大众汽车标准_VW 01106-1 英文

Vertragspartner erhalten die Norm nur über die zust?ndige Beschaffungsabteilung.

Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group.

Parties to a contract can only obtain this standard via the responsible procurement department.

VOLKSWAGEN AG

N o r m v o r A n w e n d u n g a u f A k t u a l i t ?t p r üf e n / C h e c k s t a n d a r d f o r c u r r e n t i s s u e p r i o r t o u s a g e .

T h e E n g l i s h t r a n s l a t i o n i s b e l i e v e d t o b e a c c u r a t e . I n c a s e o f d i s c r e p a n c i e s t h e G e r m a n v e r s i o n s h a l l g o v e r n .

Q U E L L E : N O L I S

Page 2

VW 011 06-1: 2003-05

1 Scope

This standard applies to the design, layout and quality assurance of arc-welded sheet-steel joints which are predominantly subject to dynamic loads.

It encompasses the following procedures according to DIN EN ISO 4063:

Procedure Code

Characteristic

value

131 Metal inert-gas welding MIG

135 Metal active-gas welding MAG

141 Tungsten inert-gas welding TIG

for: butt and fillet welds, lap welds, plug welds and special weld forms

of: uncoated and surface-finished sheet steels and of high-alloyed steels and stainless steels;

for examples see section 3.1;

workpiece thickness 0.5 mm to 6 mm

with: test characteristics of acceptance level B (high requirement) according to DIN EN 25 817, see also DVS Specification 0705.

All fusion-welded joints that do not fall within this scope require the clarification of the responsible engineering departments. Special measures made necessary by the component, e.g. change to the acceptance level for specific irregularities, are thus permissible and must be entered in the drawing.

2 Abbreviations and definitions

2.1 Abbreviations

a Calculated throat thickness

e Penetration

f i Side wall penetration on component t i

f L Penetration length

f St Penetration at the face surface

F i Joining plane i

size

h Gap

l Weld seam length

L Length

thickness

s Throat

s i Throat thicknesses with respect to sheet i

s N Smallest common throat thickness

t i Sheet thickness of sheet i

Σt Sum total of sheet thicknesses

? Diameter

Page 3

VW 011 06-1: 2003-05

2.2 Definitions

The following definitions are valid for the application of this standard.

2.2.1 Welded

joint

Joint created by fusion welding. It comprises the weld, fusion line, zone influenced by heat and unaffected base material (Figure 1).

1

2

3 4

1 = Weld

2 = Zone influenced by heat

3 = Fusion line, fusion zone

4 = Unaffected base material Figure 1 - Fusion-welded joint

NOTE The weld and fusion line may be identical.

2.2.1.1 Welded

seam

The area of the welded joint where the workpiece(s) are joined at the weld joint. The welded seam comprises the base material and/or the filler metal.

2.2.1.2 Fusion

line

Borderline between the material melted during welding and the material that remained solid.

2.2.1.3 Weld metal

Material that solidified after welding, comprising either the base material or filler metal and base material. Elements in the weld metal can come from casings and/or accessory materials (DIN ISO 857-1).

2.2.1.4 Zone influenced by heat

Area of the base material that remained solid, but experienced thermal microstructural changes due to the energy applied during welding.

Page 4

VW 011 06-1: 2003-05

2.2.1.5 Unaffected base material

Area of the base material that experienced no evident microstructural changes as a result of the energy applied during welding.

2.2.2 Same types of material

Materials which do not differ significantly in terms of their chemical composition and their suitability for welding (DIN 8528-1).

2.2.3 Different types of material

Materials which differ significantly in terms of their chemical composition and their suitability for welding.

3 Gas-shielded arc welding procedure

Gas-shielded arc welding is a form of fusion welding. An electrical arc is used as the heat source. It burns between the electrode and the workpiece. In this process, the arc and the weld pool are protected from the atmosphere by a shield of protective gas. The type of electrode determines the classification according to the following procedures:

3.1 Tungsten inert-gas welding (TIG)

In this procedure, an arc is ignited between a non-consumable tungsten electrode and the workpiece. Argon or helium is used as the protective atmosphere. The additional material is (as in the case of gas welding) supplied from the side.

