Group standard VW 01105-2

Issue 2013-05
Class. No.: 04844

Descriptors: welding, spot welding, resistance welding, aluminum, Al

Resistance Spot Welding

Aluminum Materials

Previous issues
VW 01105-2: 1993-12, 2004-03

Changes
The following changes have been made to VW 01105-2: 2004-03:
– Standard completely revised
– Technical responsibility changed

Contents
Page
1 Scope ......................................................................................................................... 2
2 Terms and definitions ................................................................................................. 2
2.1 Spot welding, weld nugget, weld spot ........................................................................ 2
2.2 Heat-affected zone HAZ ............................................................................................. 3
2.3 Unaffected base material ........................................................................................... 3
2.4 Design ........................................................................................................................ 3
2.4.1 Spot-welded joint ........................................................................................................ 3
2.4.2 Weld joint ................................................................................................................... 3
2.4.3 Wall thickness ............................................................................................................ 3
3 Requirements ............................................................................................................. 4
3.1 Welding suitability ...................................................................................................... 5
3.2 Welding reliability (design) ......................................................................................... 6
3.2.1 Position of the weld spots .......................................................................................... 6
3.2.2 Arrangement of spots (spot position) ......................................................................... 6
3.2.3 Spot spacing .............................................................................................................. 6
3.2.4 Design examples and dimensions ............................................................................. 8
3.2.5 Tolerances ............................................................................................................... 11

Always use the latest version of this standard.

This electronically generated standard is authentic and valid without signature. Page 1 of 31
The English translation is believed to be accurate. In case of discrepancies, the German version is alone authoritative and controlling.
Numerical notation acc. to ISO/IEC Directives, Part 2.

Technical responsibility The Standards department

I/EZ-3 Martin Conrads
I/GQ-311 Markus Haiasch Tel.: +49 841 89 760802 Tel.: +49 841 89 33115

All rights reserved. No part of this document may be provided to third parties or reproduced without the prior consent of one of the Volkswagen Group’s Standards departments.
© Volkswagen Aktiengesellschaft VWNORM-2012-05o
Page 2
VW 01105-2: 2013-05

3.3 Welding capability (manufacturing) .......................................................................... 12

3.3.1 Welding equipment .................................................................................................. 13
3.3.2 Electrode shapes ..................................................................................................... 14
3.3.3 Weld bonding ........................................................................................................... 15
4 Basics ....................................................................................................................... 15
4.1 Shear ........................................................................................................................ 15
4.2 Cross-tension ........................................................................................................... 16
4.3 Peeling tension ......................................................................................................... 17
4.4 Torsion ..................................................................................................................... 19
4.5 Quasistatic and cyclical load .................................................................................... 19
4.6 Process assurance ................................................................................................... 21
4.6.1 Weld spot geometry ................................................................................................. 22
4.6.2 Number of weld spots .............................................................................................. 26
4.6.3 Surface quality class for spot-welded sheets ........................................................... 27
5 Drawing specifications ............................................................................................. 28
6 Applicable documents .............................................................................................. 30
7 Bibliography ............................................................................................................. 31

1 Scope
This standard contains the requirements and tests for spot-welded joints of aluminum materials in
car body manufacture.
The standard applies to spot-welded joints of parts that have thicknesses of 1,0 mm to 3,5 mm and
are made of aluminum materials suitable for spot welding. If the wall thicknesses are not equal, this
standard is applicable up to a wall thickness ratio of 1:2. For higher ratios, a special agreement
must be reached between the Design Engineering, Planning, and Production departments.
Materials: 5xxx, 6xxx, and 7xxx aluminum materials, both die casting alloys and also wrought al‐
loys.
Surface finish: coil-passivated/roller mill-passivated with solid lubricant, washed and passivated.
The surface finishes must be adapted to the applicable Technical Supply Specification (TL) in each
case.
Processing: within three months
This standard can be applied as relevant to spot-welded joints with deviating materials and thick‐
nesses.
Unless otherwise specified in this standard, the following standards apply:
– DVS 2932-1 (German Welding Society) Resistance spot and resistance roller seam welding of
aluminum, and aluminum alloys of an individual thickness of 0,35 to 3,5 mm – Weldability
– DVS 2932-3 Resistance point and seam welding of aluminum and aluminum alloys of an indi‐
vidual thickness from 0,35 to 3,5 mm; Preparation and execution of welding

2 Terms and definitions

2.1 Spot welding, weld nugget, weld spot

In resistance spot welding, the weld zone between the parts to be joined is heated to the melting
point using resistance heating with electrode force acting simultaneously. Size, shape, and position
 Page 3
VW 01105-2: 2013-05

of the melted base material depend on the temporal and spatial interaction of the heat quantities
generated and dissipated in the weld zone and its surroundings.
Under the influence of the electrode force, the workpieces are joined when the melt solidifies. The
welded joint in the shape of a "weld nugget" that develops during this process is referred to as a
"weld spot" (figure 1) that joins the parts at the weld joint (section 2.4.2). The nugget diameter dL is
the diameter of the melted material in the joining plane that is measured on the microsection.

