mechanically testing samples at room temperature and samples subjected
to cold soak for any mechanical property change(s) per the following:
Ambient Temperature (20° C (68° F)) – Mechanically test a minimum sample of 3 at room temperature. Evaluate the
joint through the use of known tests: Charpy Impact Test, chisel test, root bend, metallurgical, or crush test, using
coupons or surrogate parts of adequate size and mass. Perform fastener testing, as applicable.
Cold Soak Test: Mechanically test a minimum sample of 3 at -54 C (-65 F) (a known cold soak source is ATNPC
Livonia). Parts should be tested as quickly as possible, not to exceed 10 minutes, after removal from cold soak. Evaluate
the joint through the use of at least the same known tests used for ambient temperature evaluation: Charpy Impact Test,
chisel test, root bend, metallurgical or crush test, using coupons or surrogate parts of adequate size and mass. Perform
fastener testing, as applicable.
Test Results: If Charpy Impact and/or other tests indicate significant material property decrease(s), alternative actions
are required, potentially consisting of post stamping, forming, or weld process changes.
IV.REVALIDATION REQUIREMENTS
IV.1 Alteration to Production

Any of the following conditions outside the parameters in Tables II-6 Summary of ES Tests and Acceptable Parameters
or IV-1 Weld Changes / Actions that affect the welding operation require a re-run of Production Validation (PV) tests as
agreed upon by the relevant Product Development / Body and Manufacturing Engineering Departments. Changes are to
be validated using the PV “CC/ ”-Class sampling frequency and time (II.3.1.2.3.2.2 Weld Analysis…)
If following the PV “CC/ ”-Class sampling frequency and time, the weld fails to achieve the requirements of Weld
Analysis of II.3.1.2.3.2, the Supplier shall continue with sampling plan frequency associated with PV “CC/ ”-Class
welds until the Supplier Weld Inspections requirements are met.
NOTE: Weld parameters must be submitted as a part of the PPAP package.
• Process Change - Any change in the process which could alter its capability to meet the design requirements or
durability of the product. This includes:
New, different, relocated, or rehabilitated production machinery or equipment (does not include portable
manual GMA-Welding equipment)
Any change in subcontracted products or services including the use of engineering-approved alternate
materials
Changes to rework methods
Changes in the sequence of operations
Changes in chemical compounds such as lubricants, which are part of the product
Changes to filler metal or gas shielding type
• Engineering Change - Any change in the part(s) initiated by Ford Motor Company.
• Material and Coating Change - Any change in the material properties, or a change in sheet metal coating
when the new/revised coating is not listed in Section I.7.2. A change in steel supplier for steels having minimum
yield strength equal to or exceeding 310 MPa in the "as received condition" is also considered a material change.
• 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: Possible changes listed in Table IV-1 Weld Changes / Actions shall not be made in conjunction with one another.
Only one of the listed changes shall be made before scheduled section and etch occurs. If two or more such changes
are made in conjunction with each other, Travel Angle plus Work angle excepted, the weld shall be treated as a
new weld and immediately revalidated through the steps commencing with the PV “CC/ ”-Class sampling
frequency and time (II.3.1.2.3.2.2 Weld Analysis…). Any major changes affecting weld processes must be
approved and revalidated by the supplier’s weld engineer.
Note: The following are examples of changes that require notification of Ford Engineering and STA:
-EPA Notification of Water-Shed Compliance, and - Changing from Copper Coated Wire to Bare Wire or Heavy Metal
Compliance.
- Ground Water/Storm or Sewerage Floor Drain Run-Off is an immediate, mandatory report to Ford Engineering and
STA.

