DAIMLERCHRYSLER CORPORATION Document Number: PS-9172<S>

Process Standard Date Published: 2006-04-10

Category Code: D-1 Change Level: D
EASL Requirement: No
RESTRICTED: No

BODY REPROCESS PROCEDURE FOR RESISTANCE SPOT WELDS

1.0 GENERAL

1.1 Purpose of the Standard

This standard specifies the acceptable "Body" reprocess procedures for resistance spot welds that do not
meet the requirements of Process Standard PS-10947<S>, PS-9471<S> (PS-1682<S> if called out on the
detail assembly, CATIA drawings, weld only drawings or weld releases).

A shielded section <S> in this standard applies to safety welds as designated on the welding releases. In
this situation, the safety weld must comply with the requirements of EM-10001<S> ("Shield" Requirements
- Corporate Assembly Plants), EM-10002<S> ("Shield" Requirements - Corporate "Internal Supplier"
Plants), and EM-10003<S> ("Shield" Requirements - "External" Supplier" Plants) as shown in the possible
conditions below:

Condition 1 - The weld drawing doesn't have a safety symbol on the weld, and there is no safety shield on
specific sections of the weld standard. Interpretation - For this specific non-safety shielded weld,
conformance to the above EM standards is not necessary for any conditions defined in non-safety
shielded sections of the weld standard. However, the weld standard requirements must still be met by this
weld.

Condition 2 - The weld drawing has a safety symbol on the weld, but there is no safety shield on specific
sections of the weld standard. Interpretation - For this specific safety shielded weld, conformance to the
above EM standards is not necessary for any conditions defined in non-safety shielded sections of the
weld standard. However, the weld standard requirements must still be met by this weld.

Conditions 3 - The weld drawing doesn't have a safety symbol on the weld, but there is a safety shield on
specific sections of the weld standard. For this specific non-safety shielded weld, conformance to the
above EM standards is not necessary for any conditions defined in safety shielded sections of the weld
standard. However, the weld standard requirements must still be met by this weld.

Condition 4 - The weld drawing has a safety symbol on the weld, and there is a safety shield on specific
sections of the weld standard. For this specific safety shielded weld, conformance to the above EM
standards is necessary for any conditions defined in safety shielded sections of the weld standard. The
weld must conform to both the "EM" standard's requirements and meet the weld standard's requirements.

Any deviation to the Supplier Quality lot control requirement as called out in EM-10001<S>, EM-
10002<S>, or EM-10003<S> must be approved by the Supplier Quality Office and the Product Releasing
Group.

Special welding requirements specified in a purchase order shall be placed on the supplier's drawing or
welding release.

1.2 Purpose of the Process

This process shall be used to reprocess all "Body" discrepant resistance spot welds.

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1.3 Hazardous Material Control

ARC welding may generate hazardous fumes and the user shall comply with applicable Corporate and/or
Government fume ventilation requirements.

1.4 Coverage of this Standard

This standard is applicable to all body components fabricated from weldable zinc, iron-zinc coated or un-
coated steels.

1.5 Correlation to Other Standards

Specifications for "Welding - Structural Classification and Surface finish Requirements" and "PF-
Safety<S>/ Emissions Weld Area and Quality Requirements" are in Process Standards PS-1756 and PS-
5595. In accordance with changes in these standards, this standard refers to what had previously been
known as critical welds as diamond welds, and is shown as diamond (critical). The parentheses
around critical show that this is the old term and is included to clarify this issue. Similarly, this standard
refers to refers to what had previously been known as ordinary welds as standard welds, and is shown
as standard (ordinary).

1.6 Requirements on Part Drawings

Any weld quality requirements designated on the engineering releases take precedence over the
requirements specified herein.

2.0 PROCESS

2.1 Requirements***

All Arc Welding and inspection will be performed by personnel that meet the qualification/certification
requirements of DaimlerChrysler Advanced Technical Training (ATT). The ATT contact person is Glen
Knight (248.512.4882, T/L 722.8442). The period of qualification/certification of an individual is for a two
(2) year period from date of receiving (passing) the qualification/certification test. All training must be
documented.

2.1.1 Resistance Spot Welds

All reprocess resistance spot welds shall meet the quality requirements of PS-9471<S>, PS-10947<S>
and any additional requirements called out on the engineering releases.