Figure 1 – Weld spot

2.2 Heat-affected zone HAZ

Area of the base material that remained solid but experienced changes in microstructure due to the
thermal energy applied during welding.

2.3 Unaffected base material

Area that experienced no evident microstructural changes as a result of the energy applied during
welding.

2.4 Design

2.4.1 Spot-welded joint

Connection of two or more parts joined directly at the weld joint by one or more "weld spots" or
"spot seams". The parts involved are designated on drawings as an ASSY (assembly) or WA (wel‐
ded assembly).

2.4.2 Weld joint

Form element in which the parts are joined to each other by spot welding. The respective joint type
is determined by the design relationships of the parts to each other.

2.4.3 Wall thickness

t1 and t2 are wall thickness values of the single-shear spot-welded joint. Especially for the calcula‐
tion, the thinnest sheet of the joint must always be designated as t1 if there are different sheet
thicknesses. The thicker sheet of the joint is designated as t2 (see figure 2).
Page 4
VW 01105-2: 2013-05

Figure 2 – Example of a 3-sheet joint

3 Requirements
To achieve the greatest possible form strength during manufacturing, in the sense of the design
goal with adequate safety and optimum cost-quality ratio, each spot-welded construction must be
"appropriate for welding", i.e., the dimensions in the spot-welding equipment and the electrode
space requirements, as well as accessibility to the workpiece, must be considered as early as ad‐
vance engineering. The weldability is dependent on three influencing variables:
– Welding suitability (material)
– Welding reliability (design)
– Welding capability (manufacturing)
All three criteria are of equal priority for weldability, see figure 3 (for a definition, see also
DIN Technical Report ISO/TR 581 "Weldability - Metallic materials - General principles").
 Page 5
VW 01105-2: 2013-05

Figure 3 – Schematic representation of the weldability of spot-welded joints

3.1 Welding suitability

A material possesses welding suitability for resistance spot welding if, in the course of production,
the chemical, metallurgical, and physical properties as well as the surface characteristics inherent
in the material allow a weld to be made that satisfies the requirements stipulated in the particular
case. The less the factors governed by the material have to be taken into account when determin‐
ing the welding procedure for a given design, the better is the welding suitability of a material within
a material group.
Aluminum and aluminum alloys have distinctly higher electrical and thermal conductivity values
than steels and therefore require a welding current that is many times greater. Deviating welding
parameters may be necessary for special procedure variants.
Upon exposure to oxygen, a natural oxide layer is spontaneously formed on the surface of the
component. Depending on the type and thickness of this oxide layer, welding may be impaired to a
greater or lesser extent.
The electrical conductivity is essentially determined by the chemical composition (see
DIN EN 573-3). This conductivity decreases as the alloy content (e.g., Mg, Mn, Cu, Zn, Sn) increa‐
ses.
In addition to the electrical and thermal conductivity, the contact resistance is an important influ‐
encing factor in resistance spot welding of aluminum and aluminum alloys.
NOTE 1: The likelihood of hot cracks is less in resistance welding with pressure than in fusion
welding. The alloy composition also has an effect with regard to hot-crack sensitivity (Si content).
Due to high electrode forces in connection with a decreasing welding current (down slope), the for‐
mation of cracks in the center of the nugget can be reduced.
Page 6
VW 01105-2: 2013-05

3.2 Welding reliability (design)

Welding reliability is of particular importance for design. The design-related welding reliability is
mainly influenced by the material and to a slight extent by manufacturing.
Welding reliability is present if, with the material used, a component remains functional under the
intended operating conditions due to its design.

3.2.1 Position of the weld spots

The position of the weld spots must be specified by Design Engineering in consultation with Pro‐
duction and Planning departments. If possible, the electrodes should contact the part perpendicular
to the part surface. Otherwise, i.e., if they contact the part surface at a different angle, the nugget
diameter may be significantly smaller and elliptical.
The key criteria for the distance between the weld spot and the perpendicular flange are the mini‐
mum distance A = 2,0 mm from the current-carrying parts, the transition radius Ri, as well as the
electrode shank diameter dS or electrode tip diameter dT.
For further information on the design of spot-welded joints, see DVS 2902-3.

