STANDARD

Classement prvu : 01 - 50 - 912 / - - B Sce NTl

Responsable du document P. SCHWARTZ 65810 53130
Pilote(s) technique(s) A. LANNE 65304
Date de mise jour :
Normalisation Renault Automobiles
01 - 50 - 912 / - - B
ELECTRIC RESISTANCE
LAP SPOT WELDING
(FOR NEW DESIGNS))
Service 65810
Section Normes et Cahiers des Charges
S
R
VISA RESPONSABLE(S)
SIGNATURE :
NOM :
SERVICE :
DATE :
15/01/2002
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This document is to be considered as a whole, the parts of which shall not be separated.
"Seul le texte franais fait foi, les traductions n'tant faites que pour en faciliter l'emploi".
"The French text alone is valid. The translations are provided to assist the reader in understanding the
standards".
RENAULT 2002.
No duplication permitted without the consent of the issuing department.
No circulation permitted without the consent of RENAULT.
DATE OF ISSUE
April 1994 - - - This issue originates from Draft NC 92 425 / - - D.
REVISIONS
March 2001 - - A Annex 3 modified.
This issue originates from Draft NC 2001 0038 / - - -.
March 2002 - - B Complete revision.
This issue originates from Draft NC 2001 0938 / - - A.
REFERENCED DOCUMENTS
Standards : 00-10-040, 01-50-902.
Product Specifications : 32-00-017.
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CONTENTS
Page
1. GENERAL 5
1.1. VARIOUS SPOT WELDING PROCESSES 6
1.2. SPOT WELDING PROCESS 7
1.3. DESCRIPTION OF SPOT WELDED JOINTS - TERMINOLOGY 7
2. SCOPE 8
3. TYPES OF ASSEMBLIES 9
3.1. TWO-SHEET ASSEMBLY 9
3.2. THREE-SHEET ASSEMBLY 9
3.3. SPECIAL ASSEMBLIES 9
3.4. VALIDATION OF ASSEMBLIES 9
4. DEFINITION OF WELDING SPOTS AND WELDING SPOT AREAS 10
4.1. WELDING SPOT CATEGORIES 10
4.2. WELDING SPOT AREAS 10
4.3. TIME LIMIT FOR CHARACTERISTIC DEFINITION 10
4.4. POSITION 11
5. STANDARDISED REPRESENTATION 11
6. APPEARANCE OF WELDING SPOTS 12
6.1. APPEARANCE A 12
6.2. APPEARANCE B 12
6.3. APPEARANCE C 12
6.4. IDENTIFICATION 12
7. APPEARANCE WELDING SPOT SPECIFICATION 12
8. WELDABILITY OF METALS 12
9. DIMENSIONAL AND MECHANICAL CHARACTERISTICS OF WELDING SPOTS 12
10. OVERLAP DIMENSION "L" (OR EDGE WIDTH) AND AXIS POSITION FOR WELDING SPOT
"A" (SEE ANNEX 5) 13
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CONTENTS (continued)
Page
11. MINIMUM WELD PITCH (CENTRE DISTANCE): P MIN. (SEE ANNEX 4) 13
ANNEX 1 ASSEMBLY REQUIREMENTS 14
ANNEX 2 WELDABILITY OF 3 THICKNESS - 2 JOINT TYPE ASSEMBLY 15
ANNEX 3 DIMENSIONAL AND MECHANICAL CHARACTERISTICS 18
ANNEX 4 MINIMUM PITCH (P min.) BETWEEN WELDING SPOTS (CENTRE DISTANCE) 21
ANNEX 5 OVERLAPPING DIMENSIONS "L" - AXIS POSITION FOR WELDING SPOTS "A" 23
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1. GENERAL
Spot welding consists in making an overlapping assembly with one or two unions at one or several
points.
The welding spot is a disk of melted, then solidified, metal which forms the union between the parts of
an overlapping assembly.
Spot welding machines which are used to simultaneously make several welding spots are called
"multi-spot welding machines".
