Transamerican Manufacturing Group

Explorer Pro Comp Chula Vista CA

Document Title: Weld Standards, Steel.

Document Number: WELD_STANDARDS_TAP
Document Filename: WELD_STANDARDS_TAP.docx

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Revision Revision DCO/ECO Revision

Level Date Number Description of Revision Author
DRAFT 1/11/2016 YY-00001 Draft T. Unger
DRAFT 1/11/2016 YY-00001 Draft 2 T. Unger
DRAFT 2/15/16 YY-00001 Draft 3 J. Bennett

COMPANY PROPRIETARY AND CONFIDENTIAL

TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

Table of Contents

Table of Contents ................................................................................................................................................... 2

1.0 Purpose ........................................................................................................................................................ 4

2.0 Scope ........................................................................................................................................................... 4

3.0 Definition Of Terms .................................................................................................................................... 4

3.1 ANSI/AWS D1.1:2015 ..................................................................................................................... 4
3.2 ANSI/AWS D8.8M:2014 .................................................................................................................. 4
3.3 ASTM A36........................................................................................................................................ 4
3.4 QCDB Quality Database ................................................................................................................... 4
3.5 Burn through ..................................................................................................................................... 4
3.6 Meltback ........................................................................................................................................... 4
3.7 Notching ............................................................................................................................................ 4
3.8 Skip ............................................................................................................................................ 4

4.0 Responsibilities ............................................................................................................................................ 4

4.1 Engineering. ...................................................................................................................................... 4
4.2 Manufacturing. .................................................................................................................................. 4
4.3 QCDB Inspection. ............................................................................................................................. 4

5.0 References ................................................................................................................................................... 4

6.0 Welding Qualifications ................................................................................................................................ 5

6.1 Material and equipment Specifications ............................................................................................. 5
6.2 Welding Processes ............................................................................................................................ 5

7.0 Weld Specifications ..................................................................................................................................... 5

7.1 Weld Quality ..................................................................................................................................... 5
7.1.1 Undercut ............................................................................................................................. 5
7.1.2 Craters ................................................................................................................................. 6
7.1.3 Cracks ................................................................................................................................. 6
7.1.4 Burn through ....................................................................................................................... 6
7.1.5 Skip ..................................................................................................................................... 6
7.1.6 Surface porosity .................................................................................................................. 6
7.1.7 Inclusions ............................................................................................................................ 6
7.1.8 Meltback ............................................................................................................................. 6
7.1.9 Melt through ....................................................................................................................... 6
7.1.10 Notching ............................................................................................................................. 6
7.1.11 Overlap ............................................................................................................................... 6
7.1.12 Spatter ................................................................................................................................. 6
7.1.13 Combinations of discontinuities ......................................................................................... 6
7.2 Weld tolerances ................................................................................................................................. 6
7.2.1 Surface preparation ............................................................................................................. 6
7.2.2 Temporary and Tack welds ................................................................................................. 6
7.2.3 Tubular weld alignment ...................................................................................................... 7
7.2.4 Width/Depth pass limitation ............................................................................................... 7
7.2.5 Depth of filling ................................................................................................................... 7
7.2.6 Faying surfaces ................................................................................................................... 7
7.2.7 Fillet welds ......................................................................................................................... 7
7.2.8 Plug welds........................................................................................................................... 7
7.2.9 Slot welds ........................................................................................................................... 7
7.2.10 Butt welds ........................................................................................................................... 7
7.2.11 Tubular weld alignment ...................................................................................................... 7
WELD_STANDARDS_TAP COMPANY PROPRIETARY AND CONFIDENTIAL Page 2 of 16
TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

7.2.12 Width/Depth pass limitation ............................................................................................... 7

7.3 Weld Profiles .................................................................................................................................... 7
7.4 Tubular Connections ......................................................................................................................... 9

8.0 Appendix – Weld Overview ...................................................................................................................... 14

8.1 Joint types ....................................................................................................................................... 14
8.2 Weld types ...................................................................................................................................... 14
8.3 Weld terms and symbols ................................................................................................................. 15

9.0 References ................................................................................................................................................. 15

WELD_STANDARDS_TAP COMPANY PROPRIETARY AND CONFIDENTIAL Page 3 of 16

TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

1.0 Purpose
This document contains the requirements for welded connections composed of tubular and non tubular
components at TransAmerican Auto Parts Group and Explorer Pro Comp Chula Vista. When this
standard is stipulated on a drawing, conformance with all provisions shall be required.

2.0 Scope
This procedure applies to all welded components including but not limited to: Bumpers, upper and lower
control arms, axles, and exterior accessories manufactured for TransAmerican Auto Parts Groups Pro
Comp Chula Vista CA.

