螺母与螺栓凸焊(翻译)

I. GENERAL 概述………………………………………………………………..………..

I.1 Scope of Engineering Specification, General Statement ………….……….….

总体说明，本规适用围

I.2 Process Description ……………………………………………….………..…….

焊接过程描述

I.3 Design Guidelines 设计准则……………………………………………………………..….

I.3.1Fastener Size Relative to Base Sheet Metal Thickness 紧固件对板材厚度的相对尺寸

I.3.2Hole Size in Base Sheet Metal 板材上孔的尺寸

I.3.3Fastener Strength 紧固件强度

I.3.4Flatness of Base Sheet Metal 板材的平面度

I.3.5Location of Fastener 紧固件的位置

I.4 Applicable Materials 适用材料………………………………………………………

I.5 Joint Identification Symbols 焊接接头识……………………………………………………II. SUMMARY OF PRODUCTION VALIDATION AND IN-PROCESS TESTS ……..

生产验证及过程测试总述

III. TEST PROCEDURES AND REQUIREMENTS ………………………………

试验过程及要求

III.1Applicability of Test Procedures for PV- and IP-Test Phases ………………….

PV试验阶段及IP试验阶段的适用性

III.2 Weld Parameter Monitoring 焊接参数监控……………………..…...…………………

III.2.1 Introduction 简介

III.2.1 Welding Current over Time [A] 焊接电流

III.2.2 Electrode Force [N] 电极力

III.3 Dimensional and Vis ual Inspection of the Welded Fastener ……………………

被焊紧固件的尺寸校核及目视检查

III.3.1 Introduction 简介

III.3.2 Gap between Fastener and Base Sheet Metal 紧固件与板材的间隙

III.3.3 Burn Through into Base Sheet Metal 板材的烧穿

III.3.4 Deformation of Fastener Body 紧固件的变形

III.3.5 Cracks 破裂

III.3.6 Flash on Threads 螺纹上的毛刺

III.3.7 Metal spatter 金属飞溅

III.3.8 Position of Nut on Component 螺母在部件中的位置

III.3.9 Perpendicularity of Bolt 螺栓的垂直度

III.4 Inspection of Section Cuts 剖面切割检查……………………………………………

III.4.1 Introduction 简介

III.4.2 Gap between Fastener and Base Sheet Metal 紧固件与板材之间的间隙

III.4.3 Penetration into Base Sheet Metal 板材的焊透率

III.4.4 Porosity 气孔

III.4.5 Cracks 破裂

III.4.6 Inclusions 夹杂

III.4.7 Hardness 硬度

III.5 Destructive, Non-Destructive, and Functional Testing ………………………….

有损检测，无损检测及功能检测

III.5.1 Introduction 简介

III.5.2 Static Tensile Test 静态拉伸试验

III.5.3 Torque Test 扭矩试验

III.5.3.1 Torque Test (Destructive) 扭矩试验（有损）

III.5.3.2 Torque Test (Non-Destructive) 扭矩试验（无损）III.5.4 Push Out / Pull Out Test (Destructive)推出/剥落试验（有损）

III.5.5 Hammer/Chisel Test 榔头/凿子试验

III.5.6 Thread Test 螺纹测试

III.5.7 Leakage Test 密封性试验

III.5.8 Durability / Fatigue Test 寿命/疲劳测试

III.6 Permissible Repair Methods ……………………………………………...…...…

允许的返修方法

IV. REVALIDATION REQ UIREMENTS ……………………………………

再验证要求

V. INSTRUCTIONS AND NOTES …………………………………………说明及注意事项

VI. COMPILATION OF RE FERENCE DOCUMENTS ……………………

参考文件

I. GENERAL 综述

I.1 Scope of Engineering Specification, General Statement 总体说明，本规适用围

This Engineering Specification is issued to define design factors and performance requirements applicable to the joining of nuts and bolts using the projection welding process. It covers manual and automated projection welding on sheet steel having a minimum of 0.5 mm and a maximum of 3.0 mm thickness. It covers metric dimensions up to M16 and property class 4.8 and 8.8 fasteners, but not fasteners of the property class 10.9.

本规用于规定螺母及螺栓凸焊的设计要素和焊接过程要求，它涉及厚度从0.5~3.0mm的钢板的手工凸焊和自动凸焊。本规囊括了公制M16以下的紧固件，其性能等级为4.8和8.8，而不包括性能等级为10.9的紧固件。

This Engineering Specification harmonizes the requirements globally for Ford Motor Company and is applicable to new model programs. 本工程规对全球的福特公司均有效并适用于新车型项目。

This Engineering Specification does not replace the requirements of the Ford world-wide fasteners standards, which focus on the performance of the fastener itself. Instead, it defines the requirements for the projection- welded joint between the fastener and the base sheet metal. Applications that require special fasteners are not dealt with here and require a case-by-case approval by the appropriate Fastener, Body and Manufacturing Engineers.

本工程规不替代全球通用的福特紧固件标准（该标准主要讨论紧固件本身的性能），而是规定紧固件和板材之间的凸焊接头的各种要求。采用特殊紧固件的情况不在本规讨论之，如有采用需经紧固件工程师，车身工程师和制造工程师逐项批准。

This Engineering Specification is a supplement to the released part drawing, and all requirements herein must be met in addition to all other requirements of the part drawing. Each section specifies the minimum measures necessary for documenting compliance with this specification.