Spot welding machines may be fixed or mobile. In the latter case, they are called "welding guns"
because of their special shape.
The assemblies produced in this way may consist of two or three sheets; the thicknesses of the
sheets forming these assemblies may be different.
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1.1. VARIOUS SPOT WELDING PROCESSES
PROCESSES EQUIPMENT REMARKS
Single direct
spot welding
Double series
spot welding
Indirect spot
welding
"Push-pull"
welding
Seam
welding
Disk depression
welding
* Manual guns
* Multi-spot
(S.P.M.)
* "Robot" guns
* Multi-spot
(S.P.M.)
* Multi-spot
(S.P.M.)
* Multi-spot
(S.P.M.)
* Manual
contact rollers
* Machines
* Welding press
- A single spot per cycle
- The tool should have access
to either side
of the assembly
- Possible welding of 2 and 3
thicknesses
- Spot quality
Use recommended
- 2 spots per cycle
- Tool on one side only
- No bottom
imprint
- Welding of 2 compatible
thicknesses only
- Limited quality welding
spots
Use taking special care
- 1 welding spot per cycle
- Tool on one side only
- No bottom
imprint
- Limited welding spot quality
- Welding of 2 thicknesses
only
Use taking special care
- 2 welding spots per cycle
- Perfectly symmetrical
tools on either side
of the assembly
- Quality welding in the
centre of large parts
- Welding spots correctly
spaced, or secant spots
(tight weld seams)
- Welding of 2
thicknesses only
- Making of several
welding spots/cycle.
- Welding of small parts
(clamps, nuts, screws, etc.)
- High power machines
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1.2. SPOT WELDING PROCESS
During spot welding, the parts are superimposed, and welding is limited to one or more spots.
Electrodes localising the force and welding current are used.
When the required clamping force is reached at the electrodes, the electric current flows. The areas
corresponding approximately to the active surface area of the electrodes are heated when the current
flows through the sheets. The heating is mostly localised at the contact surfaces of the sheets. The
combined effect of the force and heating causes the creation of a weld seam jointing the sheets
This technique mainly applies to the welding of fine steel or light alloy sheets of thicknesses
between 0,5 mm and 5 mm.
Spot welding may be used for uncoated, galvanised, or electrozinc-coated steel sheets. These sheets
may consist of mild steel or steel with a high yield strength. However, the welding conditions vary for
the various materials and for the zinc-coated and uncoated sheets.
1.3. DESCRIPTION OF SPOT WELDED JOINTS - TERMINOLOGY
Welding spot area : all the spots which provide the same function.
Indentation : mark left by the electrode on the part surface.
Indentation depth : depth of the mark left by the electrode on the part surface during welding.
Weld core : disk of melted and cooled metal ensuring continuity between the sheets.
Material rivet (or button) : part of sheet remaining on one of the parts after a destructive test.
Transformer, primary circuit winding
Thyristor
contactor
Magnetic core
of transformer
Transformer,
secondary circuit
winding
Switch
Schematic representation of spot welding process
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Material rivet diameter : the mechanical strength of a welding spot is characterised by the diameter of
the material rivet or of the area pulled out (d) at the interface after the sheet separation test. The
measurements can be made at the base of the material rivet. If the material rivet is asymmetrical, the
measurements are made from the direction giving the lowest value.
Definition of material rivet diameter
Good welding spot : welding spot checked with sheet separation, or another similar method with a
diameter of the material rivet or area pulled off at the interface equal to or greater than the specified
diameter.
Defective welding spot : welding spot checked with sheet separation, or another similar method with a
diameter which is less than the specified diameter.
Any missing point is considered as a defective welding spot.
Welding spot with edge position defect : welding spot causing deformation of the sheet. See figure
below.
Definition of an edge position defect
2. SCOPE
This document relates to the spot welding of extra mild steel high yield strength sheets (uncoated,
electro-zinc coated, and galvanised); their mechanical characteristics may differ depending on the
application. Any other steel grade shall be the subject of special specifications.