Table IV-1 Weld Changes / Actions (Ref: Table II-6)
Change SREA a/ and Sampling Quantity Comments
Validation (successive samples)
Required?
∆ Fixture combining operations, or Yes 6 piece verification and
separating operations into new determination
fixtures not positioned in the same
location or robot.
∆ Wire size Yes 3 piece verification and Requires change to all
determination parameters
∆Wire type –part of 280 MPa or Yes 3 piece verification and e.g. ER70-S6 to ER70-S3
greater yield strength steel determination or from bare to Cu coated
or Cu coated to bare
∆ Wire type – part less than 280 No e.g. ER70-S6 to ER70-S3
MPa yield strength steel or from bare to Cu coated
or Cu coated to bare
∆ Wire manufacturer – if wire Yes 3 piece verification and
chemistry CANNOT be verified determination
∆ Wire manufacturer – wire Yes 3 piece verification and For wholesale changes,
chemistry CAN be verified, but determination. weld cut and etch, bend
unfamiliar supplier to Ford or tier and peel and durability
one supplier proveout may be required
per engineering request
∆ Wire manufacturer – wire No
chemistry CAN be verified, and
supplier known within Ford and tier
one supplier
∆ Wire feed speed – change is Yes 6 piece verification and
greater than 10% in mm or more. . 1/ determination
∆ Wire feed speed – change is less No
than 10% in mm
∆ Wire stick out – 3.2 mm or more. . Yes 6 piece verification and
1/
determination
∆ Wire stick out – less than 3.2 mm No
∆ Welding voltage – change is +/- 5 No
% or more before process stability
(before IP) is demonstrated.
∆ Welding voltage – change is +/- 5 Yes 3 piece verification and
% or more after process stability is determination
demonstrated. 1/
∆ Welding voltage – change less No
than +/- 5%
Welding current – change is +/- 5% No
or more before process stability is
demonstrated
∆ Welding current – change is +/- Yes 3 piece verification and
5% or more after process stability is determination
demonstrated. 1/

Required?
∆ Welding current – change is less No
than +/- 5%
CTWD (Contact to work distance) – No
less than 2.0 mm
CTWD – 2.0 mm or more Yes
∆ Travel Angle – Change Yes 6 piece verification and See Figure 21
10°horizontal or 2°vertical or more. . determination
1/
∆ Travel Angle – Change less than No
10°horizontal or 2°vertical
∆ Work Angle – +/- 2.5°horizontal Yes 6 piece verification and See Figure 21
1/
or 2.0° vertical or greater. . determination
∆ Work Angle – less than +/- 2.5° No
horizontal or 2.0° vertical
∆ Weld travel speed – change is Yes 6 piece verification and
greater than 10% in mm or more. . 1/ determination
∆ Weld travel speed – change is less No
than +/- 10% in mm
∆ Wire feed motor current, - increase No Address issue causing high
of more than 25% current
∆ Polarity Yes 6 piece verification
∆ Welding direction Yes 6 piece verification
∆ Changes from air to water cooling Yes 6 piece verification Individual validation
or vice-versa
∆ Re-sequence Weld – same part No
∆ Re-teach Weld Yes 6 piece verification and Individual validation
determination
∆ Material thickness outside of Yes 6 piece verification and Individual validation
tolerance specified. determination
∆ Add welds Yes 6 piece verification and Individual validation
determination
∆ Torch model No Unless welds are re-taught
∆ Mode of transfer Yes 6 piece verification and Requires change to all
∆ Dwell Yes 6 piece verification and
determination
∆ Torch Oscillation Yes 6 piece verification and
determination
∆Wave form Yes 6 piece verification and
determination
∆ Gas type and mixture Yes 6 piece verification and Requires change to all
∆ Gas flow rate – change over +/- No Address gas flow rate
15%
Required?
∆ to chemicals such as die lubricant SREA Validation may be required
at engineering and / or
STA request
∆ Cleanliness
∆ - New, different, rehabilitated or SREA 6 piece last off Validation may be required
relocated equipment. Does not (rehabilitated or relocated), at engineering and STA
include portable , manual welding and 6 piece first on request
equipment verification and
determination
∆ subcontracted materials, source(s), SREA Validation may be required
or services including engineering at engineering and / or
approved alternate materials STA request
∆ rework methods SREA Validation may be required
at engineering and / or
STA request
∆ parts initiated by Ford Motor Validation may be required
Company at engineering and / or
STA request
∆ material properties or change in Validation may be required
coatings not listed in Tables I – 2 or at engineering and / or
I-4 STA request
∆ suppliers of steels of 310 MPa or SREA Validation may be required
greater at engineering and / or
STA request
∆ where the supplier incorporates SREA Validation may be required
optional designs specified on the at engineering and / or
released engineering drawing or STA request
relevant CAD model
∆ Joint fit up (gap) < 80% of No
maximum
∆ Joint fit up (gap) ≥ 80 % of No Take action to address gap
maximum before attains maximum
∆ Joint fit up (gap) > maximum Yes Ford to determine if parts
are acceptable
∆-Joint width for welding
a/
SREA – Supplier Request for Engineering Approval, Ford Form 1638, available at:
https://web.qpr.ford.com/sta/SREA.html
1/
. For power supply's with adaptive controls, a base schedule shall be the point of reference for changes
that are made manually to the weld program. Adaptive changes to the weld schedule made by the Power
Supply during the course of a weld are accepted, as long as the base schedule is always the point of adaptive
reference