2.1.2 Arc Welds

All reprocess arc welds shall meet the quality requirements of PS-9472<S> and any additional
requirements called out on the engineering release.

The surface of the steel part at the time of welding shall be free of all contaminants, mill oils, or coatings
that would adversely affect weld quality.

The arc weld process shall not be used in areas where adhesives or sealers are present or closer than
25.4 mm ( 1 in.).

2.1.3 Rivets

Special requirements for rivets are found in paragraph 2.2.5 of this standard.

2.2 Methods

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Methods 1 through 4 are to be employed when discrepant welds are found prior to the application of E-
coat or paint. Method 5 is to be employed only if Methods 1 through 4 cannot be employed.

2.2.1 Method 1 - Resistance Spot Weld

2.2.1.1 Usage Restrictions

Method 1 may be used for reprocessing all resistance spot welds that are classified safety, diamond
(critical) or standard (ordinary) welds.

Prior Structural Engineering approval is not required to use this method.

2.2.1.2 Discrepant Resistance Spot Welds

2.2.1.3 Missing Resistance Spot Welds

Missing resistance spot welds can be replaced with another resistance spot weld at the location of the
missing weld (see Figure 1).

2.2.1.4 Other Discrepant Resistance Spot Welds - Replacement Welds Maximum Distance Placement

The replacement resistance spot weld shall be made in such a manner that it is no greater than 9.52 mm
(.375 in.) from the discrepant resistance spot weld (see Figure 2). The weld set-up (schedule) may need
increased current to compensate for shunt current flowing through the discrepant weld.

2.2.2 Method 2 - Ring Fillet Arc Weld

2.2.2.1 Usage Restrictions

Method 2 shall not be used to reprocess discrepant resistance spot welds that utilize weld-through sealers
or adhesives.

Method 2 may be used for reprocessing all resistance spot welds that are classified safety, diamond
(critical) or standard (ordinary) welds.

No prior Structure Engineering approval is required for materials up to 2.03 mm (.080 in.) in thickest part.
For materials thicker than 2.03 mm (.080 in.) Structure Engineering's written concurrence is required.

2.2.2.2 Material Preparation for Ring Fillet ARC Welding (see Figure 3)

Use a 9.52 mm (.375 in.), PN 89-214-0220, and/or 15.88 mm (.625 in.), PN 89-214-0270, blair hole saw
cutter (arbors - PN 89-299-2217) or equivalent, as required, to drill holes in one or two metal thicknesses
for 2T or 3T conditions, respectively.

NOTE: Take care to minimize gouging of the bottom layer of metal during the cutting procedure.

2.2.2.3 Ring Fillet Arc Weld Requirements (see Figure 3)

The appropriate arc welding process and filler wire shall be used per PS-9472<S> according to metal
thickness and coating type being welded.

The required weld is a fillet type weld around the inner diameter of the cut hole.

The fused legs shall not be less than the thickness of the thinner of the two metals being joined.

The remainder of the hole shall be filled in using the above arc welding process and filler wire.

2.2.2.4 Surface Finish Requirements

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This method shall not be used where a Class 1 or 2 surface finish is required.

2.2.2.5 Class 3 Surface Finish Requirements

The remainder of the hole shall first be filled using the appropriate arc welding process. The raised
surface shall then be ground to obtain the required Class 3 finish per PS-1756.

2.2.3 Method 3 - Fillet Arc Weld

2.2.3.1 Usage Restrictions

Method 3 shall not be used to reprocess discrepant resistance spot welds that utilize weld-through sealers
or adhesives that are within 25 mm of the edge to be welded.

Method 3 is restricted to missing resistance spot welds that are classified diamond (critical) or standard
(ordinary) welds.

This method shall only be applied to lap joints as shown in Figure 4.

All safety welds require Structure Engineering's written concurrence.

The appropriate arc welding process and filler wire shall be used per PS-9472<S> according to metal
thickness and coating type being welded.

2.2.3.2 Minimum Acceptable Arc Weld Length

Find the minimum acceptable arc weld length according to steel type and thickness for both steels from
Table 1.