This standard is intended to define :
a) the types of assemblies,
b) the standardised representation of weld areas and of the corresponding welding spots,
c) the categories of welding spots and weld areas,
d) the appearance of the welding spots,
e) the relationships between the appearance and the location of the welding spots,
f) the dimensional and mechanical characteristics of the welding spots.
NOTE: Sub-paragraphs c), d), e) and f) are the controlling factors for the welding equipment
(making of direct or indirect welding spots, welding current value, current flow time,
electrode tip dimensions, coupling time, holding time) and the inspection procedures to be
implemented.
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3. TYPES OF ASSEMBLIES
A minimum of 2 welding spots is required to assemble a part.
3.1. TWO-SHEET ASSEMBLY
Each two-sheet assembly shall satisfy the requirements of annex 1.
3.2. THREE-SHEET ASSEMBLY
For a three-sheet assembly, and if it appears in the configurations grouped in annex 2, this assembly
should be considered as an assembly which can be produced industrially.
However, the welding spots which should be specified as category 1 shall be the subject of written
approval from the "Welding Process Engineering" Department.
3.3. SPECIAL ASSEMBLIES
a) Each two-sheet assembly which does not meet the requirements of annex 1 shall be the subject
of approval from the "Welding Process Engineering" Department.
b) For three-sheet assemblies which are not part of the configurations of annex 2, it is possible to
specify assemblies of 3 thicknesses and 1 joint with the approval of the "Welding Process
Engineering" Department.
3-sheet assemblies and 1 joint shall be the subject of a written indication on the Engineering
Centre (B.E.) drawing derived from the digitisation of the "Welding Spots". The indication of the
joint to be made is entered in the welding spot list.
In addition, all exemptions relating to a welding drawing shall be the subject of a "Welding
Process Engineering" Department summarising memorandum.
c) Generally, for any sheet assembly not covered by the specifications of annexes 1 and 2; it is
possible, with the approval of the "Welding Process Engineering" Department, to specify weld
cores of reduced diameter with respect to those of annex 3; the values are then entered on the
welding drawing.
These assemblies shall be limited to exceptional cases.
3.4. VALIDATION OF ASSEMBLIES
- Validate the feasibility of special assemblies ( 3.3.).
- On the prototype, validate the minimum guaranteed assembly quality (mechanical strength).
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4. DEFINITION OF WELDING SPOTS AND WELDING SPOT AREAS
The minimum guaranteed quality level is given in Product Specifications 32-00-017.
4.1. WELDING SPOT CATEGORIES
The welding spot category is defined by the Engineering Centre according to their function; the
welding spots are distributed into two categories:
CATEGORY 1: spots, the mechanical strength of which is preponderant (requiring filling according
to Standard 00-10-415). These welding spots belong to areas providing an important
resistance or safety-critical function.
CATEGORY 2: other welding spots..
4.2. WELDING SPOT AREAS
The welding spots, which are derived from the "Welding Spots" data base, are defined on the welding
drawings by the Engineering Centre.
The Engineering Centre and the "Welding Process Engineering" Department jointly divide the vehicle
into areas of spots. These areas are groups of welding spots performing the same product function
(Customer Performance).
4 EXAMPLES OF WELDING SPOT AREAS ON A SUBFRAME
The areas contain in the order of 10 to 60 resistance welded spots.
The allocation of the spots within the areas is given in the list associated with the welding drawing.
If several versions of a vehicle are examined (B, C, J, etc.), only identical areas (identical number of
welding spots and same tolerances, etc.) keep the same number. Otherwise, the areas have different
numbers, which indicates that a welding spot can belong to several areas only on different versions.
4.3. TIME LIMIT FOR CHARACTERISTIC DEFINITION
The categories of the welding spots and the welding spot areas shall be defined with the first change
letter of the welding drawing.
Area 203 Area 227 Area 120 Area 222
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4.4. POSITION
The theoretical position of the welding spots is defined by the Engineering Centre.
The drawing of the Engineering Centre is the sole reference.