IV.2 Repair Methods
IV.2.1 For weldments that are not immediately repairable:

Assemblies with weldments that do not meet the requirements of II.3.2 Weld Quality Evaluations … must be
isolated into a separate storage area. The supplier shall furnish to Ford Engineering and Ford STA a listing of
the defects and quantity of parts involved for deviation consideration. Ford Engineering will then analyze these
discrepant weldments, and approve and/or determine a weld repair method as acceptable. After approving a
repair method an Alert should be issued to authorize a repair procedure for each specific condition and for
specific quantities. Welds may not be repaired after finish coating without exact prescribed details of the repair
and the process provided and agreed to by Ford PD and STA in writing. If impractical to repair, the alternative is
to scrap these parts.
IV.2.2 The following procedures are to be followed when weld repairing. Each supplier or body shop must demonstrate
compliance and obtain Product Development, or both Body and Manufacturing Engineering, approval for
specific defect locations and conditions/facilities utilized for repair. A visual aid display of these procedures in
the repair area is required. Weld repairs are allowed anywhere on the part unless otherwise specified on the
assembly detail.
A program / part specific repair procedure must be defined for each GMA-Weld joint within the structure during
the design process. Repair procedures must be inline with process guidelines as defined in Sections I.3. Process
Description and I.9 Welding Processes.
All non-compliance shall be documented. Documents shall be reviewed at least semi-annually to determine
resolution to any repetitive issues. The minimum documentation required is: part(s) identification, root cause,
and repair procedure(s). Commencing at IP, the engineering or line supervisor shall submit these documents to
the Quality lead for the assembly line for review and signature, supported by welding data as appropriate.
In the case of a discrepant weld, when reworking becomes necessary, the following rules apply, unless specified
differently on the assembly drawing or in the CAD-file:
• Any welds that are missing, contain skips, are of inadequate leg or fillet size, below specified length,
contain discontinuities, or insufficient throat thickness may be brought within specification by additional
welding, using the same welding process and filler wire applied to make the original weld.
• Burn through 9.0 mm or less in diameter:
- Grind off any excess metal from the burn through area, using a disk having a maximum courseness of
60 grit.
- Remove the oxide and bevel the edges of the hole
- A chill block may be used if required
- Puddle weld the hole using the same process that was used to make the original weld.
- Using the same grinding tool, remove any metal representing excessive weld penetration if accessible.
- Build up any localized areas which visual examination indicates an under-filled weld condition
- Grind off any excess metal, if required for clearance purposes
• Any burnt off wire, fishhooks, or any similar sharp protrusion that exceed 5 mm in height must be
removed.
• Weld Porosity is repairable after grinding out the porosity
• Undercuts greater than allowed and less than 50% T1 are repairable by added welding to meet specification
requirements.

