automotive aluminium weldingd8.14m-d8.14 (00)

Specificationfor Automotiveand Light TruckComponents WeldQuality—AluminumArc Welding

AWS D8.14M/D8.14:2000An American National Standard

Copyright American Welding Society Provided by IHS under license with AWS Licensee=Shell Services International B.V./5924979112

Not for Resale, 09/16/2005 14:58:13 MDTNo reproduction or networking permitted without license from IHS

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550 N.W. LeJeune Road, Miami, Florida 33126550 N.W. LeJeune Road, Miami, Florida 33126

AWS D8.14M/D8.14:2000An American National Standard

Approved byAmerican National Standards Institute

February 11, 2000

Specification for

Automotive and Light Truck

Components Weld Quality—

Aluminum Arc Welding

Prepared byAWS D8 Committee on Automotive Welding

Under the Direction ofAWS Technical Activities Committee

Approved byAWS Board of Directors

AbstractDefined in this specification are practical tolerances and requirements needed to achieve satisfactory weld quality whendealing with the production volumes associated with automotive structural parts made of aluminum. Gaps in the weldjoints have a significant effect on structural performance and weld quality. Automatic and robotic arc welding requiresspecified part fit-up in the weld joints for consistent weld quality. Therefore, metal stampings and press-formed partsmust be made to produce weld joint fits within the ranges allowed by this specification.

Key Words— Aluminum automotive structures, passenger cars, light trucks, arc welding, aluminum



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Statement on Use of AWS American National Standards

All standards (codes, specifications, recommended practices, methods, classifications, and guides) of the AmericanWelding Society are voluntary consensus standards that have been developed in accordance with the rules of the AmericanNational Standards Institute. When AWS standards are either incorporated in, or made part of, documents that areincluded in federal or state laws and regulations, or the regulations of other governmental bodies, their provisions carrythe full legal authority of the statute. In such cases, any changes in those AWS standards must be approved by thegovernmental body having statutory jurisdiction before they can become a part of those laws and regulations. In allcases, these standards carry the full legal authority of the contract or other document that invokes the AWS standards.Where this contractual relationship exists, changes in or deviations from requirements of an AWS standard must be byagreement between the contracting parties.

International Standard Book Number: 0-87171-591-0

American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126

© 2000 by American Welding Society. All rights reservedPrinted in the United States of America

AWS American National Standards are developed through a consensus standards development process that bringstogether volunteers representing varied viewpoints and interests to achieve consensus. While AWS administers the processand establishes rules to promote fairness in the development of consensus, it does not independently test, evaluate, orverify the accuracy of any information or the soundness of any judgments contained in its standards.

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether spe-cial, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use of, or reliance on thisstandard. AWS also makes no guaranty or warranty as to the accuracy or completeness of any information published herein.

In issuing and making this standard available, AWS is not undertaking to render professional or other services for or onbehalf of any person or entity. Nor is AWS undertaking to perform any duty owned by any person or entity to someoneelse. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the adviceof a competent professional in determining the exercise of reasonable care in any given circumstances.

This standard may be superseded by the issuance of new editions. Users should ensure that they have the latest edition.

Publication of this standard does not authorize infringement of any patent. AWS disclaims liability for the infringementof any patent resulting from the use or reliance on this standard.

Finally, AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.

Official interpretations of any of the technical requirements of this standard may be obtained by sending a request, in writ-ing, to the Managing Director Technical Services, American Welding Society, 550 N.W. LeJeune Road, Miami, FL 33126(see Annex D). With regard to technical inquiries made concerning AWS standards, oral opinions on AWS standards maybe rendered. However, such opinions represent only the personal opinions of the particular individuals giving them. Theseindividuals do not speak on behalf of AWS, nor do these oral opinions constitute official or unofficial opinions or interpre-tations of AWS. In addition, oral opinions are informal and should not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS D8 Committee on Automotive Welding. It must be reviewedevery five years and if not revised, it must be either reapproved or withdrawn. Comments (recommendations, additions, ordeletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed toAWS Headquarters. Such comments will receive careful consideration by the AWS D8 Committee on Automotive Weld-ing and the author of the comments will be informed of the Committee’s response to the comments. Guests are invited toattend all meetings of the AWS D8 Committee on Automotive Welding to express their comments verbally. Proceduresfor appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the TechnicalActivities Committee. A copy of these Rules can be obtained from the American Welding Society, 550 N.W. LeJeuneRoad, Miami, FL 33126.

Photocopy Rights

Authorization to photocopy items for internal, personal, or educational classroom use only, or the internal, personal, oreducational classroom use only of specific clients, is granted by the American Welding Society (AWS) provided that theappropriate fee is paid to the Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923, Tel: 978-750-8400;online: http://www.copyright.com.



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Personnel

AWS D8 Committee on Automotive Welding

T. W. Morrissett, Chair DaimlerChryslerJ. C. Bohr, 1st Vice Chair General MotorsP. Howe, 2nd Vice Chair Bethlehem Steel Corporation

T. R. Potter, Secretary American Welding SocietyR. Baldwin Oxford Automotive

B. J. Bastian Benmar AssociatesW. H. Brafford CMW IncorporatedS. C. Chapple Midway Products Group

*J. F. Hinrichs The Welding-LinkR. W. Jud, DaimlerChryslerF. W. Kern Society of Automotive Engineers

D. R. Kolodziej Ford Motor CompanyS. M. Mapes Interior and Lighting Systems

J. S. Noruk Tower Automotive, IncorporatedJ. P. Osborne Ford Motor CompanyC. F. Padden Ford Motor Company

H. Zhang University of Michigan

AWS D8C Subcommittee on Automotive Arc Welding

J. S. Noruk, Chair Tower Automotive CompanyM. M. Weir, Vice Chair Panasonic Factory Automation

T. R. Potter, Secretary American Welding SocietyB. Altshuller Alcan Aluminum

G. Armstrong Inmet, Division of Multimatic, IncorporatedR. Baldwin Oxford Automotive

B. J. Bastian Benmar AssociatesR. Carlson NAO/CRW

S. C. Chapple Midway Products GroupB. Christy Alcan Aluminum

P. B. Dickerson ConsultantR. M. Dull Edison Welding Institute

G. Gibbs Kaiser Aluminum Center for Technology*H. Gruss Lobdell Emery Manufacturing*R. W. Jud DaimlerChrysler Corporation

*J. F. Hinrichs The Welding-LinkA. P. Lee DOFSCO

G. E. Livingston Budd CanadaK. A. Lyttle PraxairA. Marisca Consultant/Soudco

W. A. Marttila DaimlerChrysler CorporationE. J. Michaud Centerline Ltd.—Special Machinery

*T. W. Morrissett DaimlerChryslerR. P. Munz The Lincoln Electric CompanyH. Serchen Budd Canada Incorporated

T. A. Siewert NISTI. Stol Alcoa Automotive Structures

*Advisor



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Foreword

(This Foreword is not a part of AWS D8.14M/D8.14:2000, Specification for Automotive and Light Truck ComponentsWeld Quality—Aluminum Arc Welding, but is included for information purposes only.)