When the thickness falls between the table's thickness value, use the table's next higher sheet thickness
to determine the arc weld length.
The minimum acceptable arc weld length shall be the lesser value as determined above.

2.2.4 Method 4 - Notch and ARC Weld

2.2.4.1 Usage Restrictions

Method 4 is restricted to missing resistance spot welds that are classified as standard (ordinary) welds.

Structure Engineering's written concurrence is required for Jeep and Truck usage. Exception: Structure
Engineering's concurrence is not required for use on Minivans.

This method shall only be applied to joints as shown in Figure 5.

2.2.4.2 Notch and Weld Procedure:

- Upset metal flange using special tool (PN -2SAD2361).

- Grind raised surface flush.

- Eliminate any gap that may exist between pieces to be joined.

- Arc weld, using proper arc weld process and filler metal per PS-9472<S>, along the area as shown in
Figure 5.

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- Grind the arc weld flush with the original surface.

- For the 3T condition, repeat the same process on the reverse side.

2.2.5 Method 5 - Structural Rivet

2.2.5.1 Usage Restrictions

Method 5 is restricted to missing resistance spot welds that are classified as diamond (critical) or standard
(ordinary) welds. This reprocessing method shall only be used when none of the other previous four
methods are available, and is only to be used when E-coat or paint is present.

The manufacturing plant Quality Control Department and the DaimlerChrysler Customer Advocate Group
shall assess cosmetic and customer perspective aspects of the proposed reprocessing. The written
concurrence of both of these groups is required for the proposed weld reprocessing.

Structure Engineering's written concurrence is required when using this method. Structures Engineering
shall perform an analysis of the part in which the proposed reprocessing will occur, and verify that joint
strength, and long term durability and reliability requirements are maintained. Body Structures
concurrence certifies that the Structural Rivet Reprocess restores or exceeds the joints design intent
structural performance.

Clearance for the rivet head shall be available.

Structures Engineering shall consider methods to address the following issues in their written instructions
to the plant personnel responsible for the addition of structural rivets:

- Joint relaxation - Limit by reducing number of thicknesses to be riveted.

- Assurance of flat surfaces for installation of structural rivet - this requires placing the rivet in an area that
hasnt been changed by welding efforts (shall not place rivet in same location that the weld to be
reprocessed is placed), but is still sufficiently close to the discrepant weld so that the structural purpose of
the weld can be fulfilled by the rivet.

2.2.5.2 Corrosion Protection for Riveted Joints

The appropriate corrosion prevention method shall be selected from those listed below: These methods
may be supplemented by additional measures as needed for specific situations:

Two side access non-cosmetic requirement (sealer is non-paintable)

- Drill hole(s) in accordance with the requirements of Table 2 Method 5 in this standard.
- Prepare both surfaces that will be clamped together such that burrs or foreign materials are not present.
- Install rivet(s) using an appropriate tool.
- Inspect both surfaces of the clamped material to ensure the rivet head and bulb are perpendicular and
seated properly.
- Flash dry.
- Apply MS-CD-929<S> or MS-CD-128 sealant. MS-CD-929<S> supersedes MS-CD-927<S>.
- Apply sealer in all areas requiring sealing for water or gas intrusion and needing corrosion protection per
the instructions of Body-in-White Engineering. Be certain that the sealer covers the entire rivet head and
is also overlapped onto adjacent painted surface area to assure maximum adhesion.
Two side access cosmetic requirement

- Drill hole(s) in accordance with the requirements of Table 2 Method 5 in this standard.
- Prepare hole(s) in accordance with Paint Standard Operating Procedure PSOP-1011 (titled Cold

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Phosphate).
- Prepare both surfaces that will be clamped together such that burrs or foreign materials are not present.
- Install rivet(s) using an appropriate tool.
- Inspect both surfaces of the clamped material to ensure the rivet head and bulb are perpendicular and
seated properly.
- Prepare both sides of the installed rivet(s) for further processing by again applying PSOP-1011 (Cold
Phosphate), making certain that the application covers the entire rivet area as well as the exposed
mandrel within the rivet(s) that had been broken off during rivet installation.
- Prime both sides of the rivet(s) and adjacent area following the requirements of PSOP-1003 (titled
Flash Prime).
- Prepare both sides of the rivet(s) for painting by following the requirements of PSOP-8500 (titled
Reprocess Preparation).
- Apply paint in accordance with the requirements as follows:
The following plants shall meet the requirements of PSOP-8501 (titled Final Line Reprocess) for solvent
borne applications: Jefferson North Assembly Plant, Lago Alberto Assembly Plant, Pillette Assembly
Plant, Toledo Parkway Assembly Plant, and Warren Truck Assembly Plant.