In addition, the Engineering Centre shall give the tolerances on the welding spot positions in
agreement with the "Welding Process Engineering" Department if the general tolerances indicated in
Product Specifications 32-00-017 are unsuitable.
5. STANDARDISED REPRESENTATION
The representation of line or staggered spot welding calls for a longitudinal view or an edge-on view,
accompanied by an end view or cutaway view:
- the line of welding spots on the longitudinal view is materialised by a mixed medium thickness line;
- upright projection:
. for category 1 welding spots, the location of the welding spots is indicated by symbol for
a joint, or for two joints, and is defined according to the general dimensioning rules,
. for category 2 welding spots, the location of the welding spots is indicated by symbol
for a joint, or symbol for two joints, and is defined according to the general dimensioning
rules.
- cutaway view: all the joints are represented by symbol .
If there are many welding spots in line, it is only necessary to represent 2 or 3 spots at the ends of this
line.
NOTE: Safety-critical and/or regulation-controlled areas shall be defined and identified by symbol
in compliance with Standard 00-10-040.
- Designation to be entered on the drawing (or on AO sheet) (to be applied as cross-reference):
11 SRP 30
. number of spots
. welding process code
. welding spot pitch (mm)
Special spots are identified by symbol *. This cross-refers to the list.
The special welding spots are:
- the process engineering spot,
- the favoured joint,
- the spot under flexible joint,
- small core spot,
- etc..
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6. APPEARANCE OF WELDING SPOTS
6.1. APPEARANCE A
This appearance is incompatible with the requirements of CATEGORY 1, with three-thickness
assemblies, and with externally-coated sheet assemblies.
This appearance is retained only for CATEGORY 2 welding spots. The appearance which is
demanded for the visible part of welding spots located on visible sides, and for which no marking is
permitted, is defined in this way.
6.2. APPEARANCE B
The appearance which is demanded for welding spots located on surfaces visible only when the
doors, luggage compartment door, etc. are open is defined in this way. Electrode indentations of
depth equal to or less than 0,1 mm are allowed. But the welding spots shall be perfectly positioned in
all the cases.
In addition to the characteristics defined above, the welding areas shall be free of scale, grease,
oxidation, and burrs.
6.3. APPEARANCE C
This appearance shall satisfy the requirements of Product Specifications 32-00-017.
6.4. IDENTIFICATION
Welding spots of appearance A and B are identified on the drawings (spots of appearance C are not
identified).

7. APPEARANCE WELDING SPOT SPECIFICATION
The Engineering Centre specifies the appearance welding spots after acceptance by the Quality
Department (Department 0611) of representative samples produced by the "Welding Process
Engineering" Department (samples before and after painting), prior to the making of tooling.
8. WELDABILITY OF METALS
Refer to Standard 01-50-902.
9. DIMENSIONAL AND MECHANICAL CHARACTERISTICS OF WELDING SPOTS
A table in annex 3 specifies the minimum guaranteed diameter for welding spots depending on the
thickness of the chosen sheets and mechanical strength.
Diameter D
t
is the minimum guaranteed theoretical diameter of the welding spot.
11 SRP 30 appearance B
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10. OVERLAP DIMENSION "L" (OR EDGE WIDTH) AND AXIS POSITION FOR WELDING SPOT "A"
(SEE ANNEX 5)
The values for L are defined in annex 5.
The axis position for the welding spot "A" with respect to the edge of the sheet is defined in annex 5.
A A
A
A A A
11. MINIMUM WELD PITCH (CENTRE DISTANCE): P MIN. (SEE ANNEX 4)
The values which are indicated for P are those which do not require any special precautions to
compensate for current drifts by adjacent spots.
Two nominal values are suggested depending on the number of sheets forming the assembly.
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ANNEX 1
ASSEMBLY REQUIREMENTS
ASSEMBLY
TYPES
Max
thickness
Min
thickness
.
.