3.0 Definition of Terms

3.1 ANSI/AWS D1.1:2015

Structural Welding Code - Steel.

3.2 ANSI/AWS D8.8M:2014

Specification for Automotive Weld Quality—Arc Welding of Steel.

3.3 ASTM A36

Specific Grade of Carbon Steel used in welded components.

3.4 QCDB Quality Database

Quality Database where Nonconformance Tracking, Lot Acceptance, Corrective Action,
Document Control Activities are Entered.

3.5 Burn through

A case of excessive melt-through in which the weld pool cannot be supported resulting in a hole
through the base metals joined.

3.6 Meltback
This occurs where the base metal melts back from the edge, but does not become part of the weld.
This condition leaves a void between the weld deposit and the base metal.

3.7 Notching
A weld heat related burn back of material at the end of the joint resulting in a notch.

3.8 Skip
An unwelded portion of a designated weld.

4.0 Responsibilities

4.1 Engineering.
Engineering is responsible for correctly annotating production drawings with the necessary weld
callouts. Engineering is also responsible for determining the correct welds for the given
application.

4.2 Manufacturing.
Responsible for welding components per the standards in this document.

4.3 QCDB Inspection.

Responsible for Performing QC Duties as dictated by Work Order, traveler, or management’s
discretion.

5.0 References
R&D Design Guidelines
QC Inspection
QCBD NCRM Log Entry – Online Database Tracking of Non Conformances.
WELD_STANDARDS_TAP COMPANY PROPRIETARY AND CONFIDENTIAL Page 4 of 16
TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

ANSI/AWS Specifications
Welding Instructions
6.0 Welding Qualifications

6.1 Material and equipment Specifications

The materials and equipment used must meet the following specifications:

 Electrode (weld wire): AWS A5.18, Classification ER70S-6, ER70C-#C, or ER70C-#M. Use
.035” (0.9mm) Dia. electrode for materials up to ¼” (6mm), use .045” (1.14mm) Dia. wire for
materials over ¼” (6mm).
 Shielding Gas: 75%Ar/25%CO2 minimum required, 85%Ar/15%CO2 preferred.
 Power Supply: Constant Voltage (CV) inverter.
 Environment: All welding shall not be done in a draft or wind unless the weld is protected by a
shelter. Shelter shall be appropriate to reduce wind velocity to a maximum of 5MPH (8KPH).
Welding shall not be done:
o When the ambient temperature is lower t an 0 (- 0 )
o When surfaces are wet or exposed to rain or snow
o When welding personnel are exposed to inclement conditions
6.2 Welding Processes
Gas metal arc welding (GMAW) WPSs (Welding Procedure Specifications) which conform to all
of the provisions of section 7 are approved for use. Only the Base Metal/Metal filler combinations
referred to in this document are approved.

7.0 Weld Specifications

7.1 Weld Quality

Figure 7.1 – Weld discontinuity examples

Figure 7.2 Weld joint

7.1.1 Undercut
Undercut shall not be permitted wit in 1/ ” (13mm) of t e start or end of t e weld.
Undercut is permitted to range from 0 to 0. T over a maximum cumulative lengt of 1/8”
of the weld length w en material t ickness exceeds 0.039” (1mm). Material less t an
.039” (1mm) s all ave no undercut.

WELD_STANDARDS_TAP COMPANY PROPRIETARY AND CONFIDENTIAL Page 5 of 16

TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

7.1.2 Craters
Weld craters shall not be considered part of the effective weld length.

7.1.3 Cracks
Cracks shall not be permitted.

7.1.4 Burn through

Holes caused by melting through the base metal shall not be permitted.

7.1.5 Skip
Skips shall not be permitted.

7.1.6 Surface porosity

Surface porosity shall not be permitted.

7.1.7 Inclusions
Nonmetallic inclusions shall not be permitted.

7.1.8 Meltback
Meltback in lap fillet welds shall not exceed the stock thickness in depth of the plate edge
at the top of meltback and shall decrease to zero at the root of the joint. Complete fusion
shall be obtained at the root of the joint. Meltback shall be limited to 15% of the weld
length.

7.1.9 Melt through

Melt through shall not exceed 1.3T 1.

7.1.10 Notching
Notching or gouging of the base metal at the ends or at the edge of the joint shall not be
permitted.

7.1.11 Overlap
The protrusion of weld metal beyond the weld toe is not allowed.

7.1.12 Spatter
Any spatter should be removed from the finished weld, and not interfere with the fit or
function of the part.

7.1.13 Combinations of discontinuities

The presence of more than one of the above discontinuities in any weld shall not be
permitted if any one of the evaluated discontinuities is at the maximum allowed limit.