3.2 Gas-shielded metal-arc welding (MIG/MAG)

In this procedure, an arc is ignited between the consumable end of the wire electrode (additional material) and the workpiece. The welding current flows via sliding contacts in the gun holder to the wire electrode.

When inert gases (non-reactive gas, e.g. noble gases such as argon, helium or mixtures of both) are used as protective atmospheres, this is called metal inert-gas welding (MIG).

When active gases (e.g. CO2 or mixed gases that contain CO2 and some oxygen) are used, this is called metal active-gas welding (MAG). This procedure is used to weld unalloyed and low-alloy steels.

Page 5

VW 011 06-1: 2003-05

4 General requirements

Welds that are subject to mandatory documentation shall be evaluated according to the relevant type and/or component-specific test standards.

Deviations with respect to the weld geometries and weld executions shall be detailed in the drawing, assured in tests and described in test standards.

Further requirements with respect to gas-shielded arc welding are contained in the following. VW 011 06-2 Rework on Sheet Steel Joints VW 011 06-3 Al Welded Joints

VW 011 42

Rework on Al Welded Joints

When creating arc-welded sheet steel joints, the greatest possible design strength in terms of the design goal must be realized while also ensuring sufficient reliability and a favorable cost/quality ratio. To this end, every welded joint must be “suitable for welding”, i.e. the dimensions of the welding equipment and the accessibility of the weld according to DVS 0929 must be taken into consideration in the development design.

"Weldability for service" of a sheet steel joint is deemed to exist if the component, on the basis of its design (section 4.2) and with the material used (section 4.1), remains functional (Figure 2) under the intended operating stresses (section 4.3).

Figure 2 - Representation of weldability according to DIN 8528-1

4.1 Materials

The following list is not complete . Its purpose is to provide an overview of the weldable materials currently used in the automotive industry. The following have good welding properties:

a) Cold-rolled flat products made from soft steels for cold working:

DIN EN 10130

Material No. DIN 1623-1 (02.83)1) DC01 1.0330 St 12 DC03 1.0347 RSt 13 DC04 1.0338 St 14 1)

DIN 1623-1 was replaced in October 1991 by DIN EN 10130.

Material Welding suitability

Welding capability Manufacturing

Weldability for service

Design

Component weldability

Page 6

VW 011 06-1: 2003-05

b) Cold-rolled strips St 2 to St 4 with the surface finish BK, RP, RPG according to DIN EN 10139.

c) Hot-rolled strips with ≤ 0.20% C content, e.g. according to TL 1111.

The following are also weldable:

d) Hot-rolled products of unalloyed structural steels

DIN EN 10025Material No. DIN 17100 (01.80) 2)

-- 1.0037 St 37-2

S 235 JR 1.0114 St 37-2 R St37-2

S 235 JO 1.0116 St 37-3

S 355 J2G3 1.0570 St 52-3

weldable to a limited

extent:

E295 1.0050 St 50-2

2) DIN 17100 was replaced in March 1994 by DIN EN 10025.

e) Cold-rolled strip and sheet with higher yield point for cold working made from micro-alloyed

steels (SEW 093 of March 1987)

f) Isotropic micro-alloyed cold-rolled strip (according to VW 500 17) is a further development of

the traditional micro-alloyed cold-rolled strip ZStE260 to ZStE420 (formerly SEW 093).

NOTE VW 500 17 defines the material requirements of isotropic micro-alloyed steels, placing particular emphasis on the mechanical properties.

g) Cold-rolled flat products with high yield point for cold working made from micro-alloyed steels:

DIN EN 10268Material No.

H240LA 1.0480

H280LA 1.0489

H320LA 1.0548

H360LA 1.0550

H400LA 1.0556

DIN EN 10292Material No.

H260LAD+Z, +ZF 1.0929

H300LAD+Z, +ZF 1.0932

H340LAD+Z, +ZF 1.0933

H380LAD+Z, +ZF 1.0934

H420LAD+Z, +ZF 1.0935

h) Hot-rolled flat products made from steels with a high yield point for cold working:

DIN EN 10149-2 Material No.

S315MC 1.0972

S355MC 1.0976

S420MC 1.0980

S460MC 1.0982

S500MC 1.0984

S550MC 1.0986

S600MC 1.8969

S650MC 1.8976

S700MC 1.8974

Page 7

VW 011 06-1: 2003-05 i) Cold-rolled strip and sheet with higher yield point for cold working made from phosphorus-alloy

steels

SEW 094 Material No.