• Any other condition of non-compliance with this Weld Specification requires review with the PD Engineer,
PD Technical Expert and STA.
• In the case of GMA-Welds on high or ultra high strength steels (780 MPa tensile strength or greater,
Category DP, TRIP, MSW, BORON in Table I-2, Section I.7 Applicable Materials), both repair steps,
additional welding and re-welding after grinding, require specific care and shall not be executed without
the prior approval of the relevant Product Development Engineer, PD Technical Expert and STA Engineer,
and/or Body and Manufacturing Engineering Department as applicable.
• If additional welding at the initial location or grinding off and re-welding are not possible, place an
additional weld next to the discrepant one if prior approval is received from Product Development or Body
Engineering.
IV.3 Process Actions
IV.3.1 Off-Line Visual Inspection

Any visual non-destructive weld joint quality characteristics out of specification must have operator and/or
equipment adjustment(s) prior to the next scheduled weld joint quality inspection.
IV.3.2 Section Inspection

When any substandard welding is evident in any weld section, the supplier must bring the welding operation
into compliance within 24 hours (one working day). Supplier can self-certify good stock. (This shall be
documented as non-compliance).
If the supplier cannot apply corrective action to eliminate the substandard weldment within 24 hours (one
working day), the supplier must notify Ford Engineering and Ford STA by phone; and telex or e-mail, within the
next 24 hours (one additional working day) for process and Quality and Reliability performance assessment. All
suspect stock shall be quarantined. Once stock has been certified and accepted by Ford, the supplier can ship to
the production facility. (This shall be documented as non-compliance).
IV.4 Weld Issues - Requalification
IV.4.1 Unacceptable “S”. “K”, “KB” and/or Unclassified weld(s) / brazing received by Ford Assembly Plant(s). These
become class “CC/ ” or “S” only if concurred through both Ford Engineering and STA. This may be processed
through a WERs Notice and detail revision.
IV.4.2 Unacceptable “S”. “K”, “KB” and/or Unclassified weld / brazing issues that can't be resolved within 24 hours of
identification are elevated to class “CC/ ” unless Ford Engineering and STA grant exception to the supplier in
specific incidences. This may be processed through a WERs Notice and detail revision.
IV.4.3 Unacceptable welds / brazing that are temporarily re-classified "CC/ " per paragraphs IV.4.1 or IV.4.2 can be
reclassified to the original level of “S”” or sub-sequentially to an original level of “K/KB” or "U" upon proof of
sustainability.
Note: Once a weld / braze has been moved to the "CC/ " list, per items IV.4.1 or IV.4.2, it can be removed
only after an IP-1 level of quality has been re-established (ref: Sections II.3.1.2 and II.3.1.3 {Commodity
Specific} Frequency and Sample Requirements), and increased sampling for each weld sample has been
maintained a minimum of ten (10) working days. Depending on the severity of the production quality
concerns, Ford Motor Company Design and STA representatives can require that a higher sampling
frequency be utilized, and/or longer sample time be required to achieve IP-1 status. The supplier shall submit
a SREA to request engineering and STA to consider accepting this weld(s) reverting to a "S", "K"/"KB", or
"U" class weld/ braze. Welds / brazing may be individually assessed for status change by plant and/or
assembly line.
IV.4.4 At anytime from DV through Production, quality occurrences may be cause for sections to be taken from the
area or areas that have demonstrated a failure instead of or in additon to location(s) as indicated on the part
detail(s). Sectioning location(s) as defined on the part details may be changed to improve the scrutiny of sample
tests. Change of location requires agreement between Ford STA, PD, and Manufacturing. The location of the
section and etch shall not be moved to areas where this technique is not valid (start/stop overlap, radii, etc.).
V. INSTRUCTION AND NOTES
NOTE: See ISO/TS 16949:2002, Control of Subcontracted Suppliers; Retention of Inspection and Test Samples;
Notification of Completion of Inspection and Testing; Changes in Manufacturing Process; Change Approval
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.
For Seat Systems and per Seat SDS ST-0812, all GMAW welding parameter controls will be identified, noted as SC's on
the Control Plans and monitored on-going to assure sustained quality. Process parameter setting ranges are chosen as
part of demonstrating welding capability during pre-DV, DV, PV and IP phases (i.e., Welding Implementation
Readiness). These settings will remain in place unless a Ford-approved (approved by responsible Ford PD and STA
Engineers as well as by Global Seats Engineering Welding Design Leader/Technical Specialist) SREA accompanied by
a robust capability/correlation study demonstrating sustained weld quality is approved.
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, with their sample sizes and frequencies which will be performed in order to:
• Confirm whether the process is being managed effectively.
• Further identify significant process characteristics.
• 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, ISO/TS 16949:2002. Internal
reference documents can also be found in procedure VOPQUG-051 (Control Plans – Vehicle Operations Procedure –
Global).
V.1 Supplier Data
V.1.1 The physical test specimens or photographs of it are to be retained in an orderly and retrievable manner for 1
month. Adequate written records and photographs to adequately describe qualities of all section inspections are
to be kept through the current model year and one (1) year thereafter by the supplier. These specimens and