This specification was developed by the D8C Subcommittee on Automotive Arc Welding of the AWS D8 Committeeon Automotive Welding.

Recent changes in automotive design caused by the desire to reduce fuel consumption have resulted in new automo-tive structures being made of aluminum. AWS D8.8, Automotive and Light Truck Components Weld Quality—Arc Weld-ing addresses only steel. This specification was undertaken to prepare minimum standards for arc welding ofcomponents associated with the body and supporting structural members such as frames, space frames, cradles, and sus-pensions. One objective of the committee was to prepare a specification that would be useful for the smaller suppliers ofautomotive components, who generally have no quality standards of their own, in the establishment of standards for min-imum arc welding quality in their plants.

The weld quality requirements given in this specification provide a workmanship standard to be adhered to, andwhere possible, reflect a relationship to fitness-for-purpose standards. Fitness-for-purpose reflects performance require-ments such as fatigue life, brittle fracture, static strength, and corrosion. This specification does not specifically addressrequired welding and repair procedures except for areas involved with preparation of the weld joint.



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Table of ContentsPage No.

Personnel .................................................................................................................................................................... iiiForeword...................................................................................................................................................................... ivList of Tables................................................................................................................................................................ viList of Figures.............................................................................................................................................................. vi

1. Scope .....................................................................................................................................................................1

2. General Provisions ................................................................................................................................................12.1 Referenced Documents...............................................................................................................................12.2 Application .................................................................................................................................................12.3 Standard Units of Measurement .................................................................................................................12.4 Welding Processes ......................................................................................................................................22.5 Definitions ..................................................................................................................................................22.6 Limitations..................................................................................................................................................32.7 Welding Symbols........................................................................................................................................42.8 Safety Precautions ......................................................................................................................................42.9 Types of Weld Joints and Applicable Welds ..............................................................................................52.10 Joint Thickness Differential........................................................................................................................52.11 Structural Welds .........................................................................................................................................5

3. Requirements.........................................................................................................................................................63.1 Weld Length ...............................................................................................................................................63.2 Weld Location.............................................................................................................................................73.3 Weld Size....................................................................................................................................................73.4 Weld Quality...............................................................................................................................................9

Annex A—Aluminum Alloys Used for Automotive Applications ................................................................................11

Annex B—Aluminum Filler Metal Selection Guide for Structural Automotive Components .....................................13

Annex C—Information Concerning Causes of Discrepancies....................................................................................15

Annex D—Guidelines for Preparation of Technical Inquiries for AWS Technical Committees .................................19

AWS List of Documents on Automotive Welding ........................................................................................................21



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List of Tables

Table Page No.

1 Weld Length Tolerance ..................................................................................................................................72 Weld Evaluation Cross Section Report ........................................................................................................10A1 Typical Aluminum Alloys Used for Automotive Applications....................................................................11A2 Typical Weldable Aluminum Alloys............................................................................................................12A3 Basic Aluminum Alloy Groups....................................................................................................................12B1 Aluminum Filler Metal Selection Guide for Structural Automotive Components ......................................13

List of Figures

Figure Page No.

1 Lap Fillet Weld Leg Requirements for a Gap Condition ...............................................................................22 Examples of Some Discrepancies Found in Arc Welds.................................................................................23 Example of Notching at End of Weld ............................................................................................................34 Suck-Back in Sheet Fillet Weld .....................................................................................................................35 Suck-Back in Overhead Groove Weld ...........................................................................................................36 Minimum Weld Flange Dimensions for Lap Welds.......................................................................................47 Fillet Weld Measurement Criteria ..................................................................................................................58 Bevel-Groove Weld—Partial Joint Penetration..............................................................................................59 Flare-V-Groove Weld .....................................................................................................................................5

10 Flare-Bevel-Groove Weld ..............................................................................................................................611A Arc Plug Weld Profile—Convexity................................................................................................................611B Arc Plug Weld Profile—Depth of Fusion ......................................................................................................611C Arc Plug Weld Profile—Underfill..................................................................................................................611D Arc Plug Weld Geometry ...............................................................................................................................712 Single Fillet Weld in a Slot ............................................................................................................................713 Double Fillet Weld in a Slot...........................................................................................................................714A Illustration of Fillet Weld—Concavity...........................................................................................................814B Illustration of Fillet Weld—Convexity...........................................................................................................815 Groove Weld Size...........................................................................................................................................9



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AWS D8.14M/D8.14:2000

1. ScopeThe purpose of this specification is to provide pro-

cessing recommendations for the minimum quality require-ments necessary for arc welding structural automotiveparts made of aluminum including passenger car, lighttruck and other types of vehicles. In addition, generalprocessing recommendations are made as they relate toattaining required weld quality. See Annex A, Table A1for typical structural components on vehicles made fromaluminum.

2. General Provisions2.1 Referenced Documents

(1) AWS D8.8, Specification for Automotive FrameWelding Quality—Arc Welding

(2) AWS A2.4, Standard Symbols for Welding, Braz-ing, and Nondestructive Examination

(3) AWS A3.0, Standard Welding Terms and Definitions(4) AWS A5.10/A5.10M, Specification for Bare Alu-

minum and Aluminum Alloy Welding Electrodes and Rods(5) AWS A5.32/A5.32M, Specification for Welding

Shielding Gases(6) AWS D1.2, Structural Welding Code—Aluminum(7) Welding Handbook, Volume 3, Eighth Edition,

American Welding Society(8) Welding Aluminum: Theory and Practice, Alumi-

num Association1

(9) ANSI Z49.1, Safety in Welding, Cutting, and AlliedProcesses, published by AWS

(10) AWS F1.1, Methods for Sampling Airborne Parti-cles Generated by Welding an Allied Process

1. AA, 900 19th Street, NW, Washington DC 20006.

(11) AWS F1.2, Laboratory Method for MeasuringFume Generation Rates and Total Fume Emission forWelding and Allied Processes

(12) AWS F1.3, A Sampling Strategy Guide for Evalu-ating Contaminants in the Welding Environment

(13) AWS F1.4, Methods for Analysis of Airborne Par-ticulates Generated by Welding and Allied Processes

(14) AWS F1.5, Methods for Sampling and AnalyzingGases for Welding and Allied Processes

(15) AWS F3.1, Guide for Welding Fume Control(16) Compressed Gas Association2 P-15, “Filling of

Industrial and Medical Nonflammable Compressed GasCylinders”

2.2 Application

2.2.1 This specification is applicable to the design andmanufacture of passenger car, light truck, and similar ve-hicle structures when specified on engineering drawings.

2.2.2 Any requirements deviating from the limits ofthis specification should be designated on the engineer-ing drawings.

2.2.3 Should any conflict occur between specified re-quirements herein and those specified on the engineeringdrawings, the latter has precedence.

2.2.4 Where weld quality limits do not exist, the weldattributes and discrepancies should be specified by thefabricator and/or customer on the basis of required per-formance in service.

2.3 Standard Units of Measurement. This standardmakes use of both the International System of Units (SI)and U.S. Customary Units. The measurements may notbe exact equivalents; therefore, each system must be usedindependently of the other without combining in any way.