ZstE220P 1.0397

ZstE260P 1.0417

ZstE300P 1.0448

DIN EN 10 292 Material No.

H220PD+Z, +ZF 1.0358

H260PD+Z, +ZF 1.0431

H300PD+Z, +ZF 1.0443

j) Strip and sheet from stainless steels (DIN EN 10088-2):

e.g. austenitic steels X5CrNi18-10 1.4301 ,

or ferritic steels X2CrTi12 1.4512

Page 8

VW 011 06-1: 2003-05

4.2 Design

The following specifications and the notes on design from the DVS 0929 Specification are used as the basis for the production-friendly design of arc-welded sheet-steel joints.

types

4.2.1 Joint

The weld joint is the area in which the parts are joined by welding. The respective type of joint is determined by the arrangement of the parts with respect to each other (extension, reinforcement, branching) (table 1).

Table 1 – Joint types (DIN EN 12345)

Page 9

VW 011 06-1: 2003-05 types

4.2.2 Seam

The seam type is determined by the

─type of weld joint

─type and scope of preparation, e.g. gap optimization (see DIN EN 25817)

─material

─welding method.

4.2.2.1 Fillet

weld

The parts lie in two planes with respect to one another, form a fillet joint and are joined by welding. It is possible to differentiate between a

─fillet weld (Figure 3 and Figure 5) – a double fillet weld (Figure 4)

─

Figure 8 - Fillet weld on lap joint

Page 10

VW 011 06-1: 2003-05

4.2.2.4 Front seam See Figure 9.

Figure 9 - Front seam

4.2.2.5 Plug weld See Figure 10.

Figure 10 - Plug weld

4.3 Calculated joint dimensions 4.3.1

Throat thickness a and s

The calculated throat thickness a is required to be able to calculate the forces acting on a welded joint.

For example, the following applies to the design of a fillet weld:

a ≤ 0.7 t min.

The throat thickness s is the height of the largest possible isosceles triangle that can fit in the weld cross-section.

In production, the actually measured throat thickness s must always be greater than or the same as the calculated throat thickness a.

s ≥ a

If the throat thickness s (Figure 11) cannot be determined in a straightforward manner, the smallest common throat thickness s N (Figure 12) can be used as the alternative criterion.

Figure 11 - Fillet weld

Figure 12 - Fillet weld with deep penetration

s N

Page 11

VW 011 06-1: 2003-05

4.3.2

Weld seam length

The calculated weld seam length l is the seam length defined by the designer for the weldment. Both the starting and end areas (end crater) are used to determine the seam length.

In order to determine the dynamic load capacity, the seam length can exceed the component length (Figure 13).

Figure 13 - Extension of the seam length

Proof of sufficient strength is provided by the component-specific strength tests. 5

Requirements and quality assurance of welds

In general, the welding quality requirements according to DIN EN 729-1 shall be taken into consideration together with the comprehensive quality requirements set out in DIN EN 729-2.

The execution of a weld shall be described clearly by indicating the weld seam length, thickness and quality.

These requirements are part of the drawing specifications (see section 6).

Unless other specifications are noted in the drawing, the requirements of sections 5.1 to 5.5 shall apply.

5.1 Weld quality

If there is no component-specific test standard, DIN EN 25817, acceptance level B, high, shall also apply to sheets < 3.0 mm. For sheets < 3.0 mm, the limit values for irregularities must be adjusted appropriately.

5.2 Penetration depths

The welded joint is sufficient once a continuous matter-closed joint with a measurable penetration depth of f ≥ 0.2 mm is created between the sheets involved.

For certain weld forms – e.g. fillet weld on lap joint or flanged joint – the penetrations f cannot always be determined if 100% of the face surfaces is included in the weld.

Permissible penetration depths f < 0.2 mm must be indicated in the drawing or specified in a component-specific test standard. The seam quality and/or strength must be verified by means of a dynamic strength test and a microscopic examination.