3.2.2 Arrangement of spots (spot position)

The arrangement of spots must be selected such that the force F to be transferred is distributed as
uniformly as possible over all spots. If the load distribution is not uniform, there will be a negative
effect on both the vibration resistance and the crash behavior.
With multiple-row spot seams, the spot arrangement is to be agreed upon with the Design Engi‐
neering, Numerical Simulation, Strength, Planning and Production departments.
Spots that cannot be welded properly due to difficult accessibility must be avoided (see figure 7).
"Quarter, third, half, and three-quarter spots" reduce the load-carrying capacity (for an example of
a three-quarter spot, see figure 4). In checked exceptional cases, a defined portion of half and
three-quarter spots can be permitted by the Testing department (Vehicle Strength and Vehicle
Safety) in certain areas. This must be noted separately in the assembly drawing.

Figure 4 – Example for three-quarter spot

3.2.3 Spot spacing

The spot spacing e (i.e., the center-to-center distance between two adjacent weld spots, see
figure 5) must be at least 6 x dL and is preferably greater. Lower spot spacing values are permissi‐
ble if the current is increased after the first welding, to compensate for the shunt effect, and if the
required weld quality (equal weld nugget diameter) can be achieved. See DIN EN ISO 18595.
 Page 7
VW 01105-2: 2013-05

The spot spacing eshunt indicates the distance below which the shunt can no longer be ignored dur‐
ing the welding process. The portion of the current that flows over spots of the seam that are al‐
ready present does not contribute to heating the actual weld area.
The shunt has a greater effect when:
– The spot spacing decreases.
– The spot diameter increases.
Otherwise, the following applies: e ≥ eshunt
The reference value for the spot spacing for single-row joints can be: e ≥ 6 x dL
NOTE 2: Due to the higher electrical conductivity, the shunt effect is much greater in aluminum al‐
loys than in steel.

Figure 5 – Left: single-row, single-shear spot seam; Right: double-row, single-shear spot seam

Figure 6 shows different forms of the shunt.

Page 8
VW 01105-2: 2013-05

Legend
a) Shunt at the sheet metal due to electrode contact
b) Shunt via the centering pin (due to close distance)
Figure 6 – Forms of shunt

The figure does not show shunt forms caused by:

c) The clamps
d) The fixture
e) The current-carrying parts of the welding gun

3.2.4 Design examples and dimensions

Designs with poor accessibility are not permissible, since specially shaped electrodes and/or elec‐
trode arms in aluminum cannot be used (figure 7 and/or figure 11). Due to process reliability, it
must be assumed that special electrode tip shapes or high welding gun forces (up to 8 kN) must be
used.
 Page 9
VW 01105-2: 2013-05

Figure 7 – Examples of impermissible and permissible accessibility for the welding electrodes at
the weld flanges

3.2.4.1 Overlap b
Overlap b is the width of the contact surface of the weld flanges on the sections. The planes of the
contact surfaces must be parallel and touch each other (figure 8). b is the shortest distance be‐
tween the limit lines.

3.2.4.2 Seam spacing f

For multiple-row spot seams, the seam spacing f is the shortest distance between the spot centers
of adjacent seams (figure 5). In general, the following applies: f ≥ e.

3.2.4.3 Seam length l

The seam length l is the distance between the spot centers of the first and last spots of a spot
seam (figure 5).

3.2.4.4 Edge distance v

The edge distance v is the distance between the weld spot center and the closest boundary line of
the flat contact surface (figure 5 and/or figure 8).
The edge distance v must be defined by the Design Engineering department in consultation with
the Structural Durability, Vehicle Safety, Production, and Planning departments.
Page 10
VW 01105-2: 2013-05

Figure 8

3.2.4.5 Flange width a

The flange width a (figure 9) is the value that must be adhered to in order to guarantee a reliable
welding procedure and also to ensure the function, so that
– The position of the weld spot is not too close to the edge of the sheet metal,
– The welding equipment (electrode shank and tip) does not create any shunt to the bent sheet
metal
– The bending radius of the sheet is not selected to be too large and the flat part of the flange
width is sufficient to guarantee adherence to the minimum edge distances
Unless specified otherwise, the flange width must be agreed upon between the Design Engineer‐
ing, Structural Durability, Vehicle Safety, Production, and Planning departments.

Figure 9 – Flange widths

For multiple-row spot seams, the flange width a is to be increased according to the seam spacing f.
The flange width is measured from the end of the flange to the angled sheet and is composed of
the edge distance v and the clearance FM, as well as the tolerance TG.

3.2.4.6 Flange offset i

The flange offset i is the maximum projection of the primary flange with respect to the secondary
flange, e.g., for the mounting of seals (figure 9). The secondary flange must not protrude over the
primary flange on the trim edge.
 Page 11
VW 01105-2: 2013-05

3.2.4.7 Flange heights c and h, offset g

The dimensions c and h (figure 9) take into account the dimensions of the spot-welding equipment,
the electrode space requirements, and the workpiece accessibility in manufacturing (see also
section 3.3, "Welding capability").
The dimension g specifies the maximum permissible offset (figure 10).
Unless specified otherwise, the values must be agreed upon between the Design Engineering,
Planning, and Production departments.

