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大众汽车标准_VW_01106-3_英文_气体保护焊-铝焊接接头.pdf

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大众汽车 标准 _VW_01106 英文 气体 保护 焊接 接头
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Klass.-Nr. 04 81 7 April 2002 Gas-Shielded Arc Welding Part 3: Al Welded Joints VW 011 06-3 Konzernnorm Replaces PV 6465 Descriptors: welding, gas-shielded arc welding, MIG, metal inert-gas welding, aluminum, weld Page 1 of 14 Fachverantwortung/Responsibility Normung/StandardsN/GQ-554 Hr. Nicola I/ET-31 Tel: +49-841 89 33904 Gradl Vertraulich. Alle Rechte vorbehalten. Weitergabe oder Vervielf?ltigung ohne vorherige schriftliche Zustimmung einer Normenabteilung der Volkswagen AG nicht gestattet. 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 Standard Department of the Volkswagen Group,. Parties to a contract can only obtain this standard via the responsible procurement department. ? VOLKSWAGEN AG Form FE 41 - 1 Norm vor Anwendung auf Aktualit?t prüfen / Check standard for current issue prior to usage. Contents Page 1 General ................................................................................................................................1 1.1 Scope...................................................................................................................................1 1.2 Validity of requirements........................................................................................................2 2 Requirements and evaluation ..............................................................................................2 3 Test ......................................................................................................................................2 3.1 Characteristics for the external findings...............................................................................2 3.2 Characteristics for the internal findings................................................................................2 3.3 Sampling ..............................................................................................................................3 4 Evaluation criteria ................................................................................................................3 4.1 External findings (visual inspection).....................................................................................4 4.2 Lap joints with fillet weld ......................................................................................................5 4.3 T-joint with fillet weld............................................................................................................8 4.4 Butt joint with square butt weld ..........................................................................................12 4.5 Evaluation of porosity.........................................................................................................14 5 Referenced standards........................................................................................................14 Changes The following changes have been made as compared to VW 011 06-3: 2000-08: ─ Section 4.2, table 3, no. 3: h ≥ 0.25 mm changed to h ≥ 0.25 t ─ Section 4.3, table 5, no. 3: h 1/2≥ 0.25 mm changed to h 1/2≥ 0.25 t Previous issues VW 011 06-3: 2000-08 1 General 1.1 Scope This standard defines evaluation criteria for irregularities in MIG fusion welded joints for various types of joint (lap joint, T-joint, butt joint). It is valid for joints with material thicknesses from 0.8 mm to 5 mm. These evaluations relate to the production quality and not to the performance capability. The per- formance capability must be verified by suitable crash tests, vehicle endurance tests and function tests. The tests must be performed by qualified personnel using technically appropriate test methods that comply with the current state of the art. QUELLE: NOLISpage 2 VW 011 06-3: 2002-04 1.2 Validity of requirements The requirements shall apply to all welds if the number of this VW standard is indicated in a draw- ing or a technical supply specification or if its application is agreed as part of other specifications. If the drawings or other specifications (e.g. those of the responsible engineering departments or rework catalogs) contain individual deviating stipulations, then these shall have priority. Likewise, a component-specific test specification has priority over this VW standard if this is defined in the drawing. The joint types described in this standard are ideal representations. Welded seams that are not shown are to be treated analogously. The standard is divided into evaluations of type A and type B. If the index is not given in the draw- ing, type A shall be used for the evaluation. Type B stipulates slightly lower requirements for some evaluation criteria. The responsibility for allocating joints to type B rests with the engineering department. 2 Requirements and evaluation ─ OK evaluation: The test according to VW 011 06-3 is evaluated as OK if the welded seams comply with the listed evaluation criteria. ─ Conditionally OK evaluation: The test according to VW 011 06-3 is evaluated as being conditionally OK if max. 2 “soft” evaluation criteria according to Table 2:, Table 4:, Table 6: or Table 8: are not OK. The “hard” evaluation criteria according to table 1, Table 3:, Table 5: and Table 7: as well as the porosity evaluation according to Table 9: must be OK under all circumstances. Steps must be taken to ensure that the items that were not OK are rectified. ─ Not OK evaluation: The test according to VW 011 06-3 is deemed not to be OK in all other cases. 3 Test 3.1 Characteristics for the external findings According to Table 1: and Table 2: by visual test. The dimensions, position, number and presence of seams are evaluated according to the drawing and the evaluation criteria set out in Table 1: and Table 2: in a visual test. The test is performed with the naked eye. In case of doubt, other suitable test procedures and/or equipment must be used (e.g., magnifying glass, stereo microscope, dye-penetration procedure). 