- The following plants shall meet the requirements of PSOP-8502 (titled Final Line Reprocess) for water
borne applications: Belvidere Assembly Plant, Bramalea Assembly Plant, Eurostar Assembly Plant,
Newark Assembly Plant, Saltillo Assembly Plant, Sterling Heights Assembly Plant, St. Louis North
Assembly Plant, St. Louis South Assembly Plant, Steyr Assembly Plant, Toluca Assembly Plant, and
Windsor Assembly Plant.

Single side access non-cosmetic requirement

- Reprocess method shall be developed for the specific application and occurrence. Materials
Engineering/Corrosion personnel shall be consulted to assist in the reprocess development.

Single side access cosmetic requirement

- -Reprocess method shall be developed for the specific application and occurrence. Materials
Engineering/Corrosion and Materials Engineering/Paint personnel shall be consulted to assist in the
reprocess development.

The method and reprocess procedure determined acceptable to meet corrosion and paint requirements
shall be included in Structures Engineering written instructions to the plant responsible for the
reprocessing of the parts.

2.2.5.3 Required Structural Rivet

See Table 2 for the required structural rivet size.

3.0 QUALITY

Refer to CS-9801 for general quality requirements.

4.0 DEFINITIONS

Discrepant Resistance Spot Weld - A Discrepant Resistance Spot Weld is one that does not meet all the
requirements as listed in PS-9471<S> (PS-1682 if called out on the detail assembly, CATIA drawings,
weld only drawings or weld releases), and any additional requirements called out on the detail assembly,
CATIA drawings, weld only drawings or weld releases. Even though these welds differ, they still
have useful engineering properties.

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Missing Weld A resistance spot weld location that has not had any weld current flow through it, although
slight marking by the electrodes may be evident.

Resistance Spot Welding - A welding process wherein the parts are fused together by the heat obtained
from resistance to the flow of electric current through the area held together under pressure by electrodes.

Reprocessed Weld - A Reprocessed Weld is a replacement weld for a discrepant resistance spot weld.
This can be either another resistance spot weld, an arc weld or a structural rivet as described in section
2.0 of this standard.

5.0 GENERAL INFORMATION

Three asterisks *** after the section/paragraph header denotes single or multiple technical changes to
the section/paragraph.

Certain important information relative to this standard has been included in separate standards. To assure
the processes submitted meet all of DaimlerChrysler requirements, it is mandatory that the requirements
in the following standards be met.

CS-9800 - Application of this standard, the subscription service, and approved sources
CS-9003 - Regulated substances and recyclability

Within Engineering Standards, the Regulatory (Government-mandated) requirements are designated by

<S> and <E> which correspond to Safety and Emission Shields respectively. The DCC-mandated
requirements are designated by <D> and correspond to the Diamond symbol respectively.

For specific information on this document, please refer to the contact person shown in the "Publication
Information" Section of this document. For general information on obtaining Engineering Standards and
Laboratory Procedures, see CS-9800 or contact the Engineering Standards Department at
engstds@dcx.com.

6.0 REFERENCES

CS-9003
CS-9800
CS-9801
EM-10001<S>
EM-10002<S>
EM-10003<S>
MS-CD-128
MS-CD-929<S>
PF-SAFETY<S>
PSOP-1003
PSOP-1011
PSOP-8500
PSOP-8501
PSOP-8502

(PSOPs are available through System 9000. If not accessible, contact T. Bjelica of Body Materials
Engineering.)

