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1、ThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppWeld Quality Awareness Induction TrainingMike BellThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppAims of the sessionTo understand the importance of weld qualityLearn to reco
2、gnize basic weld defectsUnderstand how the most common defects are causedAppreciate the contribution operators can make to preventing defects getting into cars.ThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppIntroductionTogether with press-forming, welding is o
3、ur main business.Almost all welding is done by robotsRobots are consistent and tireless, butAt the moment robots do not have eyes and ears. That is why we depend on YOUThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppWhy defects are importantBad welds = poor dur
4、abilityDurability is how long the parts are expected to last before failureTarget durability is 150,000 miles or 10 yearsChassis part failure can lead to :- Serious injury or deathWarranty costs / recallLoss of contracts and jobsThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive Com
5、panyThyssenKruppFatigue failureFatigue occurs when loads are applied backwards and forwards many timesThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppEventually a crack will appear and grow.Usually the crack will start at a weld toeThe higher the stress, the fa
6、ster the growth.Defects increase the stress and make parts fail soonerThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppMIG / MAG ProcessThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppParent materialThroatLeg lengthPenetrat
7、ionFillet weld termsThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppTo obtain a good weld the parts must be in the right place The main cause of defects is poorly placed parts or weldThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThy
8、ssenKruppPart position incorrect gives a poor weldHere the weld is biased giving a small leg length and poor penetrationEffect of poor positionThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppOK weldThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomo
9、tive CompanyThyssenKruppBiased weld not OKThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppThis time the part is incorrectly located the other way giving eitherPoor fusion and small leg to lower,orBurnthroughEffect of poor positionThyssenKrupp Automotive Tallent
10、 Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppWHAT IS WRONG WITH THIS?ThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppReasons for position fault may be:orPart not placed against fixtureLoose fixtureThyssenKrupp Automotive Tallent Chassis LtdA ThyssenK
11、ruppAutomotive CompanyThyssenKruppReasons for position fault may be:Spatter on fixtureThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppLap weldsGood weldThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppTop sheet mispositione
12、dResults in weld being too smallEdge of sheet visibleThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppFit up gap gives same effectSmall weldThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppTop sheet mispositioned towards wel
13、dSmall weld this sideWeld is highThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppUndercut reduces the thickness of the material and concentrates stressThyssenKrupp Automotive
14、 Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppThe worst defects of allOmittedComplete misweldThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppMispositioned weld causes:-Weak, undersize weldsPoor fusionEarly failureBurnthroughHigh scrap and rewo
15、rk costsThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppGas shroudPorosityThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppPorosityMakes welds weakMight be worse than you thinkCan only be repaired by grinding outLeads to ex
16、pensive rework and scrapThyssenKrupp Automotive Tallent Chassis LtdA ThyssenKruppAutomotive CompanyThyssenKruppHow can you helpRemember why defects are importantReport defects and equipment faultsAlways work to your standard operation instructionDo all clean and check activities thoroughlyLearn to recognize defects