7.2 Weld tolerances

7.2.1 Surface preparation

Surfaces on which weld metal is to be deposited shall be smooth, uniform, and free from
fins, tears, cracks, and other discontinuities which would adversely affect the quality or
strength of the weld. Surfaces to be welded, and surfaces adjacent to a weld, shall also be
free from loose or thick scale, slag, rust, moisture, grease, and other foreign material that
would prevent proper welding or produce objectionable fumes. Mill scale that can
withstand vigorous wire brushing, a thin rust-inhibitive coating, or antispatter compound
may remain.

7.2.2 Temporary and Tack welds

Temporary welds shall be subject to the same welding procedure requirements as the
final welds. These shall be removed as required by the engineer. When they are removed,
the surface shall be made flush with the original surface. Tack welds not incorporated
into the final welds shall be removed.
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TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

7.2.3 Tubular weld alignment

Abutting parts to be joined by girth welds shall be carefully aligned.

7.2.4 Width/Depth pass limitation

Neither the depth nor the width in the cross section of weld metal deposited in each weld
pass shall exceed the width at the surface of the weld pass.

7.2.5 Depth of filling

The depth of filling for plug or slot welds in metal 5/8in (16mm) thick or less shall be
equal to the thickness of the material. In metal over 5/8in (16mm) thick, it shall be at
least one-half the thickness of the material, but no less than 5/8in (16mm).

7.2.6 Faying surfaces

The separation between faying surfaces of plug and slot welds, and of butt welds landing
on a backing, shall not exceed 1/16in. (2mm). The use of filler plates is prohibited except
as specified on the drawings or as specifically approved by the Engineer.

7.2.7 Fillet welds

The parts to be joined by fillet welds shall be brought into as close contact as practicable.
The root opening shall not exceed 3/16in. (5mm). Weld joints shall be as detailed in
section 7.1. Refer to section 7.7 for acceptable weld profiles and sizes.

7.2.8 Plug welds

The minimum diameter of the hole for a plug weld shall be no less than the thickness of
the part containing it plus 5/16in (8mm). The maximum diameter shall equal the
minimum diameter plus 1/8in (3mm) or 2 ¼ times the thickness of the member,
whichever is greater.

7.2.9 Slot welds

The length of the slot for a slot weld shall not exceed ten times the thickness of the part
containing it. The width of the slot shall be no less than the thickness of the part
containing it plus 5/16in (8mm). The maximum width shall equal the minimum width
plus 1/8in (3mm) or 2 ¼ times the thickness of the member, whichever is greater.

7.2.10 Butt welds

Parts to be joined in butt joints shall be carefully aligned. Where effectively restrained
against bending due to eccentricity in alignment, an offset not exceeding 10% of the
thickness of the thinner part joined, but in no case more than 1/8in (3mm), shall be
permitted as the departure from the theoretical alignment.

7.2.11 Tubular weld alignment

Abutting parts to be joined by girth welds shall be carefully aligned

7.2.12 Width/Depth pass limitation

Neither the depth nor the width in the cross section of weld metal deposited in each weld
pass shall not exceed the width at the surface of the weld pass.

7.3 Weld Penetration

A weld’s strengt is determined by achieving complete fusion without cracking or
distortion. Incomplete fusion will result in a potential weld failure. If penetration is too
deep, centerline cracking (a form of hot cracking) may become an issue. See Figure
2 for an example of a centerline crack in a fillet weld. A balance must be maintained
between the depth of penetration and the width of the root pass. The depth to width ratio
(W/D ratio) should not exceed 1 to 1.2. This keeps the shape of the weld fairly uniform.
As the weld metal solidifies, the shrinkage stresses are thus fairly uniform in all
directions. However, if the weld is significantly deeper than wide, then the shrinkage
stresses are unequal and the weld will crack in the center of the bead as a result.

WELD_STANDARDS_TAP COMPANY PROPRIETARY AND CONFIDENTIAL Page 7 of 16

TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

Figure 7.3.1

Figure 7.3.2

7.4 Weld Profiles

Table 7.1 - Minimum approved weld size
Base metal thickness Minimum weld size
in. (mm) in. mm.
1/8 (3) to 3/16 (5) incl. 1/16 2
Over 3/16 (5) to 1/4 (6) incl. 1/8 3
Over 1/4 (6) to 1/2 (12) incl. 3/16 5
Over 1/2 (12) to 3/4 (20) inc I. 1/4 6
Over 3/4 (20) to 1-1/2 (38) incl. 5/16 8
Over 1-1/2 (38) to 2-1/4 (57) incl. 3/8 10
Over 2-1/4 (57) to 6 (150) incl. 1/2 12
Over 6 (150) 5/8 16

The following are examples of acceptable and unacceptable weld profiles.

Note: convexity, C, of a weld or individual surface bead with dimension W shall not exceed the value of the following table unless
otherwise specified.