NOTE Due to the smaller “welding window” the test intervals (e.g. using microsections) shall be conducted at shorter time intervals or on smaller batch sizes. The processes shall be coordinated with all the departments involved (Design, Quality Assurance, operators).

l 1 = Calculated weld length e.g. component length

l 2 = Weld seam length

Page 12

VW 011 06-1: 2003-05

5.3 Weld forms 5.3.1

Square butt seam on butt joint

see Figure 14

Figure 14 - Square butt seam on butt joint

s = Throat thickness

s ≥ t min.

f St = Penetration at the face surface f St ≥ 100% (unless otherwise specified)

Execution as flanged seam:

Figure 15 - Flanged seam

s N = Smallest common throat thickness s N ≥ t min. (see Figure 15).

NOTE The face surfaces f St shall be 100% melted.

S N

Page 13

VW 011 06-1: 2003-05

5.3.2 Front seam See figure 1

6.

a)

b)

c )

Figure 16 – Front seam

s N = Smallest common throat thickness s N ≥ t min. f L2 = Penetration length f L2. ≥ t 1 f 1,2 = Penetration f 1,2 ≥ 0.2 mm

5.3.3

Fillet seam on lap joint

Figure 17 - Fillet seam on lap joint

s N = Smallest, common throat thickness s N ≥ s 1,2 and s N ≥ 0.7 t min.

a = Calculated throat thickness

a ≤ 0.7 t min. (design recommendation) f 2

= Side wall penetration on the component t 2:

f 2 ≥ 0.2mm

s 1,2

= Throat thickness s 1,2 ≥ 0.7 t min NOTE If the throat thicknesses s 1,2 cannot be determined in a straightforward manner, the smallest common throat thickness s N may be chosen as an alternative criterion.

s N

h

s 2

Page 14

VW 011 06-1: 2003-05

5.3.4 Fillet weld with deep penetration

see Figure 18

s N

s1,2= Throat thickness (with deep penetration) s1,2 ≥ 0.7 t min.

s N= Smallest common throat thickness s N≥ s1,2 and s N≥ 0.7 t min.

a = Calculated throat thickness a ≤ 0.7 t min.

f1,2= Side wall penetration on the component t1,2 . f1,2≥ 0.2 mm

Figure 18 - Fillet weld with deep penetration

NOTE If the throat thicknesses s1,2 cannot be determined on the microsection in a straightforward manner, the smallest common throat thickness s N may be chosen as an alternative criterion.

5.3.5 Fillet weld on bevel joint

see Figure 19

s N

Figure 19 - Fillet weld on bevel joint

s N = Throat thickness s N≥ t min.

f2 =Penetration f2≥ 0.2 mm

NOTE The face surface of the upper sheet should be 100% melted.

Page 15

VW 011 06-1: 2003-05

see Figure 20

Figure 20 - Triple joint

f1,2,3 = Penetration f1,2,3 > 0.2 mm

f St1,2 = Face surface penetration of t1,2 f St1,2 ≥ Insertion depth l

f St3 = Face surface penetration of t3f St3 = 100%

5.3.7 Plug

weld

For plug weld see Figure 21. The values in table 2 serve as reference values for the ratio of the sheet thickness to the hole diameter.

Table 2 – Hole diameter and sheet thickness

Sheet thickness used

t

(mm) Hole diameter

? or L

(mm)

Optionally, long holes for

narrow flanges

W x L (mm)

to 1.0 ≥ 6 - > 1.00 to 1.25 ≥ 7 -

> 1.25 to 1.50 ≥ 8 6 x 10

> 1.50 to 2.00 ≥ 9 6 x 12

> 2.0 to 3.00 ≥ 10 8 x 12

> 3.00 to 3.50 ≥ 14 -

NOTE Where there are gaps between the sheets, the length of the penetration f L must correspond to the length L or diameter of the hole.

Page 16

VW 011 06-1: 2003-05

f2

f St1 = Face surface penetration of t1,2 f St1 = 100%

f L = Penetration length, width and/or diameter f L≥? or L or W

f2 = Penetration depth f2 ≥ 0.2 mm

Figure 21 - Plug weld

Page 17

VW 011 06-1: 2003-05

5.4 Special weld forms

Adequate evaluation criteria shall be used to evaluate any special weld forms that are not listed here.

5.4.1 Fillet weld on multiple lap joint

s N 1

s N 2

f

Figure 22 - 3-sheet lap joint

In the case of multiple-sheet joints, the smallest common throat thickness s N of the relevant joining plane shall be used to determine the throat thickness.