PS-1682<S>
PS-1756
PS-5595<S>

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PS-9471<S>
PS-9472<S>
PS-10947<S>

7.0 ENGINEERING APPROVED SOURCE LIST

N/A

8.0 PUBLICATION INFORMATION

Contact/Phone No: N.A. Hamers, 248.512.4850

Alternate Contact/Phone No: E.P Pakalnins, 248.776.7454
Department Name and Dept. No./ Tech Club/Organization: Body Materials Engineering, Dept. 5810
Date Standard Originally (Initially) Published: 1991-05-10
Date Published: 2006-04-10
Change Notice:
Description of Change:
- 2.1 Expanded Definition Redefined Requirements and Qualifications
- 6.0 Added PS-10947 Standard
- 2.1.1 Added PS-10947 Standard

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 Missing Weld Locations

FIGURE 1: MISSING RESISTANCE SPOT WELD REPLACEMENT

Maximum Distance
9.52 mm (0.375 in.)

FIGURE 2: REPLACEMENT WELD MAXIMUM DISTANCE PLACEMENT

NOTE: The replacement spot weld shall not come in contact with the discrepant resistance spot weld.

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 9.52 mm (0.375 in.)diameter
15.88 mm (0.625 in.) diameter 15.88 mm (0.375 in.)diameter

9.52 mm (0.375 in.)diameter

15.88 mm (0.625 in.)diameter

Ring fillet arc weld - shown

with arc weld around inner
diameter of cut hole

FIGURE 3: MATERIAL PREPARATION FOR 2T AND 3T JOINTS

NOTE: The distance from the outside diameter of any hole to an edge or a radius shall not be less than
3.05 mm (0.120 in.) or 2T, whichever is greater.

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 FIGURE 4: SINGLE EDGE ARC WELD

FIGURE 5: NOTCH AND WELD

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 TABLE 1: METHOD 3-MINIMUM ACCEPTABLE ARC WELD LENGTH

Low Carbon Steels High Strength Steels

T
Thickness of the Minimum Minimum
Thinner Sheet Acceptable Arc Target Length of Acceptable Arc Target Length of
Weld Length Arc Weld Weld Length Arc Weld
mm (in.) (Note 1)
mm (in.) (Note 1)
mm (in.)
mm (in.) mm (in.)

0.64 (.025) 10 (0.40) 18 (0.70) 13 (0.55) 19 (0.75)

0.76 (.030) 11 (0.45) 19 (0.75) 16 (0.65) 24 (0.95)

0.89 (.035) 13 (0.50) 21 (0.85) 18 (0.70) 26 (1.05)

1.02 (.040) 15 (0.60) 23 (0.90) 19 (.75) 27 (1.05)

1.14 (.045) 16 (0.65) 24 (1.00) 20 (0.80) 28 (1.10)

1.27 (0.50) 18 (0.70) 26 (1.05) 22 (0.90) 30 (1.20)

1.40 (.055) 19 (0.75) 27 (1.10) 23 (0.90) 31 (1.20)

1.52 (.060) 21 (0.80) 29 (1.15) 25 (1.00) 33 (1.30)

1.78 (.070) 22 (0.90) 30 (1.20) 27 (1.05) 35 (1.40)

1.98 (.078) 23 (0.90) 31 (1.20) 29 (1.15) 37 (1.45)

2.29 (.090) 25 (1.00) 33 (1.30) 33 (1.30) 41 (1.60)

2.67 (.105) 26 (1.05) 34 (1.35) 37 (1.45) 45 (1.75)

3.05 (.120) 27 (1.05) 35 (1.40) 41 (1.60) 49 (1.95)

NOTE 1: The Target Length of Arc Weld is the weld length needed to achieve the minimum acceptable
weld length.

TABLE 2: METHOD 5 REQUIRED STRUCTURAL RIVET SIZE

Joint Total Rivet
Nominal Rivet Required Hole Size
Thickness Length
dia. DaimlerChrysler Part
Number Minimum Maximum
mm (in.) mm (in.) mm (in) mm (in.) mm (in.)

1.5 (0.059)
to less than 6.35 (0.250) 12.4 (0.49) 6034573 6.71 (0.264) 6.91 (0.272)
2.79 (0.110)

2.79 (0.110)

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 TABLE 2: METHOD 5 REQUIRED STRUCTURAL RIVET SIZE
to less than " 15.0 (0.59) 6033688
4.80 (0.189)

4.80 (0.189) 17.0 (0.67) 6033864

to less than
6.81 (0.268)

6.81 (0.268) 19.0 (0.75) 6033939

to less than
8.79 (0.346)

#####

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