CATEGORY 1 CATEGORY 2 CONDITIONS
2 thicknesses
1 union
e
E
3 X X
3 thicknesses
2 unions
See
annexes
3 and 4
Consult
"Welding
Process
Engineering"
Department
X
Electrode/electrode
direct spot welding
3 thicknesses
1 union
Consult
"Welding
Process
Engineering"
Department
Consult
"Welding
Process
Engineering"
Department
X
Electrode/electrode
direct spot welding
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ANNEX 2
WELDABILITY OF 3 THICKNESS - 2 JOINT TYPE ASSEMBLY
A
X
Y
Assembly to be excluded
X
A Y
from 0,4 to 0,54
from 0,55 to 0,64
from 0,65 to 0,74
from 0,4 to 0,54 from 0,75 to 0,84
from 0,85 to 0,94
from 0,95 to 1,09
from 1,1 to 1,19
from 0,4 to 0,54
from 0,55 to 0,64
from 0,65 to 0,74
from 0,54 to
0,64
from 0,75 to 0,84
from 0,85 to 0,94
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 0,4 to 0,54
from 0,55 to 0,64
from 0,65 to 0,74
from 0,65 to
0,74
from 0,75 to 0,84
from 0,85 to 0,94
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 0,4 to 0,54
from 0,55 to 0,64
from 0,65 to 0,74
from 0,75 to 0,84
from 0,75 to
0,84
from 0,85 to 0,94
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 0,4 to 0,54
from 0,55 to 0,64
from 0,65 to 0,74
from 0,75 to 0,84
from 0,85 to
0,94
from 0,85 to 0,94
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,5 to 1,69
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ANNEX 2 (Continued)
X
A Y
from 0,4 to 0,54
from 0,55 to 0,64
from 0,65 to 0,74
from 0,75 to 0,84
from 0,85 to 0,94
from 0,95 to
1,09
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,5 to 1,69
from 1,7 to 1,89
from 0,4 to 0,54
from 0,55 to 0,64
from 0,65 to 0,74
from 0,75 to 0,84
from 0,85 to 0,94
from 1,1 to 1,19 from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,5 to 1,69
from 1,7 to 1,89
from 1,9 to 2,09
from 0,55 to 0,64
from 0,65 to 0,74
from 0,75 to 0,84
from 0,85 to 0,94
from 0,95 to 1,09
from 1,2 to 1,29 from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,5 to 1,69
from 1,7 to 1,89
from 1,9 to 2,09
from 2,1 to 2,19
from 0,75 to 0,84
from 0,85 to 0,94
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49 from 1,3 to 1,49
from 1,5 to 1,69
from 1,7 to 1,89
from 1,9 to 2,09
from 2,1 to 2,19
from 2,2 to 2,29
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,5 to 1,69 from 1,5 to 1,69
from 1,7 to 1,89
from 1,9 to 2,09
from 2,1 to 2,19
from 2,2 to 2,29
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ANNEX 2 (Continued)
X
A Y
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,7 to 1,89 from 1,5 to 1,69
from 1,7 to 1,89
from 1,9 to 2,09
from 2,1 to 2,19
from 2,2 to 2,39
from 0,95 to 1,09
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,9 to 2,09 from 1,5 to 1,69
from 1,7 to 1,89
from 1,9 to 2,09
from 2,1 to 2,19
from 2,2 to 2,39
from 1,1 to 1,19
from 1,2 to 1,29
from 1,3 to 1,49
from 1,5 to 1,69
from 2,1 to 2,29 from 1,7 to 1,89
from 1,9 to 2,09
from 2,1 to 2,29
from 2,3 to 2,49
from 2,5 to 2,69
from 2,7 to 3
from 1,2 to 1,29
from 1,3 to 1,49
from 1,5 to 1,69
from 1,7 to 1,89
from 2,3 to 2,49 from 1,9 to 2,09
from 2,1 to 2,29
from 2,3 to 2,49
from 2,5 to 2,69
from 2,7 to 3
from 1,3 to 1,49
from 1,5 to 1,69
from 1,7 to 1,89
from 2,5 to 2,69 from 1,9 to 2,09
from 2,1 to 2,29
from 2,3 to 2,49
from 2,5 to 2,69
from 2,7 to 3
from 1,5 to 1,69
from 1,7 to 1,89
from 1,9 to 2,09
from 2,7 to 3 from 2,1 to 2,29
from 2,3 to 2,49
from 2,5 to 2,69
from 2,7 to 3
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ANNEX 3
DIMENSIONAL AND MECHANICAL CHARACTERISTICS
1. DEFINITION OF THE REFERENCE THICKNESS FOR AN ASSEMBLY: ER (mm)
The reference thickness for an assembly (ER) is the parameter which makes it possible to determine
the nominal value of the Dt for a welding spot. It is determined according to the following rules.