Width of weld face or surface bead, W Max convexity, C

W ≤ 5/16 in. (8mm) 1/16 in. (2mm)
W > 5/16 in. (8mm) to W < 1 in. (25mm) 1/8 in. (3mm)
W ≥ 1 in. ( 5mm) 3/16 in. (5mm)

WELD_STANDARDS_TAP COMPANY PROPRIETARY AND CONFIDENTIAL Page 8 of 16

TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

Note: Reinforcement R shall not exceed 1/8 in. (3 mm).

7.5 Tubular Connections

Minimum weld sizes and profiles shall be as described in sections 7.3. All welds shall conform to
the following details.

Min L For
E=0.7t E=t E=1.07t
eel 60 t 1.4t 1.5t
ide ≤ 100-110 1.1t 1.6t 1.75t
ide ≥110-1 0 1.2t 1.8t 2.0t
Toe 1 0 t 1.4t Full bevel
bevel bevel 60-90 groove

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TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

Notes:
1. t = thickness of thinner part.
2. L = minimum size.
3. Root opening 0 to 3/16 in. (5mm).
4. Φ = 15° min. Not prequalified for under 30°. or ϕ 60°, loss dimensions (Table 7.3) apply.
5. ee .39.1. for limitations on β= d/D.
6. The Z loss dimension shall be deducted from the distance from the work point to the theoretical weld face to find the minimum
weld size.

Table 7.3
Z Loss dimensions for PJP T-, Y-, and K- tubular connections
Groove Angle Z (in.) Z (mm)
Φ ≥ 60 0 0
60 ϕ ≥ 45 0 0
45 ϕ ≥ 30 1/4 6

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TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

7.4 Tubular Connection Details (continued)

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TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

7.4 Tubular Connection Details (continued)

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TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

Notes:
1. t = thickness of thinner section.
2. Bevel of feather edge except in transition and heel zones.
3. Root opening 0 to 3/16 in. (5mm).
4. Not prequalified for under 30°.
5. Weld size (effective throat) tw ≥ t: Z Loss dimensions s own in Table 7.3.
6. W.P. = work point.

7.4 Tubular Connection Details (continued)

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TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014
8.0 Appendix – Weld Overview
The following is a brief overview of basic welding terminology. For more information, refer to the
ANSI/AWS A2.4, D1.1, and D8.8 standards.

8.1 Joint types

There are five basic types of weld joints:

 Butt joint
 T joint
 Lap joint
 Corner joint
 Edge joint

8.2 Weld types

There are various types of welds that can be applied to basic joints. These include:

Butt Joint T Joint

 Square-groove butt weld.  Fillet weld.
 Bevel-groove butt weld.  Plug weld.
 V-groove butt weld.  Slot weld.
 J-groove butt weld.  Bevel-groove weld.
 U-groove butt weld.  J-groove weld.
 Flare-V-groove butt weld.  Flare-bevel-groove weld.
 Flare-bevel-groove butt weld.  Melt-through weld.

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TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014

Lap Joint
 Fillet weld.
 Plug weld.
 Slot weld.
 Spot weld. Edge Joint
 Bevel-groove weld.  Square-groove weld or butt weld.
 J-groove weld.  Bevel-groove weld.
 Flare-bevel-groove weld.  V-groove weld.
 J-groove weld.
 U-groove weld.
 Edge-flange weld.
 Corner-flange weld.

Corner Joint
 Fillet weld.
 Spot weld.
 Square-groove weld or butt weld.
 V-groove weld. Double Weld Joints
 Bevel-groove weld.  Butt weld.
 U-groove weld.  Bevel weld.
 J-groove weld.  V-groove weld.
 Flare-V-groove weld.  J-groove weld.
 Edge weld.  U-groove weld.
 Corner-flange weld.  Bevel and fillet weld.
 Fillet weld.
 Double fillet weld

WELD_STANDARDS_TAP COMPANY PROPRIETARY AND CONFIDENTIAL Page 14 of 16

TransAmerican Auto Parts Weld Standards
Explorer Pro Comp Chula Vista CA
Rev 1.0 05/22/2014
8.3 Weld terms and symbols
All drawings are prepared and annotated per the ANSI/AWS welding symbol standards. Below
are the basic weld symbols and callout. For further information, refer to AWS A2.4:2012
Standard Symbols for Welding, Brazing, and Nondestructive Examination.

9.0 References
American Welding Society AWS D1.1:2015 Structural Welding Code – Steel.

American Welding Society AWS D8.8M:2014 Specification for Automotive Weld Quality Arc-Welding
of Steel

American Welding Society AWS A2.4:2012 Standard Symbols for Welding, Brazing, and
Nondestructive Examination
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