2. CGA, 1725 Jefferson Davis Hwy., Arlington, VA 22202-4102.

Specification for Automotive and Light Truck Components Weld Quality—Aluminum Arc Welding



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The standard with the designation D8.14M:2000 uses SIUnits. The standard designation D8.14:2000 uses U.S.Customary Units. The latter are shown within parenthe-sis ( ) or in appropriate columns in tables and figures.

2.4 Welding Processes. This specification covers qualityrequirements for welds made by the gas metal arc weld-ing (GMAW), plasma arc welding (PAW), and gas tung-sten arc welding (GTAW) processes. See Annexes C3and C6 for more information on the GMAW process.

2.5 Definitions

2.5.1 The welding terms used in this specificationshould be interpreted in accordance with the definitionsgiven in the latest edition of AWS A3.0, Standard Weld-ing Terms and Definitions, supplemented by 2.5.2.

2.5.2 The following terms and definitions are not de-fined in AWS A3.0, but are defined as they relate to thisspecification.

gap. The distance or air space between two base compo-nents (see Figure 1). Note, that for butt weld jointsthis distance can be referred to as the root opening.

discrepant weld. A weld that differs from the require-ments of this standard. Even though this weld differs,it still may have useful engineering properties.

meltback. This occurs where the base metal melts backfrom an edge, but does not become part of the weld.This condition, also referred to as button hooks, leavesa void between the weld deposit and the base metal(see Figure 2).

notching. Gouging of the base metal at the ends or edgeof the welded joint (see Figure 3).

skip. An unwelded portion of a designated weld (seeFigure 2).

suck-back. A concave surface on the side of the basemetal opposite the point of weld metal application. Itis caused by the solidification shrinkage (6% by vol-ume) when penetrating a high percentage of the basemetal without complete penetration through the oppo-site side. This is illustrated in Figure 4. It also occursin the overhead position when the weld volume issuch that the gravitational force exceeds the surfacetension. This is illustrated in Figure 5.

Figure 2—Examples of Some Discrepancies Found in Arc Welds

Figure 1—Lap Fillet Weld Leg Requirements for a Gap Condition



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2.6 Limitations

2.6.1 Material. This specification covers the arc weld-ing of aluminum extrusions, castings, forgings, sheet andplate material. See Annex A, Table A1 for a list of themost common structural automotive aluminum alloys.See Annex A, Table A2 for a list of weldable aluminumalloys. See Annex A, Table A3 for categorization of alu-minum alloys based on major alloying elements.

2.6.2 Surface Condition of Aluminum. The surfaceof the aluminum part in the weld area at the time of weld-ing should be free from corrosion products, thick oxide,hydrated oxide, paint, lubricants, and other contaminantsthat would adversely affect the quality. Prior to arc weld-ing, the joint area should be free of detrimental conden-sation, hydrocarbon films, and oxides. Hydrocarbonfilms should be removed by an alkaline solution, vapordegreasing, or solvent wiping. Use caution when han-dling alkaline (caustic) solutions. They can cause chemicalburns. Before use, read and understand the manufacturer’sinstructions, Material Safety Data Sheets (MSDSs), andyour employer’s safety practices.

A chemical solution or abrading with a stainless steelwire brush should be used to remove oxides to minimizeweld metal porosity and ensure adequate joint fusion.The goal is to achieve a uniformly clean surface withminimum oxide thickness.

2.6.3 Joint Considerations

2.6.3.1 To ensure proper joint fit, all parts shouldbe fabricated, positioned, and held in place (e.g., fixtur-ing) for maximum weld quality.

2.6.3.2 Maximum allowable joint gap for specificjoints is determined by the structural performance re-quired in service and the ability to accommodate the gapduring welding. The maximum allowable weld joint gapbetween adjacent members less than 4.0 mm (0.16 in.) inthickness should be one-quarter the thickness of the thin-ner member or 1 mm (0.04 in.) whichever is less. In thecase of heavier gauges above 4 mm (0.16 in.), the gapshould not exceed 1.5 mm (0.06 in.). The gap values listedabove are the maximum recommended because tighterrestrictions may be needed depending on the weldingprocess and joint configuration used. Larger gaps thanspecified can adversely affect weld geometry, quality,and structural performance, i.e., fatigue life, strength.

2.6.3.3 On lap weld joints, the edge trim shouldleave adequate stock so as to not restrict the ability tomake a 1T-leg (T = thickness of the minimum weld flange)fillet weld. See Figure 6 for suggested weld flange basedon thickness.

2.6.4 Welding Equipment. Welding equipment meet-ing the specified welding process requirements should beused. Prior to use in production, the welding equipmentshould be tested and qualified for the specified structure.Failure to do so could result in welding difficulties inproduction, e.g., poor weld quality or equipment prob-lems. See Annex C6 for more information on weldequipment considerations.

Figure 3—Example of Notchingat End of Weld

Figure 4—Suck-Back in Sheet Fillet Weld

Figure 5—Suck-Back inOverhead Groove Weld



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2.6.5 Welding Procedure. Welding proceduresshould be qualified (proven) to consistently produce ac-ceptable welds as per the design requirements.

2.6.6 Filler Metals. Filler metals should conform tothe requirements of AWS A5.10/A5.10M, Specificationfor Bare Aluminum and Aluminum Alloy Welding Elec-trodes and Rods.3 Proper storage of rods and electrodesis essential to avoid contamination which may affecttheir performance. Packages of filler metals should notbe left outdoors or in unheated buildings because thegreater variations in temperature and humidity increasethe possibility of condensation to create hydrated surfaceoxides. The 5000-series of filler metals is especially sen-sitive to moisture pickup. See Annex C4 for informationon filler metal storage.

2.6.7 Shielding Gases. The shielding gas for weldingaluminum should be argon, helium, or a mixture of argonand helium, or any other mixture found acceptable forhigh quality welding. The argon shielding gas (AWSClass SG-A) should have a maximum level of moisturenot exceeding 10.5 ppm (dew point –60°C [–78°F]). Thehelium shielding gas (AWS Class SG-He) should have amaximum level of moisture not exceeding 15 ppm (dewpoint –57°C [–71°F]). These shielding gases are bothcertifiable to AWS A5.32/A5.32M, Specification forWelding Shielding Gases, by the gas supplier by their actof labeling the shielding gas as conforming to the AWSspecification. The act of labeling of the container by the

3. For purposes of brevity, the filler metal classification prefixletters “ER” or “E” have not been included in this specificationfor the referenced filler alloys. Instead, only the AluminumAssociation alloy series or designation has been given.

gas supplier is their certification that the containedshielding gas meets the requirements of the specificationincluding the CGA P-15 Procedure, “Filling of Industrialand Medical Nonflammable Compressed Gas Cylin-ders,” Transport of the gas from the liquid sourcethrough any tubing or compressed gas cylinders, if used,to the welding torch needs to be done in a clean, drytransport environment. Contamination in any of theseconduits or containers may introduce undesirable gasesor vapors which may adversely affect the quality of theweld. Therefore, only clean, metallic conduits or con-tainers with a minimum number of mechanical connec-tions are recommended. See Annex C5 for moreinformation on the proper storage, handling and transportof shielding gases and how to keep them from beingcontaminated.