records are to be made available to Ford Engineering upon request. All weld sections are to be identified as
stated in III.4.1.4 Cut and Etch (Cross section and etch)
Any "CC/ " level weld will have electronically retrievable, tamper-proof documentation for the life of the
program plus twelve (12) years. This shall consist of a minimum of image and section data, weld #, and Julian
Date.
V.2 Welding / Brazing Considerations
V.2.1 Considerations for Proper Stamping and Welding of New Materials or Proto-Type Materials, Stampings, and
Mechanical / Draw Pierce Operations
Note: The following requirements shall be evaluated and complied with as appropriate prior to approval for new
components, or any change in Process or materials.
Introduction:
This pertains to Materials that are classified as HSLA, UHSS, AHHS, Micro Alloy, B (Boron), Hot Form, DP (Dual
Phase), SF (Stretch Flange) TRIP, etc. (all steel alloys with tensile strengths at or above 420 MPa or those materials that
use high or low pressure bending (Hydroform, tube bending, or expanding type devices or mandrels)). This addendum
also pertains to rolling mills where special steel formulations could produce (but not limited to); folds, cold laps, banded
microstructures, ferrite counts, magnetism, and other metallurgical issues that may be detrimental to downstream
processing. This requirement is also inclusive for materials using process annealing, during stamping, bending, or
forming operations (inclusive of tube rolling mills).
Common Misconception: 40% thinning is not the same as 40% elongation. 40% thinning takes away 40% of the load
bearing capability (neglecting the effects of work hardening).
Note; The following are engineering tools which are useful in validating forming or welding processes. These tools may
be used singularly or in combination with each other, dependent on component complexity and/or material reduction (as
noted by the procedures that follow).
1) FLD (Forming Limit Diagram); shall be conducted and submitted to Ford engineering for approval, for new processes
or any change in process once approval to tool has been granted by Ford. (Source – frame assembly or final component
supplier)
2) CGA (Circle Grid Analysis); shall be conducted and submitted to Ford engineering for approval for new processes or
any change in process once approval to tool has been granted by Ford. (Source – steel mill or stamping house)
3) TLD (Thinning Limit Diagram); shall be received from / reviewed by the Steel Supplier and submitted to Ford
engineering for approval, for new processes or any change in process once approval to tool has been granted by Ford.
Steel Suppliers should support all of the items listed above at the die development stage at the die site.
V.2.2 Tools for Verification of Thinning and Splits (Ford operating procedures take precedence over the following):
1) Vernier Calipers, Micrometers, Blade Micrometers, etc., - these instruments shall be capable of accessing the specific
area in question and shall be held perpendicular or normal to the surface to be inspected. All instruments and shop tools
shall have last in house calibration date and sticker with traceability to NIST.
2) Ultrasonic Testing (refer to Ford Policy Letter L-4): Probes shall have a calibrated standard with last in house
calibration, including date and traceability, to NIST. The correct surfactant/couplant, as directed by the ultrasonic tester
and probe manufacturer(s), shall be stated and used in all calibration and inspection procedures. All probes and
standards in conjunction with the electronic box shall have last in house calibration date and sticker with traceability to
NIST.
3) NDT / NDE Processes (non-destructive testing / non - destructive evaluation);

