VW01105-4_En_042001

Vertragspartner erhalten die Norm nur über die zuständige 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 AGN 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 ät 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 .Page 2VW 011 05-4: 2001-04•The perpendicular contact of the electrodes must be ensured by the design of the part.•Special electrodes are not permitted (i.e. ensure accessibility for standard electrodes).•The use of adhesives between the sheets requires further testing and coordination between the operator, planning department, quality assurance department and the design engineering department.•Zinc layers are permitted up to a maximum nominal thickness of 12 µm per side.•Individually zinc-coated sheets are not permitted.•All 3-sheet weld points must be accessible on the finished welding group for test purposes.•The component fit must be ensured (requirement for R&D and the planning department, the supply part supplier and the production department).•3-sheet point flanges in the welding group drawings and data models must be represented asa section such that the accessibility of the tongs can be assessed.•Flange widths shall be calculated according to VW 011 05 – 1.•When determining the point diameter d P (destructive testing) or the nugget diameter d L (trans-verse microsection), respectively, the smallest sheet thickness of the relevant joining plane is relevant (see Figure 1).Figure 1 - Nugget diameter in the joining planes2.2 Special Technical and Process-Specific Specifications•When planning new systems, automated welding of 3-sheets is preferred (in the case of man-ual production an increased level of testing shall be taken into consideration)•It must be possible to select an individual welding program for every spot weld.•Sufficient and even cooling of both electrodes is required (target: 4.0 l/min).•Electrode forces depending on the sheet thickness combination up to 5.0 kN (total sheet metal thickness of up to 4.5mm).•For permissible electrode penetration depths see VW 011 05-1.•Max. "movement" of the tong arms up to 1.5 mm (Caution: Note the throat depth, see design guideline 11-59D 6770 and VW 011 05-1).Page 3VW 011 05-4: 2001-04•3-sheet joints can be performed using 50Hz alternating current or with direct current (1000Hz medium frequency).•Medium frequency technology is recommendable (e.g. in the event of a very large throat opening and weight problems arising because the medium frequency transformer weight is less, or if a very fast adjustment is required).•Pulsation welding is recommended for coated sheets. Weld times (process time) >1000ms must be given general consideration during cycle time studies.•Welding using copper back-up bars is not permissible. Direct welding is required.•Cap milling with start milling required (flange and work surface milling).•The aim when determining the weld parameters: required shear diameter (d pmin) +20%. Pay due consideration to milling cycles in cycle time studies.•Process reliability when determining parameters: Welding range of min. 1.5 kA in width, see Figure 2.Weld time t[Periods]A Spot weld too smallS SpatteringD∆ > 1.5kAWelding current I [kA]Figure 2 - Welding range•For rows of weld points, the orientation of the welding tongs may not be changed (polarity!).•Increased vigilance is required with regard to leakages (e.g. equipment, fault current monitor-ing, point spacing). Flange width a shall if required be greater than that calculated according to VW 01105-1. The required extra width shall be coordinated between the design engineering department, the planning department and the operator and specified in the drawing.•Due to the influence of the coating, there shall not, wherever possible, be any change in coat-ing from point to point.•Control technology: Only weld, once the required force has been completely built up.Page 4VW 011 05-4: 2001-042.3 References in DrawingsAn overview of all 3-sheet points in the assembly shall be given.The nugget diameter must be indicated for every joining plane (d L1, d L2, see Figure 1 and Figure 3).Legend:d L1, d L2,Nugget diametern Number of pointse Point spacingv Peripheral spacingOG2Surface quality class (see VW 011 05-1)Figure 3 - Representation in drawings3 Referenced StandardsVW 011 05 – 1Resistance Spot Weld Joints,Design, Calculation and Process Monitoring;Uncoated SteelsOperating equipment design guideline 11-59D 6770。