2.7 Welding Symbols. Welding symbols on productdrawings should be those in the latest edition of AWSA2.4, Standard Symbols for Welding, Brazing, and Non-destructive Examination. Special conditions should befully explained by added notes or details.

2.8 Safety Precautions. Welding, cutting, and allied pro-cesses can be done safely with minimal health risk, pro-vided proper procedures are followed and properprecautions are taken. The primary resource for informa-tion related to welding safety is ANSI Z49.1, Safety inWelding, Cutting, and Allied Processes, available fromthe American Welding Society, 550 N.W. LeJeune Road,Miami, FL 33126. Other excellent sources of informa-tion include the Safety and Health Fact Sheets from AWS,and the several publications related to the sampling andanalysis of welding fume, AWS F1.1–F1.5. Each of thesepublications is available from AWS at the address above.

The heat and ultraviolet radiation emitted from an arcor flame generate varying quantities of solid particulate(fume) and gases, which are unavoidable by-products ofwelding and cutting processes. For aluminum, the majorconstituent of the fume is aluminum oxide, with somesmall amounts of complex particles containing alumi-num-copper, aluminum-magnesium, and other aluminumalloys (depending upon the filler material used). Currentpublished exposure limits for welding fume shall be con-sulted to evaluate any exposure data collected in alumi-num welding operations.

Among the more predominant gases produced duringarc welding of aluminum is ozone. Ozone is uniqueamong contaminant gases as it is formed, not by thermalor chemical reactions, but by the action of a specificwavelength band of ultraviolet (UV) radiation on oxygenmolecules in the arc environment. Ozone-creating radia-tion is found in arcs shielded with argon and where me-tallic elements such as silicon are found in vapor form.Welding variables such as voltage and current (as it influ-

NOTE: Weldments with welds longer than 150 mm (6 in.) or withmultiple welds may require larger welds and wider flanges.

Figure 6—Minimum Weld Flange Dimensions for Lap Welds

T (Sheet Thickness,mm [in.])

WF (Minimum Weld Flange,mm [in.])

Less than 4 (0.16)4–6 (0.16–0.24)Greater than 6 (0.24)

10 (0.39)T + 4 (0.16)T + 6 (0.24)



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ences the type of metal transfer), and the total weldingfume level also affect the amount of UV radiation gener-ated which can form ozone.

In aluminum welding, higher levels of ozone may bepresent when using silicon-alloyed filler alloys such as4043 and where 100% argon is used for shielding. Theuse of magnesium-containing wires (5000-series), he-lium, or nitric oxide additions in the shielding gas willreduce the amount of ozone generated but will increasethe level of welding fumes. Since many variables whichaffect welding fume and gas generation may be unique toa specific welding application, it is important to be awareof potential exposure guidelines/limits and have mea-surements taken by a qualified safety/health professional.

Aluminum fine particles in the air or accumulated indry exhaust/filtering systems can explode. Therefore, forthe cases when portions of welds have to be removed andrewelded (e.g., excessive convexity) make provisions toensure safe handling of aluminum chips.

2.9 Types of Weld Joints and Applicable Welds(1) Fillet weld. See Figure 7.(2) Square-groove weld.(3) V-groove weld.(4) Bevel-groove weld. See Figure 8.(5) U-groove weld.(6) J-groove weld.(7) Flare-V-groove weld. See Figure 9.(8) Flare-bevel-groove weld. See Figure 10.(9) Plug weld. See Figure 11D.

(10) Single fillet weld in a slot. See Figure 12.(11) Double fillet weld in a slot. See Figure 13.

2.10 Joint Thickness Differential. The thickness differ-ential of the components to be welded should be kept to aminimum. When thicknesses need to be different for lapjoints it is good practice to try to weld “thin to thick,”i.e., put thinner sheet on top. On butt joints with differingthickness the arc should be directed into the thicker part.

2.11 Structural Welds

2.11.1 Critical Welds. These are welds where failurewould affect the structural integrity of the product whenused in normal operation. These welds should be notedon the engineering drawings.

2.11.2 Federal Welds. These welds require complianceto the Federal Motor Vehicle Safety Standards. Thesewelds should be so designated on engineering drawings.

Figure 7—Fillet WeldMeasurement Criteria

Figure 8—Bevel-Groove Weld—Partial Joint Penetration

Figure 9—Flare-V-Groove Weld



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2.11.3 Normal or Noncritical Welds. These arewelds where failure would not seriously affect normaloperation of the product. These welds do not require spe-cial designation.

3. Requirements3.1 Weld Length

3.1.1 Unless specifically noted on engineering drawings,the minus tolerance shown in the Table 1 should apply.

3.1.2 Any portion of a weld not meeting the individualquality requirements shall not be included in the effectiveweld length.

3.1.3 Welds may be permitted to be longer than speci-fied, provided that the part configuration remains func-tional, meets targeted dimensional tolerances and satisfiesthe performance specifications.

Figure 10—Flare-Bevel-Groove Weld

Figure 11A—Arc PlugWeld Profile—Convexity

Figure 11B—Arc PlugWeld Profile—Depth of Fusion

Figure 11C—Arc PlugWeld Profile—Underfill



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3.2 Weld Location

3.2.1 Any portion of the weld off-seam or off-jointshall not be included in the effective weld length.

3.2.2 Where a specified weld start or stop location isgiven, the start or stop points of the weld should bewithin 6 mm (1/4 in.) of those shown on the drawing for

welds under 150 mm (6 in.) and within 13 mm (1/2 in.)for welds over 150 mm (6 in.) and longer.

3.3 Weld Size

3.3.1 Fillet Welds

3.3.1.1 Figure 7 identifies the nomenclature whichdescribes the cross section of a T-fillet. Figures 14A and14B illustrate both convex and concave fillet welds in lapjoints.

TOP DIAMETER (T.D.) = H.D. + 3 mm (1/8 in.) (MIN)HOLE DIAMETER (H.D.) = 5 × T1 (MIN)INTERFACE DIAMETER (I.D.) = 4 × T1 (MIN, IF T2 – T1 < [T1 × 1.5])

Figure 11D—Arc Plug Weld Geometry

Figure 12—Single Fillet Weld in a Slot

Metal Thicknessmm (in.)

Slot Width (W)mm (in.)

Slot Length (L)mm (in.)

0.7–3 (0.03–0.12)0.3–5 (0.12–0.20)

10 (3/8)13 (1/2)

25 -0(1)/032 (1-1/4)

Figure 13—Double Fillet Weld in a Slot

Metal Thicknessmm (in.)

Slot Width (W)mm (in.)

Slot Length (L)mm (in.)

0.7–3 (0.03–0.12)0.3–5 (0.12–0.20)

13 (1/2)16 (5/8)

25 -0(1)/032 (1-1/4)

Table 1Weld Length Tolerance

Specified Lengthmm (in.)

Minus Tolerancemm (in.)

Up to 25 (1)Over 25 to 150 (1 to 6)

Over 150 to 300 (6 to 12)Over 300 (12)

0 (0)6 (1/4)13 (1/2)

13* (1/2)

*For welds over 300 mm (12 in.) in normal or noncritical locations, anadditional 13 mm per 300 mm (1/2 in. per 12 in.) of weld is permissible.