1.1. Case of a two-thickness assembly
ER(mm) = finest value for the thickness of the assembly sheets.
Possible cases Assembly profile example ER
Sheets with the same
thicknesses A
B
A = B ER = A
Sheets with different
thicknesses.
A
B
A
B
or
B > A
ER = A
finest thickness
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ANNEX 3 (Continued)
1.2. Case of a three-thickness assembly
1.2.1. General case
The characteristics of the two melted cores, one for the (Sheet1-Sheet2) connection, and one for the
(Sheet 2-Sheet 3) connection should be determined. Therefore, there are two reference thicknesses
to be determined (ER1 and ER2).
Sheet No
1
Sheet No 2
Sheet No 3
1
st
melted core (Sheet1-Sheet2
connection)
2
nd
melted core (Sheet2-Sheet3
connection)
The definition of the reference thickness is identical: ER(mm) = finest value of the assembly sheet
thickness.
1.2.2. ER value examples for different three-thickness assembly types
This table does not describe all the possible cases; it is only intended to illustrate a few significant
examples.
Possible cases Example of possible profiles for the assembly ER
Sheets with the
same thicknesses
Core No 1 (ER1)
Core No 2 (ER2)
Thickness of
sheet No 1 = A
Thickness of
sheet No 2 = B
Thickness of
sheet No 3 = C
A = B = C
ER1 = ER2 =A
Two sheets with
the same
thicknesses; third
sheet with a finer
thickness
(different
stacking)
Core No 1 (ER1)
Core No 2 (ER2)
Thickness of
sheet No 1 = A
Thickness of
sheet No 2 = B
Thickness of
sheet No 3 = C
A = B
C < A = B
ER1 = B
ER2 = C
All sheets with
different
thicknesses.
Core No 1 (ER1)
Core No 2 (ER2)
Thickness of
sheet No 1 = A
Thickness of
sheet No 2 = B
Thickness of
sheet No 3 = C
A < B < C
ER1 = A
ER2 = B
Sheets with
different
thicknesses but
finest sheet in the
middle of the
assembly.
Core (ER)
Thickness of
sheet No 1 = A
Thickness of
sheet No 2 = B
Thickness of
sheet No 3 = C
A/B 3
and
C/B 3
ER = finest sheet
between the two
external sheets,
that is to say C <
A, therefore ER
= C
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ANNEX 3 (Continued)
2. WELDING SPOT STRENGTH AND DIMENSIONAL VALUES
Reference thickness
of assembly ER (mm)
Diameter of welding
spot D
t
(in mm)
Shear
tensile strength
(in daN) (1)
Crosswise
tensile strength
(in daN)(1)
0,55 3 200 160
0,6 3 230 184
0,65 3 250 200
0,7 3 280 224
0,75 3 300 240
0,8 4 350 280
0,85 4 400 320
0,9 4 450 360
0,95 4 480 384
1 4 500 400
1,1 4 600 480
1,2 4 650 520
1,3 6 910 728
1,4 6 960 768
1,5 6 1 000 800
1,6 6 1 080 864
1,7 6 1 150 920
1,8 6 1 200 960
1,9 6 1 280 1 024
2 6 1 350 1 080
2,2 8 1 700 1 360
2,5 8 2 100 1 680
2,8 8 2 250 1 800
3 8 2 500 2 000
Any deviation with respect to this table shall be the subject of a written agreement between the
Engineering Centre, the "Welding Process Engineering" Department, the Materials Engineering
Department (DIMAT), and the project team.