Here the following applies:

In the relevant joining plane the throat thickness must be

s N ≥ 0.7 Σ t above or s N ≥ 0.7 Σ t below the joining plane.

f3 = Penetration depth f3≥ 0.2 mm

f St1,2 = Face surface penetration of t1,2 f St1,2 = 100%

The following applies to Figure 22:

Throat thickness: s N1 ≥ 0.7 t(1) with: t1 < (t2 + t3 )

s N2 ≥ 0.7 t (3) with: t3< (t1+ t2)

Page 18

VW 011 06-1: 2003-05

5.4.2 Multiple front seam

Fi = Joining plane i

*1) If it is clear that one sheet arrangement in a multiple-sheet arrangement is to be considered as a single sheet, then this sheet shall not be included in the overall evaluation when determining the throat thickness s N .

Figure 23 - Four-fold front seam

In the case of multiple-sheet joints, the smallest common throat thickness s N of the relevant joining planes is used to determine the throat thickness s, as is the case for a multiple lap joint. Here the following applies:

In the relevant joining plane (in Figure 23 - Four-fold front seam – four-fold front seam with the joining planes F1, F2 and F3) the throat thickness must be

s N ≥ Σ of the sheet thicknesses on the right or Σ of the sheet thicknesses on the left of the joining plane.

The following applies to Figure 23, for example: s N1 ≥ t (1) t 1

< (t 2 + t 3 + t 4 ) s N2 ≥ Σ t (3+4) t 3 + t 4 < (t 1 + t 2 ) s N3 ≥ Σ t (4)

t 4

< (t 1 + t 2 + t 3 )

f St = Face surfaces

f St 1,2,3,4 = 100%

N1

t 1 t 2 t 3 t 4

s N2

*1)

s N3

Page 19

VW 011 06-1: 2003-05

Figure 24 - Fillet weld

Figure 25 - Fillet weld with deep penetration

For Figure 24 determine the throat thickness s approximately: On workpieces with different

geometrical shapes, the shortest distance of the median line between the two workpieces shall be selected as the dimension s.

s = Throat thickness s ≥ 0.7 t min For fillet welds on components with a round

cross section it is recommended that the smallest common throat thickness s N be determined as shown in Figure 25.

s N = Smallest common throat thickness s N ≥ a.

NOTE In the event of irregularities, e.g. undercuts, DIN EN 25 718 shall apply. 5.4.4

Square butt seam on flanged joint

Figure 26 - Square butt seam on flanged joint

s N = Smallest common throat thickness s N ≥ t min..

f 1,2 =

Penetration depth f 1,2 ≥ 0.2 mm s N

t f 2

Page 20

VW 011 06-1: 2003-05

5.5

Evaluation of irregularities

5.5.1 Weld spatter

Weld spatter must be avoided in as far as possible.

Any globules or welding residues that remain stuck to the parts and which could lead to an impairment of function are not permitted.

Spatter-free areas shall be defined in the drawing or in a test standard. 5.5.2 General irregularities

Irregularities such as cracks, pores, lack of fusion and gap sizes shall be evaluated, unless otherwise indicated in the drawing, according to DIN EN 25817, evaluation group B “high”. 6 Drawing entries

The graphical representation (for example see Figure 27), dimensioning and symbols for the welding procedures named in section 1 shall be executed according to DIN EN 22553.

Legend:

s8 = Actual throat thickness

(with deep penetration) 8 mm

a6 = Design throat thickness (without deep penetration) 6 mm n = Number of welds

l = Minimum weld length; tolerance +5 mm, unless otherwise indicated e = Distance between the welds v = Initial dimension

Explanation:

Weld produced by means of metal inert-gas welding (code number 131 according to DIN EN ISO 4063); evaluation according to VW 011 06-1; horizontal position h according to DIN EN ISO 6947.

Figure 27 - Example of application for interrupted fillet weld with initial dimension;

symbolic representation

7 Referenced standards

The last publication date of withdrawn standards is provided in parentheses.

DIN 1623-1 (02.83) Flat Steel Products; Cold-Rolled Strip and Sheet; Technical Supply

Specifications; Soft, Unalloyed Steels for Cold Working DIN 8528-1

Weldability; Metallic Materials, Definitions

s8a6

n x l (e)

131/ VW01106-1/h v