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3.3.1.2 The length of the legs of a fillet weld oneach side of the joint determines the fillet size and shouldconform to the following dimensions:

(1) The minimum leg size should be equal to ninetypercent of the thickness of the thinner material being welded.

(2) When gaps are present, the leg should be in-creased by the width of the gap (see Figure 1).

3.3.1.3 The weld throat thickness should conformto the following:

(1) The minimum measured effective throat thicknessshould not be less than 60% of the thinner material beingwelded (see Figure 7).

(2) When applicable, convexity limits should be spec-ified (see Figure 14B). Concavity will be limited by throatrequirements.

3.3.2 Welds in Butt Joints

3.3.2.1 The types of welds in butt joints are listedin 2.9.

3.3.2.2 The effective weld size should be equal toor exceed 90% of the thickness of the thinner materialbeing joined.

3.3.2.3 No limit should be set on the height of theweld reinforcement or convexity, if all other provisionsof this specification are satisfied and the part remainsfunctional and meets the performance specifications (seeFigure 15).

3.3.2.4 The joint penetration should extend to thejoint root, except as 3.3.2.2 applies (see Figure 7).

3.3.2.5 Weld size and definitions for flare-bevel-and flare-V-groove welds should be used as shown inFigures 9 and 10.

3.3.3 Plug and Slot Welds

3.3.3.1 Depth of Fusion. The minimum depth offusion should be 20% of the thickness of the bottommember (see Figure 11D).

3.3.3.2 Depth of Fill. The effective depth of fillshould be the thickness of the thinner material beingjoined (see Figure 11B).

3.3.3.3 Weld Profile. The weld profile should con-form to the following provisions:

(1) The maximum reinforcement should not exceed3 mm, unless otherwise specified on the drawing (seeFigure 11A), and

(2) Any underfill requirement should be specified onthe drawings (see Figure 11C).

3.3.3.4 Weld Diameters. The following minimumdimensions should be observed when welding arc plugand slot welds:

(1) Plug Welds. The top diameter (weld size) shouldbe at least 3 mm (1/8 in.) larger than the hole size. Theinterface diameter (weld size) should be at least fourtimes T1, where T1 is the thickness of the thinner materialbeing welded (see Figure 11D). The hole should be fivetimes T diameter if the hole is in the thinner member andthe thickness differential is less than one and a half timesT. All other combinations should be experimentally qual-ified prior to production.

Figure 14A—Illustration ofFillet Weld—Concavity

Figure 14B—Illustration ofFillet Weld—Convexity



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(2) Slot Welds. Single-side slot welds on material-thicknesses of 3 mm (1/8 in.), or less, should have a slotwidth of at least 10 mm (0.39 in.) and a minimum weldlength of 25 mm (1 in.). Stock thicknesses over 3 mm(0.12 in.) for single-side slot welds should have a mini-mum slot width of 13 mm (1/2 in.) and a minimum weldlength of 32 mm (1-1/4 in.) (see Figure 12). A double-sided slot weld on material thicknesses of 3 mm (0.12 in.)or less, should have a slot width of at least 13 mm (1/2 in.)and a minimum weld length of 25 mm (1 in.) on eachof the two sides of the slot. A double-sided slot weldon stock thicknesses over 3 mm (0.12 in.) should have aslot width of at least 16 mm (0.63 in.) and a minimumweld length of 32 mm (1-1/4 in.) on each of the twosides of the slot (see Figure 13). See Figure 1 for arc welddiscrepancies.

3.4 Weld Quality. The ability of a weld to perform inservice determines the quality required. Weld quality canbe determined by visual and/or metallographic inspectionof a cross section. See Figure 2 for arc weld discrepan-cies. See Table 2 for an example of a cross section report.Unless otherwise specified, the following discrepanciesshould not be permitted in welds:

3.4.1 Undercut. A weld is discrepant if the parentmetal is undercut by more than 10% of its thickness formore than 20% of the length of weld or within the first13 mm (1/2 in.) of the ends of the welds.

3.4.2 Craters. Weld craters should not be considereda part of the designated weld length unless they are filledand meet all the requirements of this specification.

3.4.3 Cracks. Cracks should not be permitted in theeffective weld length unless allowed by the engineeringdrawing. See Annex C1 for more information.

3.4.4 Porosity

3.4.4.1 Surface Porosity. Individual pinholes, sep-arated by at least their own diameter, and other scatteredsurface porosity should be permitted. The total length ofporosity (sum of diameters) should not exceed 6.4 mm inany 25 mm (1/4 in. in any 1 in.) of weld. The maximumpinhole diameter should not exceed 1.6 mm (1/16 in.).See Annex C2 for more information.

3.4.4.2 Internal Porosity. Internal porosity shouldnot exceed 15% of the area of the weld being examined.

3.4.5 Inclusions. Inclusions greater than 1.6 mm(1/16 in.) diameter should not be permitted.

3.4.6 Burn-Through. Holes caused by meltingthrough the base metal should not be permitted.

3.4.7 Meltback. Meltback (button hooks) in lap filletwelds should not exceed the stock thickness at top andshould decrease to zero at the root of the joint (see Figure 2).Complete fusion should be obtained at the root of the joint.

3.4.8 Notching. Notching or gouging of the basemetal at the ends or at the edge of the joint should not bepermitted (see Figure 3).

3.4.9 Root Concavity. A concave root surface (suck-back) on the side of the base metal opposite the weld metalis permitted. This concavity should not exceed 0.8 mm(1/32 in.) and reinforcement should be added to the weldwith a height equal to the concavity dimension.

3.4.10 Combination of Discrepancies. The presenceof more than one of the above discrepancies in any weldshould not be permitted if any one of the discrepancies(inclusions, undercut, porosity, or meltback) is at themaximum permissible limit. The total length of imper-fections in any cross section should not exceed 0.2 timesthe metal thickness.

Figure 15—Groove Weld Size



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AW

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8.14M/D

8.14:2000

10

Table 2Weld Evaluation Cross Section Report

PartNumber

Micro #Photo #

ThinnestMembermm (in.)

RootOpeningmm (in.)

MinimumSection

dimensionmm (in.)

MinimumFillet

Leg Length0.9 T

MeasuredLeg Length

mm (in.)

MeasuredLeg Length

mm (in.)

Depthof

FusionGeometric

Discrepancies Discrepancies

ConformityWith

AWS D8.14

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Shell S

ervices International B.V

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ot for Resale, 09/16/2005 14:58:13 M

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AWS D8.14M/D8.14:2000

Annex A

Aluminum Alloys Used for Automotive Applications

(This Annex is not a part of AWS D8.14M/D8.14:2000, Specification for Automotive and Light Truck ComponentsWeld Quality—Aluminum Arc Welding, but is included for information purposes only.)