(1) : These values have been defined for steels for which Rm < 350 MPa. For steels with extra deep
drawing properties or steels for which Rm 350 MPa, they will be given by the DIMAT
(Department 64140 - Flat Products BWU) upon the request of the project teams for the
configurations which are contemplated on the vehicle.
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ANNEX 4
MINIMUM PITCH (P min.) BETWEEN WELDING SPOTS (CENTRE DISTANCE)
The minimum pitch between welding spots is defined according to the thickness of the reference
sheet which is determined below.
1. DETERMINATION OF THE ASSEMBLY REFERENCE THICKNESS
1.1. Case of a two-thickness assembly
Trf (mm) = Finest sheet thickness.
Possible cases Assembly profile example ER
Sheets with the same
thicknesses A
B
A = B Trf = A
Sheets with different
thicknesses.
A
B
A
B
or
B > A
Trf = A
thinnest
thickness
1.2. Case of a three-thickness assembly
Trf = Average thickness of assembly sheet + 0,2 mm.
A
B
A = B = C
C > A > B
A + 0,2
Trf
C
A
B
C
A + 0,2
A
B
C
B > C > A C + 0,2
A
B
C
C > B > A B + 0,2
A
B
C
A = C > B A + 0,2
A
B
C
B = C > A B + 0,2
Trf
A
B
C
A = C < B A + 0,2
A = B < C A + 0,2
A
B
C
NOTE: The definition of the reference thickness "Trf" above is also used to determine the
overlapping dimensions and welding parameters.
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ANNEX 4 (Continued)
2. MINIMUM VALUES OF THE PITCH BETWEEN SPOTS
Reference thickness of
assembly (in mm)
Minimum pitch between
welding spots (in mm)
Minimum pitch between
welding spots (in mm)
(Trf) Two-thickness assemblies Three-thickness assemblies
0,4 10 14
0,5 10 14
0,55 10 14
0,6 10 14
0,65 11 15
0,7 11 15
0,75 12 17
0,8 13 18
0,85 15 20
0,9 17 22
0,95 19 23
1 20 24
1,1 20 24
1,2 22 26
1,3 23 27
1,4 23 27
1,5 24 29
1,6 26 30
1,7 26 30
1,8 28 32
1,9 30 34
2 32 36
2,2 35 39
2,5 39 43
2,8 41 45
3 43 48
Any deviation with respect to this table shall be the subject of a written agreement between the
Engineering Centre, the "Welding Process Engineering" Department, and the "Project" team.
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ANNEX 5
OVERLAPPING DIMENSIONS "L" - AXIS POSITION FOR WELDING SPOTS "A"
Account shall be taken in the sheet edge dimensions of the product requirements (thicknesses,
stamping depths, lengths of cut-off edges) and also of the process requirements (stamping or folding
radiuses R, clearance angle , diameter of electrode cylinder, positioning dispersions, sheet trimming
dispersions, etc.).
1. GENERAL CASE (except door sills, opening panels, window pillars)
The values below are standard "across flats" values measured on the sheet which mostly stands
back; they apply in most assembly cases, except for door sills, window pillars, and opening panels.
Hypotheses for the definition of L:
- the assemblies with two parts each with an angle of 90are not concerned;
- dimensioning with robot electrodes complying with EM34.SO.122. Matching is: centred straight
electrode with centred straight electrode. Average electrode wear estimate: 5mm;
- taking into account of the dispersions obtained from the trimming, assembly, and electrode/sheet
positioning tolerances;
- the reference thickness is determined according to the number of assembled sheets and stacking
case in accordance with annex 4.
Values for L and A:
Thickness of
reference sheet
(according to
annex 4)
L across flats
(mm)
A
(mm)
0,6 to 0,8
13
(1)
6,5
0,81 to 1,2 15
(1)
7,5
1,21 to 2 18,6 9,3
2,1 to 3 21,6 10,8
3,1 to 4 25,6 12,8
(1): Since this "standard" value highly depends on radius R and angle , the value L should therefore
be adapted according to them (see table below).