本工程规是所发放零件图纸的补充，除了要满足图纸的要求，也必须满足本规的要求。每部分规定了遵从本规的最基本的措施。

This Engineering 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.

本工程规作为常规的材料检查，尺寸检查和过程控制的说明补充，而决不能反过来影响其它的检查操作。

Preparation and submission of an acceptable control plan are the responsibility of the manufacturing source. The manufacturing source will retain the original control plan and any later revisions per QS-9000 and provide a copy to the design responsible Product Engineering activity.

制造资源有义务准备与提交一份可接受的控制计划，制造资源保留原有的控制计划和任何之后经过QS-9000标准的修订版本，并且复制一份给负责设计的工程小组。

I.2 Process Description 过程描述

Projection welding is a resistance welding process that produces a weld by the heat obtained from the resistance to the flow of the welding current. The resulting welds are localized at predetermined points by local or annularprojections. Figure 1 shows the sequence of the projection welding process.

凸焊是一种利用电流流过电阻产生热量进行焊接的焊接方法。发生焊接的位置位于预制的环形凸点上。图1所示即为凸焊的焊接过程。

Figure 1: Example of Projection Weld Sequence 图1.凸焊过程示例

Figure 2 shows the representative weld fasteners covered in this document. Fasteners not shown here are not covered by this engineering specification and need to be treated on a case-by-case basis.

图2所示为本规包含的代表性焊接紧固件。没有在图表中列出来的紧固件不在本规所涵盖的围，这些紧固件要采取“逐项原则”（case-by-case原则）对待。

Figure 2: Projection Fasteners Covered by this Specification 图2.本规涵盖的凸焊紧固件

(a) Weld bolt with three circular projection s (b) Weld bolt with “banana” projections (c) Weld bolt with four circular projections(NOT recommended for new FORD designs) (d) Weld bolt with continuous ring projections (e) Square weld nut with four projections (NOT recommended for new FORD designs) f) Piloted weld nut with three circular projections (NOT recommended for new designs) g) Flanged hexagon weld nut with three “banana” (h) Flanged round weld nut with three "banana" (i) Flanged hexagon weld nut with three circular (j) Flanged round weld nut with three circular (k) Flanged hexagon weld nut with continuous ring (l) Flanged round weld nut with continuous ring

I.3 Design Guidelines 设计准则

The following design guidelines describe the generic conditions for the proper projection welding application of nuts and bolts. It is the Design Engineer's responsibility to determine the design requirements for the weld fastener necessary to achieve the design objective.

以下设计准则描述了螺母和螺栓凸焊的一般情况。设计工程师负责决定焊接紧固件的设计要求及其所要达到的目标。

Many factors influence the choice of fastener type, such as loading conditions, sheet thickness and grade, manufacturing preferences, quality assurance, etc. In general, weld nuts are preferred over weld bolts. One should thoroughly consider the functionality of the fastener, whether it is intended to carry high static and/or fatigue loads, or only serve as an attachment point for earth wirings (grounds). It is important to establish which part of the fastener joint system is the limiting factor (thread strength or the fastener's attachment to the sheet part) in order to avoid expensive over-dimensioning.

紧固件类型的选择受多种因素的影响，比如加载状况，板料厚度及等级，制造偏好，质量保证等等。总的说来，焊接螺母优于焊接螺栓。我们必须彻底考虑紧固件的功能：它是否需要承受高的静态载荷和/或疲劳载荷，或者仅仅作为地线的一个附属点。为了避免采用过大尺寸的紧固件而造成更高的成本，确定焊接紧固件接头系统的限制性因素（螺牙强度或者与板材的连接强度）是很重要的。

For lower loads and small thread sizes (M6 and M8,) mechanically joined fasteners and weld fasteners could be considered as equal in their ability to carry load. In which case, the manufacturing process may dictate the type of fastener to use.

对于小载荷和小螺纹尺寸（M6和M8，），机械连接紧固件和焊接紧固件具有相同的承载能力。在这种情况下，制造过程决定所用的紧固件类型。

For higher loads and larger thread sizes, a welded fastener is recommended.For these conditions, it is also important to locate a weld nut on the side of the sheet component which is opposite to the loading direction. With such a design, the occurrence of weld discrepancies are of minor importance to the performance of the joint as the fastener has to be pulled through the sheet or nut plate. For high fatigue loads, fasteners with a continuous ring projection are the best choice, although these are also more difficult to weld.

对于大载荷和大尺寸螺纹，推荐使用焊接紧固件。对于这种情况，在板件上与载荷方向相反的另一边设置一个焊接螺母是很重要的。有了这种设计，焊接偏差的发生对于焊接接头性能的影响就不那么重要了，因为如果要产生破坏紧固件必须穿过板材或者螺母板。对于大的疲劳载荷，使用带有连续型环形凸块的紧固件是最好的，尽管这样也会增加焊接难度。

I.3.1 Fastener Size Relative to Base Sheet Metal Thickness

紧固件相对于板材厚度的尺寸大小

Table I.3.1 lists the permissible range of base sheet thickness for the respective size and type of nut and bolt.

表I.3.1列出了各种螺母螺栓的类型尺寸及其对应的允许使用的板材厚度围。