Table A1Typical Aluminum Alloys Used for Automotive Applications

Inner and Outer Body Panels: 2008, 2010, 2036, 3004, 5052, 5182, 5754, 6009, 6010, 6016, 6022, 6111

General Structural Components: 6005, 6005A, 6009, 6061Extrusions 6063, 6082, 7005Luggage racks, air deflectors 6463Spare tire carrier parts 6061

Bumper Components:Ace bars 5052, 6009,Reinforcements 6009, 6061, 7003, 7004, 7021, 7029Brackets 6009, 7021

Seats:Shells 7036, 6010Headrest bars 7116, 7129Tracks 6010, 5182, 5754, 6009

Load Floors: 2036, 5182, 5754, 6009

Wheels: 5454, 6061, A356.0

Suspension Parts: 6061 (forgings)

Drive Shaft: 6061 (tube), aluminum metal matrix alloys

Drive Shaft Yokes: 6061 (forgings and impact extrusions)

Engine Accessory Brackets and Mounts: 5454, 5754

Sub-Frames and Engine Cradles: 5454, 5754, 6061, 6063

Miscellaneous:Radiator tubes; heater cores; radiator,heater and evaporator fins; oil coolers;heater and air conditioner tubes 3003Radiator, heater and evaporator fins 3005Condenser tubes 3102Condenser and radiator fins 7072



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Table A2Typical Weldable Aluminum Alloys

Aluminum alloys suitable for arc welding:

2036 30045052518254545754

60052, 6005A60096010

260162

260222

606160636082

261112

6463

700370047005

Aluminum alloys not considered suitable for arc welding:

20082010

70217029

7116

General Note:1. Special care is required.

Table A3Basic Aluminum Alloy Groups

Major Alloying Elements Designation1

99.0% Min. AluminumCopperManganeseSiliconMagnesiumMagnesium and SiliconZinc

1xxx2xxx2

3xxx4xxx5xxx6xxx2

7xxx2

General Notes:1. Aluminum Association Designations2. Heat-treatable



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AWS D8.14M/D8.14:2000

Annex B

Aluminum Filler Metal Selection Guide for Structural Automotive Components


Table B1Aluminum Filler Metal Selection Guide for Structural Automotive Components

For Welding ➛These Alloys ➛

203650525454

51825754

6005A6005A

60616063608261166463

60096010611160166022

Al-SiCastings

Al-MgCastings

700370047005

ToTheseAlloys

319.0356.0443.0

511.0512.0513.0514.0535.0

7003, 7004, 7005

NR NR53565183

53565183 NR NR 4043

51835356

55565183

Al-Mg Castings511.0, 512.0, 513.0,

514.0, 535.0NR 5356

53565183 5356 NR

NR

40435356

51835356

Al-SiCastings

356.0443.0 4145

40434010 NR

40434010

43404010 4145

40434010

319.041452319 4043 NR

41454043

41454043

41454043 4145

6009, 6010, 61116016, 6022

4145 5356 5356 4043 4043

6005, 6005A,6061, 6063,

6082, 6116, 64634145 5356

40435356 5356

5183

5182, 5754 NR 535653565183

5042, 5454NR

535651835554

203641452319

Notes:1. NR = Not recommended.2. Filler alloy 4047 may be interchanged with 4043 filler alloy.3. Filler alloy 5556 may be interchanged with 5183 filler alloy.4. Filler alloys 5356, 5185 and 5556 are not recommended for sustained elevated temperature service above 66°C (150°F).5. AWS filler metal classifications prefix letters “ER” and “R” have not been included.6. Suitability of filler metal/base metal combinations should be chosen based on performance criteria.

➛



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AWS D8.14M/D8.14:2000

C1. Weld CrackingMolten aluminum shrinks about 6% in volume during

solidification, so it is much more prone to the develop-ment of crater cracks at weld termination than ferrouswelds. The weld pool often needs to be tapered down insize before extinguishing the arc to avoid the terminationcrater crack formation. Weld termination on a flat surfaceof a previous weld or base metal is better than in a grooveor fillet, so as to reduce the surface tension forces re-straining the weld metal from flowing to the center of thecrater.

Underbead cracking can occur when the weld pene-tration is 80–99% of the thickness of the sheet, since theremaining unmelted metal does not possess sufficientstrength to withstand the tensile forces from the thermalexpansion. Lesser penetration or complete joint penetra-tion is much preferred—especially with heat treatablealuminum alloys. Thermal expansion and shrinkagestresses can also cause microscopic underbead crackingin thicker materials. Concave surface contours and largeweld beads contribute to the underbead cracking.

Transverse oscillation of a gas metal arc in a fillet orlap joint with the bottom member being thin sheet can beparticularly susceptible to this underbead cracking. Spi-raling of the electrode exiting the gun for relatively thickparts (≥ 4 mm (0.16 in.) can create the same situation.

Constant current or constant energy power is pre-ferred for aluminum, when the arc is oscillating, toobtain the most uniform penetration control. Another as-pect of the constant current type power has been its abil-ity to perform well at very high welding speeds (over2500 mm/min [100 in./min]) because of its slow reactiontime when encountering sudden changes in the joint. Thefaster reacting constant voltage power is sensitive to

burrs or contaminants and results in skips in the weld atspeeds over 1525 mm/min (60 in./min). For thinner ma-terials, constant arc length control is highly desirable, es-pecially with robotic arm welding systems. Dependingon the type of power source, this function can beachieved with constant voltage, constant current or acombination of both. In most cases the power sourcesmodulate (or pulse) the current.

C2. PorosityThe main cause of porosity in aluminum welds is the

presence of hydrogen in the weld atmosphere. Hydrogendissolves very rapidly in molten aluminum. As the weldcools, hydrogen comes out of solution again. If the weldsolidifies rapidly or is in a position, such as overhead,that prevents the gas from evolving from the weld metal,the entrapped hydrogen results in porosity.

The primary sources of hydrogen are moisture andhydrocarbons. It is present in the form of:

(1) Hydrated oxide on base and/or filler metal fromimproper storage

(2) Inadequate inert gas shielding in a humid atmo-sphere

(3) Moisture in the inert gas(4) Residual forming or machining lubricants in the

joint area(5) Residual mill lubricants on the base metal or

poorly cleaned filler material

C3. GMAW Arc TypeA “spray” arc is preferred when welding aluminum.

Globular transfer can result in excessive porosity, poor

Annex C

Information Concerning Causes of Discrepancies(This Annex is not a part of AWS D8.14M/D8.14:2000, Specification for Automotive and Light Truck Components

Weld Quality—Aluminum Arc Welding, but is included for information purposes only.)



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fusion and weld spatter. On material under 3 mm (1/8 in.)thick, pulsed DC(EP) power is used advantageously toprovide the “spray” arc at lower average welding current,with a specific electrode size than can be obtained with aconstant amperage machine. Thus, thinner material canbe welded with that electrode size. A further advantageof pulsed power is that a larger electrode diameter (0.9 or1.2 mm [0.035 or 0.045 in.]) may be used in place of0.8 mm (0.030 in.) diameter wire to weld a specificthickness which provides improved electrode feedingcharacteristics.

C4. Filler Metal Storage

C4.1 The 5000 series (A1-Mg) filler alloys are very sus-ceptible to the development of a hydrated oxide film ifexposed to a rapid temperature increase (over the dewpoint) which could result in condensation on the wiresurface. Thus, aluminum should be stored in a dry,heated area to maintain a satisfactory product.

