Confidential. All rights rerved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group.
Parties to a contract can only obtain this standard via the responsible procurement department.
T h e E n g l i s h t r a n s l a t i o n i s b e l i e v e d t o b e a c c u r a t e . I n c a s e o f d i s c r e p a n c i e s t h e G e r m a n v e r s i o n s h a l l g o v e r n .
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1 Scope
This standard applies to the design, layout and quality assurance of arc-welded sheet steel joints which are predominantly subject to dynamic loads.
It compris the following procedures according to DIN EN ISO 4063:
Reference no. Method Code
131 Metal inert-gas welding MIG
135 Metal active-gas welding MAG
141 Tungsten inert-gas welding TIG
for: butt and fillet welds, lap welds, plug welds and special weld types
of: bright uncoated and coated sheet steel as well as of both high-alloyed steels and premium steels; for examples e Section 4.1;
Workpiece thickness 0.5 mm to 6 mm
with: test characteristics of quality level B (high requirement) according to DIN EN ISO 5817, e also DVS specification 0705.
All fusion-welded joints to which this scope is not applicable require the clarification of the responsible engineering departments. Special measures made necessary becau of the component, e.g. change to the quality level for specific imperfections, are permissible and shall be entered in the drawing.
2 Abbreviations and definitions
2.1 Abbreviations
a Calculated throat thickness mm
f1,2Penetrations on sheets 1 and 2 mm
f L Penetration length mm
f St Penetration at the face surface mm or % (of face surface)
F i Joining plane -
h Gap size mm
l Throat length mm
L Length mm
s Throat thickness mm
s1,2Throat thickness with respect to sheets 1 and 2 mm
s N smallest common throat thickness mm
t1Thickness of sheet 1 mm
t2 Thickness of sheet 2 mm
HAZ Heat-affected zone -
Σt Sum total of sheet thickness mm
∅Diameter mm
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2.2 Definitions
FüThe following definitions are valid for the application of this standard:
2.2.1 Weld joint
Joint created by fusion welding. It compris the weld, fusion line, heat-affected zone and unaffected ba material (Figure 1).
1
2
3 4
Legend:
1 = weld
2 = heat-affected zone
3 = fusion line, fusion zone
4 = unaffected ba material Figure 1 – Fusion weld joint
NOTE Weld and fusion line may be identical.
2.2.1.1 Weld
The area where the workpiece(s) is/are joined at the weld joint. The weld compris the ba material and/or the filler metal.
2.2.1.2 Fusion line
Borderline between the ba metal and/or filler material melted during welding and the metal that remains solid.
2.2.1.3 Weld metal
Material that solidified after welding, comprising either the ba material or filler metal and ba material. Some elements in the weld metal can come from casings and/or accessory materials (DIN ISO 857-1).
2.2.1.4 Heat-affected zone HAZ
Area of the ba material that remained solid, but, due to the energy applied during welding, experienced microstructural changes related to temperature.
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2.2.1.5 Unaffected ba material
Area of the ba material that experienced no evident microstructural changes as a result of the energy applied during welding.
2.2.2 Same types of material
Materials which do not differ significantly in terms of their chemical composition and their suitability for welding (DIN 8528-1).
2.2.3 Different types of material
Materials which differ significantly in terms of their chemical composition and their suitability for welding.
3 Gas-shielded arc welding procedure
Gas-shielded arc welding is a form of fusion welding. An electrical arc is ud as the heat source. It burns between the electrode and the workpiece. In this process, the arc and the weld pool are protected from the atmosphere by a shield of protective gas. The classification into the following procedures depends on the electrode type:
3.1 Tungsten inert-gas welding (TIG)
In this procedure, an arc is ignited between a non-consumable tungsten electrode and the workpiece. Argon, helium, mixtures of both and sometimes added active gas, are ud to form the protective atmosphere. The filler metal is (as in the ca of gas welding) fed from the side.
3.2 Gas-shielded metal arc welding (MIG/MAG)
In this procedure, an arc is ignited between the melting end of the wire electrode (filler metal) and the workpiece. The welding current flows via sliding contacts in the electric current guide of the gun to the wire electrode.
When inert gas (low-activity gas, e.g. noble gas such as argon, helium or mixtures of both) are ud as protective atmosphere, this is called metal inert-gas welding (MIG).
When active gas are ud (e.g. CO2, or mixtures containing CO2, or, in some cas, mixtures of CO2 and oxygen), this is called metal active-gas welding (MAG). This procedure is ud to weld unalloyed and low-alloy steels.
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4 General requirements
Welds that are subject to mandatory documentation shall be evaluated according to the relevant type-specific and/or component-specific test specifications (PV).
Deviations with respect to the specified weld geometries and weld layouts shall be detailed in the drawing and verified by testing. They shall be described in test specifications (PV).
Further requirements with respect to gas-shielded arc welding are contained in the following documents: VW 011 06-2 Shielded Arc Welding - Rework on Sheet Metal Connections VW 011 06-3 Gas-Shielded Arc Welding – Part 3: Al Welded Joints
VW 011 42
Welded Seam Repairs on Aluminum Structures – Product Evaluation and
Notes on Procedure
When creating arc-welded sheet steel joints, the greatest possible design strength in accordance with the design goal must be realized while also ensuring sufficient reliability and a favorable cost/quality ratio. For this purpo, every weld joint must be suitable for welding, i.e. the dimensions of the welding equipment and the accessibility of the weld according to DVS 0929 must be taken into consideration for design.
Weldability for rvice of a sheet steel joint is given if the component, on the basis of its design (Section 4.2) and with the material ud (Section 4.1), remains functional (Section 4.3) under the intended operating stress (Figure 2).
Figure 2 – Reprentation of weldability according to DIN 8528-1
4.1
Materials
The following list is not complete.
The following products and materials have good welding properties: a) Cold-rolled flat products made from soft steels for cold forming:
DIN 1623-1 (02.83)1)
DIN EN 10130 Material no. St 12 DC01 1.0330 St 13 DC03 1.0347 St 14 DC04 1.0338
1) DIN 1623-1 was replaced in October 1991 by DIN EN 10130.
Material Welding suitability
Welding capability Manufacturing
Weldability for rvice
Design
Weldability of the part