A
L
R
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ANNEX 5 (Continued)
Thickness of reference sheet: 0,6 to 0,8 mm
Welding spot axis position (A: 6,5 mm
R/ 90 94 98 102 106 110 114 118 120 124
2 17,5 17 16,5 16 15,5 15 14,5 14 13,5 13
4 15,5 15 14,5 14 13,5 13 13 13 13 13
6 13,5 13 13 13 13 13 13 13 13 13
Thickness of reference sheet: 0,81 to 1,2 mm
Welding spot axis position (A): 7,5 mm
R/ 90 94 98 102 106 110 114 118
2 18,5 18 17,5 17 16,5 16 15,5 15
4 16,5 16 15,5 15 15 15 15 15
6 15 15 15 15 15 15 15 15
NOTE: The values for L which are defined apply by default for assemblies made with a manual
process.
Any deviation concerning these values (decrease or increase) shall be set in consultation with the
Engineering Centre, the "Welding Process Engineering" Department, and the project team. It can only
be granted on a case-by-case basis and after giving an indication of the technical and economical
effects.
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ANNEX 5 (Continued)
2. SPECIAL CASE: Door sills, window pillars, window frames
Since the following typical sections are the subject of design/vision requirements, they are specifically
treated as indicated below.
2.1. Window rabbet edge widths (pillars)
Construction hypotheses:
- sheet/electrode dispersion: 2 mm,
- assembly and cutting dispersion: 2 mm,
- radius tolerance: 1 mm,
- Electrode matching: centred straight/out of centre straight (cylinder 20 mm / end piece 14 mm
according to EM34.SO.122).
R
7
L

> 17
90
R=3 + 1
Body side
Roof drip moulding or
front pillar reinforcement
Window pillar
inner panel
Window pillar inner panel edge width:
in conformity with this drawing, with L across flats > 14 mm
and R = 3 mm + 1 mm
Body side edge width L:
in accordance with general case ( 1.)
Any deviation concerning these values (decrease or increase) shall be set in consultation with the
Engineering Centre, the "Welding Process Engineering" Department, and the project team. It can only
be granted on a case-by-case basis after giving an indication of the technical and economical effects.
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ANNEX 5 (Continued)
2.2. Door sill rabbet edge widths
Construction hypotheses:
- sheet/electrode dispersion: 2 mm,
- assembly and cutting dispersion: 2 mm,
- radius tolerance: 1 mm,
- Electrode matching: centred straight/out of centre straight (cylinder 20 mm / end piece 14 mm
according to EM34.SO.122).
L cc

R
2
Reinforcements (CdC pillars, ...)
Side sill inner panel
Inner panels (CdC pillars, ...)
Side sill closing
element
Body side (CdC)
cc
9
Rd
L
cc 100 105 110
Lcc > 18,2 mm 17,9 mm 17,5 mm
Body side edge width:
(Body side radius R = 5 mm)
Closing element or inner panel
edge width:
L across flats in conformity with the
general case
Any deviation concerning these values (decrease or increase) shall be set in consultation with the
Engineering Centre, the "Welding Process Engineering" Department, and the project team. It can only
be granted on a case-by-case basis after giving an indication of the technical and economical effects.
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ANNEX 5 (Continued)
2.3. Window frame edge widths
Hypotheses: the value defined below requires the use of special electrodes involving process
requirements (limited useful life, limitation of the number of spots) which will have to be
validated and accepted in consultation with the Engineering Centre, the "Welding
Process Engineering" Department, and the project team.
L
L
L = 9,7 mm + 0,5 mm
Any deviation concerning these values (decrease or increase) shall be set in consultation with the
Engineering Centre, the "Welding Process Engineering" Department, and the project team. It can only
be granted on a case-by-case basis and after giving an indication of the technical and economical
effects.