C4.2 The spool on the electrode feeder should be en-closed to avoid contamination of the aluminum from dustand metallic fumes in the shop atmosphere. If the spoolis left on the feeder for shifts between usage, the installa-tion of a small resistance heater on the base inside the en-closure can maintain a low relative humidity so as toavoid surface oxide hydration of the electrode whenwelding is not in progress.

C5. Inert Gases

Welding grade argon gas is universally used for gastungsten arc welding of aluminum with AC power. Amix of 90–95% helium with 10–5% argon (AWS ClassSG-HeA-5 or -10) is common for DCEN GTAW. Argonand Argon/Helium mixtures are the most commonchoice for gas metal arc welding with DCEP on alumi-num sheet. The 5000-series (A1-Mg) electrode alloysusually develop a metallic oxide “smut” on the weld sur-face and an argon-helium mixture is often used for thismaterial. The gas mixture provides a wider penetrationpattern to prevent “smut” from inhibiting good root fu-sion, as well as to permit a wider tolerance for aligningthe arc in the joint. Where primary power fluctuations areprevalent, a mixture containing from 50%–75% heliumprovides the widest tolerance for variations in the weld-ing current and voltage so as to maintain sound welds. Amix of 2 parts helium to 1 part argon (67% He–33% Ar)(AWS Class SG-HeA-33) has been found to work verywell with the 5000-series aluminum alloys when GMAwelding. One should be aware, however, that the difficul-

ties of arc initiation with GMAW increase proportionallywith the increase in helium in the shielding gas.

C5.1 Shielding Gas for the Gas Metal Arc WeldingProcess—General Recommendations

C5.1.1 For high quality welding, the purity of the gasshould have these levels of impurities controlled:

(1) Oxygen less than 5 ppmv(2) Nitrogen less than 15 ppmv(3) Hydrocarbons, less than 1 ppmv(4) Carbon dioxide less than 3 ppmv(5) Moisture less than the maximum level specified in

AWS A5.32/A5.32M for the specific AWS Class ofshielding gas.

Higher levels of purity may be required for certainapplications.

C5.1.2 To ensure the quality of incoming shieldinggas, it is highly recommended to (1) purchase shieldinggas which conforms to the AWS A5.32/A5.3M, Spec-ification for Welding Shielding Gases, or (2) require thesupplier to provide certificates of compliance that verifythat the shielding gas shipped meets the specified limits.This certificate should be based on actual tests carriedout on “material that is representative of that beingshipped.”

C5.1.3 Whenever setting up for production, considerthe amount of GMA welding and amounts of shieldinggas to support it. With higher consumption rates (e.g.,10 000 m3 [35 000 ft3] per month) it is highly recom-mended to use tanks that contain liquefied argon gas in-stead of a battery of cylinders with compressed gas. Inmany cases this affords more economical, purer andmore consistent quality of shielding gas.

C5.1.4 When using shielding gas from compressedcylinders, it is recommended to use batteries of com-pressed cylinders over single ones. Unless the consump-tion rates are very low, use of batteries of cylinders willafford more consistent gas quality over time.

C5.1.5 To avoid “back air diffusion” into empty tanksand erroneous reading on rotometer type f lowmeters/regulators, which operate at gas pressures differ-ent from those to which they have been calibrated, do notuse gas tanks whose pressure falls below 0.76 MPa(110 psi). Failure to follow this recommendation mayresult in contaminated gas and/or use of erroneous flowrates during welding.

C5.1.6 When using flow-meters/regulators (e.g., ro-tometer) to set and control the flow rate of the shieldinggas during welding, always ensure that the flow-metersare operated at the pressures to which they have been cal-ibrated. Since the gas pressure in a transmission linedrops as a function of distance from the pressurized gas



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source, placement of flow-meters away from this sourcewill cause misleading values to occur. To prevent this,make sure the gas line from source to flowmeter is sizedto prevent a large pressure drop before the flowmeter.Then place the flowmeter within 1.5 m (5 ft) of the sole-noid to minimize gas surges at the weld starts.

C5.1.7 To avoid “back air diffusion” and contamina-tion of the internal walls of the gas transmission lines,between the main source of shielding gas (i.e., liquefiedtanks, batteries of gas cylinders) and the GMA weldingstation, it is highly recommended to keep these linespressurized between 0.48 MPa (70 psi) and 0.69 MPa(100 psi). To drop the calibrated pressure (e.g., 0.31 MPaor 45 psi) of the flow meter controller, use pressure regu-lators.

C5.1.8 For maximized cleanliness of the shielding gasand integrity of its transmission to the welding station(s),it is recommended to construct the transmission lineusing austenitic stainless steel pipes whose ends are man-ually GTA welded with filler wire, using butt type joints.The use of socket type joints is not recommended be-cause it creates entrapment areas (crevices) for contami-nants within the line. Once contaminants (e.g., watercondensation) are introduced into the line, it becomesvery difficult to remove or “flush” them out. In addition,the line should be GTA welded using qualified manualwelding procedures, which include joint preparationsthat ensure a tightly abutting joint upon assembly. Al-though many welding facilities use other materials fortheir transmission lines (e.g., copper, steel, or plastic)and in many cases do not maintain the proper pressure, inthe long run the recommended approach will yield betterand more consistent GMA weld quality.

C5.1.9 To prevent “back air diffusion” and contam-ination of the gas transmission and flexible lines, it isrecommended to isolate the system from the shop envi-ronment whenever welding stops for more than twohours. This can be accomplished by keeping the trans-mission line under pressure while shutting-off its endwith the aid of a hand operated or solenoid valve while“protecting” the flexible gas line with a low continuouspurge of shielding gas or a shut-off solenoid valve, lo-cated close to the welding torch.

C5.1.10 Where threaded fittings are used (e.g., valves,regulators, and gauges), they should be straight andnever tapered (e.g., NPT fittings) and rely on metal tometal seal without any sealing aids (e.g., pastes, tapes).

C5.1.11 Prior to assembly and installation, the pipesshould be cleaned internally with an appropriate solventand dried. To remove contaminants, the completed trans-mission line will have to be evacuated until the vacuum“stabilizes” to a constant value. Next the line should be

purged with shielding gas and the compositions of incom-ing and exiting gas tested for transmission effectiveness.

C5.1.12 The gas transmission system should use pres-sure regulators/flowmeters with brass or stainless steelbodies and diaphragms.

C5.1.13 As much as possible, avoid GMA welding inareas that have airborne water or hydrocarbon mist.Therefore, it is recommended to a) avoid location ofGMA welding stations next to systems that emit such air-borne substances (e.g., steam, solvents, and machiningcoolants), b) use collection hoods and exhaust the airaround/about these systems at rates that are higher thanthe rates set at the welding stations. This will minimizeintroducing hydrogen into the weld.

C5.1.14 Develop and institute in the welding facility asystem of “routine maintenance” which includes periodicvisual inspection of gas transmission lines and their con-nections as well as pressure and leak testing of the system.