Direct Current (D.C.) - surface fine / hair line to sub-surface 0.6 mm.
Alternating Current (AC) - surface fine / hair line to just under sub-surface 0.3 mm.
4) Fluorescent Penetrant Inspection (FPI), - surface only, surface fine / hair line.
5) Stress Analysis, - X-Ray diffraction
V.2.3 Weld Past / Weld By / Weld Back

Weld
Past /
Weld By
/ Weld
Back
CAE, and design and release, need to work together on FEA analysis to ensure stamped and welded steel
components are designed to an optimized welding process. High stress zones need to be accurately identified for
parts in the lower end of the tolerance range and weld termination points should be designed to start and end
outside of those zones. Also, DV testing needs to performed with worst case production conditions to ensure
robustness of design within all levels of production variation.
ANALYSIS: Weld Past / Weld By / Weld Back

Welding the Blue part to the Orange part.
The bold green line is the required weld
Pt. A Pt. B
Pt. C for Weld Past / Weld By (Goes from Pt. A
to Pt. C).
The pink arrows indicate the direction of
the welds.
1. Start welding at Pt. A (typically 6 mm
before the theoretical start of weld)
2. Weld to Pt. B, and
3. Continue to Pt. C
4. Terminate the weld at Pt. C (outside the
Pt. B high stress region identified in
FEA).
Weld Back This technique is used if Pt. B is a high stress location, but a Weld Past is not possible.
Welding the Blue part to the Orange part.

The bold green line is the required weld
Pt A Pt. C (Goes from Pt. B to Pt. C).
Pt. B
The pink arrows indicate the direction of
the welds.
1. Start welding at Pt. A (typically 6 mm
before the theoretical start of weld)
2. Weld to Pt. B, and
3. Weld back over the weld and continue
to Pt. C
4. Terminate the weld at Pt. C (outside the
Pt. B high stress region identified in
FEA).
DISCUSSION FOR USE:
Guidelines are established for welding sign off criteria that design and release engineers need to uphold with the
assistance of CAE (Ref: WSBCPA-1B310-AA I.14.2 S Welds - …). Utilization of the weld by design
philosophy described in Frame-Subframe SDS, FR-0108 should be considered for all stamped and welded parts
with high stress areas around weld termination points.
The weld on both sides of the

part extended to 10.0 mm run-
off zone. The assembly print
was updated to reflect the
weld past (wp) requirement.

V.2.4 Trouble Shooting Guide
Table V-1 Trouble Shooting Guide

VI. COMPILATION OF REFERENCE DOCUMENTS
• ISO/TS 16949:2002, Quality System Requirements
• VOPQUE-612 – Uniform Test and Evaluation Program for Welding and other joining Operations
• VOPSSN-008 - Weld Quality Program-Spot Weld Classification & Vehicle Operations Manufacturing
Engineering Quality Policy Letter L-4 (use of Ultrasonic Testing for RSW attachments)
http://www.vo.ford.com/ss/procedures/procd-files/ssn008c.pdf or
• VOPSSN-018 – Assembly Tool Certification and Weld Specification.
http://www.vo.ford.com/ss/procedures/procd-files/VOPSSN018_6_22Final.pdf
• FoE Vehicle Operations Operating procedure VOP QUE-612, Uniform Test and Evaluation Program For
Welding and other joining Operations; http://wiki.ford.com/display/QOS/VOPQUE-
612+Uniform+Test+and+Evaluation+Program+for+Welding+and+other+joining+Operations
• ISO 10447, Welding – Peel and Chisel testing of Resistance Spot, Projection and Seam Welds
• ISO 14270, Specimen Dimensions and Procedure for Mechanized Peel Testing Resistance Spot, Seam and
Embossed Projection Welds
• ISO 14271, Vickers Hardness Testing Of Resistance Spot, Projection and Seam Welds (Low Load And
Microhardness)
• ISO 14273, Specimen Dimensions and Procedure for Shear Testing Resistance Spot, Seam and Embossed
Projection Welds, Edition 2000-11-01
• ISO 14341:2010 - Welding consumables - Wire Electrodes and Weld Deposits for Gas Shielded Metal
Arc Welding of Non Alloy and Fine Grain Steels - Classification
• ISO 16834:2012 - Welding consumables - Wire electrodes, Wires, Rods and Deposits for Gas Shielded Arc
Welding of High Strength Steels - Classification
• ISO 21952:2012 - Welding consumables. Wire electrodes, Wires, Rods and Deposits for Gas Shielded Arc
Welding of Creep-Resisting Steels-Classification
• ISO 24373:2009 - Welding Consumables – Solid Wires and Rods for Fusion Welding of Copper and Copper
Alloys-Classification
• AWS 5.18/5.18M:5005 –Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding
• AWS 5.28/5.28M:5005 - Specification for Low-Alloy Steel Electrodes & Rods for Gas Shielded Arc Welding
• AWS D8.8-2007 - Specification for Automotive and Light Truck Components Weld Quality - Steel Arc
Welding (SAE JSH-1196)
• AWS D1.3-98 - Structural Welding Code - Sheet Steel
• AWS D9.1M/D 9.1-2000 - Specification for Welding of Sheet Metal
• Standard for Testing Line Welds, Auto/Steel Partnership
End of Document
WSBCPA-1B310-AA
R3 9/7/2012