3.2 Characteristics for the internal findings According to Table 3: to Table 9: by evaluating microsections.page 3 VW 011 06-3: 2002-04 3.3 Sampling ─ Unless otherwise agreed between the engineering departments, metallographic microsections shall be taken from each welded seam at the specified points, cross-wise to the direction of the seam (e.g. defined in TLD sheets, PVs or ground section plans). ─ The microsections are sawn, ground and polished. ─ Additional microsections can be taken in the direction of the seam if required. ─ Recommended specimen removal: Seam length 10 mm 4 Evaluation criteria The evaluation takes the form of a visual inspection of the seam (section 4.1), a test of the seam and penetration geometry (sections 4.2 to 4.4) and a test of the porosity (section 4.5). A reflected light microscope must be used for evaluation as per sections 4.2 to 4.5. The use of a stereo micro- scope can also be agreed; however, impairments in the quantitative pore analysis must be taken into consideration. Definitions: t Material thickness of the thinner material t b Material thickness of the bottom material (lap joints) t t Material thickness of the top material (lap joints) t 1 Material thickness of the base material (T-joint) t 2 Material thickness of the material that is welded on (T-joint) h Height/depth of the criterion described b Width of the criterion described d Diameter of the criterion described r Radius a Throat thicknesspage 4 VW 011 06-3: 2002-04 4.1 External findings (visual inspection) The stipulations of Table 1: and Table 2: have equal weight and apply accordingly to lap joints with fillet welds, butt joints with square butt welds and T-joints with fillet welds. If series monitoring produces the result “not OK”, the agreed rework options (see e.g. VW 011 42) can be applied. Table 1: Characteristics for irregularities, external findings (visual inspection), “hard” criteria Limit values, comments No. Designation Drawing VW 011 06-3-A VW 011 06-3-B 1 Burned-through spots Not permissible Isolated permissible if d t (The geometric rela- tionships result from no. 1) b > 0.7 t 3 Penetration depth h ≥ 0.25 t A slight fall below set values in the area < 15 mm from the start of the seam is permitted. The face surface of the top material must be 100% fused. 4 Gap be- tween the joined parts h ≤ 0.5t max. 1.5 mm a z z a min t a min h h h a bpage 6 VW 011 06-3: 2002-04 Limit values, comments No. Designation Drawing VW 011 06-3-A VW 011 06-3-B 5 Undercut h ≤ 0.1 t b,t 6 Root-side suckback in the event of root pene- tration h ≤ 0.1 t b h ≤ 0.2 t b 7 Lack of root fusion Not permissible 8 Root notch Not permissible if it causes the seam or penetration geometry to be incorrect and/or if the notch is sharp-edged. Permissible if the shape is round (e.g. air inclusion) with h ≤ 0.1 mm and if the “a” dimension is fulfilled 9 Cracks Internal and external cracks in the weld metal and in the zone influ- enced by the heat (evaluated on the microsection) Not permissible t b h h hpage 7 VW 011 06-3: 2002-04 Table 4: Characteristics for irregularities, internal findings (to be assessed in the micro- section), “soft” criteria Limit values, comments No. Designation Drawing VW 011 06-3-A VW 011 06-3-B 1 Excess weld metal Permissible For visually relevant welded seams, the excess weld metal h shall be stipulated on the drawing by the responsible design department. The throat thickness a (see Table 3: no. 1) must be achieved in any event. 2W e l d concavity Permissible if the throat thickness a is achieved. For visually relevant welded seams, the weld concavity h can be limited on the drawing by the responsible design de- partment. 3 Weld edge angle (applies to the top and bottom mate- rials). α ≤ 60° The transition be- tween the weld metal/base material on the seam edges must be smooth. α ≤ 90° The transition be- tween the weld metal/base material on the seam edges must be smooth. 4 Drop- through at the root in the event of root pene- tration h ≤ 1.5 t b max. 2.0 mm Permissible as long as the function of the component is not affected. 5 Overlap on the root side b ≤ 1.0 t b max. 2.5 mm The throat thickness a (see Table 1: no. 1) must be achieved in any event. b ≤ 1.5 t b max. 2.5 mm The throat thickness a (see Table 1: no. 1) must be achieved in any event. α t b h h h b t bpage 8 VW 011 06-3: 2002-04 4.3 T-joint with fillet weld Note: The throat thickness (dimension “a”) of fillet welds is determined by entering the largest possible equilateral triangle into the sectional view. In this process, the leg length z is calculated using the formula z = a x √2. The minimum throat thickness a minmust be at least 0.7 x t (thickness of the thinner material) and/or the condition z ≥ t must be fulfilled. In practice, the throat thickness can be exceeded. As this standard describes the minimum requirements, a minis always entered in the drawings. Examples: a t 1 t 2 a z zpage 9 VW 011 06-3: 2002-04 Table 5: Characteristics for irregularities, internal findings (to be assessed in the micro- section), “hard” criteria The designations for t 1and t 2shall apply for all images in Table 5: Limit values, comments No. Designation Drawing VW 011 06-3-A VW 011 06-3-B 1 Throat thick- ness a ≥ 0.7 t a ≥ 0.5 t 2 Penetration width b 1/2 ≥ t 3 Penetration depth h 1/2≥ 0.25 t 4 Gap between the joined parts h ≤ 0.5 t max. 1.5 mm 5 Undercut h 1/2≤ 0.1 t 1/2 a t 1 t 2 h h h b 2 b 1 h h1 h2page 10 VW 011 06-3: 2002-04 Limit values, comments No. Designation Drawing VW 011 06-3-A VW 011 06-3-B 6 Root concav- ity on the rear side in the event of root penetration b ≤ 0.3 t 2 The throat thickness a (see Table 5: no. 1) must be achieved in any event. b ≤ 0.4 t 2 The throat thickness a (see Table 5: no. 1) must be achieved in any event. 7 Lack of root fusion Not permissible 8 Root notch Not permissible if it causes the seam or penetration geometry to be incorrect, impairs the function of the component and/or if the notch is sharp-edged Permissible if the shape is round (e.g. air inclusion) and the requirements of Table 5: are fulfilled. 9 Cracks Internal and external cracks in the weld metal and in the zone influenced by the heat (evaluated on the microsec- tion) Not permissible b
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