C6. GMAW Equipment FeaturesC6.1 Torch. Since aluminum is a highly conductive

material, resistance heating of the electrode does not oc-cur. Also aluminum oxide is a dielectric material, so thatthe more points of contact there are between the elec-trode and contact tube the less chance there is for arcingfrom the surface of the electrode to the inside diameter ofthe contact tube. Thus, a 100 to 150 mm (4 to 6 in.) longcontact tube is much preferred over the very short contacttubes used with the ferrous electrodes in order to providelong contact tube life without “burn-backs.”

C6.2 Electrode Drive Rolls. The drive roll contourmost desirable for aluminum is a “U” groove with radi-used corners on both the top and bottom roll for long lifeand uniform feeding. A polished drive roll surface alsoreduces aluminum build up. Knurled drive rolls dig intothe soft aluminum surface and create aluminum particleswhich build up and are carried into the contact tube (es-pecially in automated systems where the feed rolls are lo-cated above the torch) to create arcing, erratic feedingand “burn-backs.” V-shaped or a flat-to-V combinationprovide only linear contact and aluminum build-up usu-ally occurs along these linear contacts so as to roughenthe aluminum electrode and create erratic feeding.

C6.3 Liners and Guides. All liners and guidesthrough which the aluminum electrode is fed should benon-metallic to avoid scratching the wire.

C6.4 Type of Wire Feeder. The preferred type ofelectrode feeding system depends upon the electrode di-ameter, the length of the conduit from the feeder to the



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torch, and the degree of manipulation of the torch (as inrobotic versus stationary). Three types are discussed:push-type, pull-type, and push-pull types.

C6.4.1 Push-Type. The push-type wire feeder is gen-erally limited to feeding 1.6 mm (1/16 in.) diameter alu-minum electrode and larger, although 1.2 mm (0.045 in.)diameter 5000-series aluminum can often be fed satisfac-torily when great care is taken to reduce cable friction.

C6.4.2 Pull-Type. The pull-type wire feeder is nor-mally preferred for 1.2 mm (0.045 in.) diameter alumi-num electrode and smaller. An exception could be a

stationary machine torch with the drive rolls in closeproximity.

C6.4.3 Push-Pull Type. The push-pull type wirefeeder can be used in place of the pull-type and is gener-ally preferred when the spool pay-off is 3 m (10 ft) ormore distant from the torch. For robotic operations wherethe conduit is subjected to bending and twisting, the“pull” feeder should supply the main drive power andspeed control (i.e., constant speed) while the pushingfeeder should be set-up as the “shove” (i.e., constanttorque).



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AWS D8.14M/D8.14:2000

D1. IntroductionThe AWS Board of Directors has adopted a policy

whereby all official interpretations of AWS standardswill be handled in a formal manner. Under that policy, allinterpretations are made by the committee that is respon-sible for the standard. Official communication concern-ing an interpretation is through the AWS staff memberwho works with that committee. The policy requires thatall requests for an interpretation be submitted in writing.Such requests will be handled as expeditiously as possi-ble but due to the complexity of the work and the proce-dures that must be followed, some interpretations mayrequire considerable time.

D2. ProcedureAll inquiries must be directed to:

Managing Director, Technical ServicesAmerican Welding Society550 N.W. LeJeune RoadMiami, FL 33126

All inquiries must contain the name, address, and af-filiation of the inquirer, and they must provide enough in-formation for the committee to fully understand the pointof concern in the inquiry. Where that point is not clearlydefined, the inquiry will be returned for clarification. Forefficient handling, all inquiries should be typewritten andshould also be in the format used here.

D2.1 Scope. Each inquiry must address one single pro-vision of the Standard, unless the point of the inquiry

involves two or more interrelated provisions. That provi-sion must be identified in the Scope of the inquiry, alongwith the edition of the standard that contains the provi-sions or that the Inquirer is addressing.

D2.2 Purpose of the Inquiry. The purpose of the inquirymust be stated in this portion of the inquiry. The purposecan be either to obtain an interpretation of a Standard re-quirement, or to request the revision of a particular provi-sion in the Standard.

D2.3 Content of the Inquiry. The inquiry should beconcise, yet complete, to enable the committee to quicklyand fully understand the point of the inquiry. Sketchesshould be used when appropriate and all paragraphs, fig-ures, and tables (or the Annex), which bear on the in-quiry must be cited. If the point of the inquiry is to obtaina revision of the Standard, the inquiry must provide tech-nical justification for that revision.

D2.4 Proposed Reply. The inquirer should, as a pro-posed reply, state an interpretation of the provision that isthe point of the inquiry, or the wording for a proposedrevision, if that is what inquirer seeks.

D3. Interpretation of Provisions of the Standard

Interpretations of provisions of the Standard are madeby the relevant AWS Technical Committee. The secre-tary of the committee refers all inquiries to the chairmanof the particular subcommittee that has jurisdiction overthe portion of the Standard addressed by the inquiry. The

Annex D

Guidelines for Preparation of Technical Inquiriesfor AWS Technical Committees




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subcommittee reviews the inquiry and the proposed replyto determine what the response to the inquiry should be.Following the subcommittee’s development of the re-sponse, the inquiry and the response are presented to theentire committee for review and approval. Upon approvalby the committee, the interpretation will be an official in-terpretation of the Society, and the secretary will transmitthe response to the inquirer and to the Welding Journalfor publication.

D4. Publication of InterpretationsAll official interpretations will appear in the Welding

Journal.

D5. Telephone InquiriesTelephone inquiries to AWS Headquarters concerning

AWS Standards should be limited to questions of a gen-eral nature or to matters directly related to the use of theStandard. The Board of Directors’ Policy requires that all

AWS Staff members respond to a telephone request foran official interpretation of any AWS Standard with theinformation that such an interpretation can be obtainedonly through a written request. The Headquarters Staffcan not provide consulting services. The staff can, however,refer a caller to any of those consultants whose names areon file at AWS Headquarters.

D6. The AWS Technical CommitteeThe activities of AWS Technical Committees in regard

to interpretations, are limited strictly to the Interpretationof provisions of Standards prepared by the Committee orto consideration of revisions to existing provisions on thebasis of new data or technology. Neither the committeenor the Staff is in a position to offer interpretive or con-sulting services on: (1) specific engineering problems, or(2) requirements of Standards applied to fabrications out-side the scope of the document or points not specificallycovered by the Standard. In such cases, the inquirershould seek assistance from a competent engineer experi-enced in the particular field of interest.



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AWS D8.14M/D8.14:2000

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AWS List of Documents on Automotive Welding

The following is a list of documents prepared by the AWS D16 Committee on Robotics and Automatic Welding:

AWS Designation Title

D8.6-77 Standard for Automotive Resistance Spot-Welding Electrode

D8.7-88 Recommended Practices for Automotive Weld Quality—Resistance Spot Welding

D8.8-97 Specification for Automotive Frame Welding Quality—Arc Welding

D8.9-97 Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behaviorof Automotive Sheet Steel Materials

D8.14M/D8.14:2000 Specification for Automotive and Light Truck Components Weld Quality Aluminum Arc Welding

For ordering information, contact the AWS Order Department, American Welding Society, 550 N.W. LeJeune Road,Miami, FL 33126. Telephones: (800) 334-9353, (305) 443-9353, ext. 280; FAX (305) 443-7559.



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