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What is the purpose of this document?

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What welding processes are covered in the specification?

What welding processes are covered in the specification?

Weld Specification: WSBCPA-1B310-AA

Global Gas Metal Arc Weld, Hybrid Laser-GMAW, and Brazing:

CONTROL ITEM – THE ALSO IDENTIFIES CRITICAL CHARACTERISTICS DESIGNATED BY THE

Global Manufacturing Quality Office

II. Summary of Production Validation and In-process Tests

III. Test Procedures and Requirements

IV. Revalidation Requirements

V. Instructions and Notes …………………………………………………………….……… 56

VI. Compilation of Reference Documents ………………………………………................ 61

Global Manufacturing Quality

I.1 Scope of Weld Specification, General Statement

Global Manufacturing Quality

I.2 Welded Sub-Assemblies

I.3 Process Description

Global Manufacturing Quality

The characteristic parameters of the GMA

FIGURE 1: Illustration of Gas Metal Arc Welding Operation

I.4 Design Guidelines/Rules

Global Manufacturing Quality

I.5 General Design Considerations

I.5.2 Joint Integrity

Gaps per II.3.2 Gaps per II.3.2

Global Manufacturing Quality

90° R = "A" R= "A"

T1 = Thickness 1 - thinnest (per ES)

I.6 Welded Seam Identification Symbols

Global Manufacturing Quality

Figure 10 Weld Callout from CAD Standard D-3

I.6.1 Sizing of Fillet Weld, a- and z- value:

a Two different concepts exist to specify the minimum dimensions of a fillet

Figure 11: Fillet Weld Dimension

DR Dent Resistant Steels including Bake Hardening, High WSS-M1A367-A11/A14, A21/A25

HSLA High Strength Low Alloy Steels WSS-M1A367-A33/A39, A44/A49

DP 1) Dual Phase Steels WSS-M1A368-A11/A15, A21/A25, A31/A32,

FB Ferrite Bainite WSS-M1A368-A41/A43

Global Manufacturing Quality

Stainless Steel See commodity specific materials and designs

I.7.2 Standard Base Sheet Metal Coatings

Global Manufacturing Quality

Aluminum uses special wires: See Table I-5

I.7.4 GMA-Welding Of HSS/AHSS/UHSS Sheet Metal

Global Manufacturing Quality

690 100 565

760 110 660 90 At least ER90S-G G CrMo2Si

1000 145 900

Stainless Steel 409 or 439 wire

I.7.5 Shielding Gases

Global Manufacturing Quality

Figure 12 Figure 13 Figure 14

FLARE BEVEL FLARE-V (aka. V-groove, Flare-groove)

I.8.2 Welding Terms (Reference Figures 18 and 19)

Global Manufacturing Quality

Global Manufacturing Quality

Figures 20 through 25 below: some defect types