3.2.4.8 Flange and overlap spacing k

The flange and overlap spacing k is the distance between overlap b and tangent line (figure 10).

Figure 10 – Offset g, spacing k

k ≥ 2,0 mm (tolerance chain)

3.2.5 Tolerances

3.2.5.1 Trim tolerance Ta

This value represents the trim tolerance during production of the individual part and must be inclu‐
ded in the calculation.

3.2.5.2 General body-in-white tolerance TR

This value takes into account the general tolerances in car body manufacture, including the inac‐
curacies of industrial robots and must be included in the calculation.

3.2.5.3 Design tolerance compensation TK

The value takes into account the flange displacements that are provided for secondary flanges and
must be included in the calculation.

3.2.5.4 Equipment tolerance TV

This value takes into account the repetition accuracy of the equipment and must be included in the
calculation.

3.2.5.5 Total tolerance TG

The overall tolerance is made up of the tolerances Ta, TR, TK, and TV described above to the extent
that these have to be taken into account.
Page 12
VW 01105-2: 2013-05

3.2.5.6 TG = Ta + TR + TK + TV
If no special measures are taken to limit the tolerance, the general empirical value TG = 3,5 mm
must be assumed.
Unless specified otherwise, the use of different total tolerance values must be agreed upon be‐
tween the Design Engineering, Planning, and Production departments.
Deviating total tolerance values may arise due to the following influences, among other things:
TG >3,5 mm for very large individual parts with small wall thicknesses
very long welding gun arms
manually operated welding guns
TG <3,5 mm for small, thick-walled individual parts
stationary welding guns in mechanized processes

3.3 Welding capability (manufacturing)

Care must also be taken in design to ensure that the component is capable of being welded (man‐
ufacturing-related welding reliability). It must be possible to produce the planned welds properly un‐
der state-of-the-art manufacturing conditions.
During the design of components, the following manufacturing aspects must be taken into consid‐
eration:
– If the designs require production equipment with long arms spaced far apart, it must be deter‐
mined early in the process whether the available welding equipment is suitable for this pur‐
pose.
– If possible, the designs must allow short, straight and rigid arms, electrode brackets, and elec‐
trodes to be used (figure 11).

Figure 11 – Examples of electrode arm shapes to be avoided

– Double-shear and multiple-shear joints must be evaluated separately.

– The distance between the outer diameter of the electrode and/or the electrode bracket and the
inner edge of the sheet must be at least (2 +0,5) mm (figure 12). Other specifications must be
agreed upon between the appropriate departments.

Figure 12 – Poor weld quality caused by electrodes that spring back and slide
 Page 13
VW 01105-2: 2013-05

– During welding of spot seams, the welding sequence must be selected such as to avoid the
formation of cavities between the sheets (figure 13).
– To minimize the risk of the electrode sliding, a vertical alignment of the electrodes is absolutely
necessary; otherwise, non-rotationally symmetric weld spots may be created.

Figure 13 – Welding sequence to avoid the formation of cavities

– The electrode axis must be perpendicular to the sheet surface (90 ±1)° (figure 14, figure 15).

Figure 14 – Not permissible Figure 15 – Favorable

3.3.1 Welding equipment

For welding aluminum, machines with higher welding currents and higher electrode forces are nee‐
ded than for welding steel of the same thickness.
The following equipment is considered suitable:
– Welding with an inverter (direct current)
– Welding with an inverter (direct current) and intermediate process tape electrode (DeltaSpot®)
Page 14
VW 01105-2: 2013-05

The higher the electrical conductivity of the material of the joining parts and the greater the sheet
thickness is, the greater the required welding current intensity.
In direct-current welding, it must be taken into account that the positive electrode (anode) is subject
to greater thermal load than the negative electrode (cathode) due to the Peltier effect. Furthermore,
the weld nugget may shift noticeably in the direction of the anode.
In the event of asymmetric sheet thickness ratios or a combination of different types of aluminum
alloys, the Peltier effect must be taken into account with regard to the weld spot quality.

3.3.2 Electrode shapes

For the welding, electrode shapes A and B with a diameter of 20 mm and a ball radius of 75 mm to
150 mm as per figure 16 may be used. The electrode pick-up tendency may be reduced by electro‐
des (type A) with ball radii between 100 mm and 150 mm. Therefore, the number of parts produced
until the electrode cap has to be reworked can be increased.
If a process tape is used, other electrode shapes may be used (figure 17).

Figure 16 – Examples for electrode shapes

The electrode pick-up tendency can be further reduced through the use of a process tape (e.g.,
DeltaSpot® technology, figure 17).

Figure 17 – Electrode including process tape (see the DeltaSpot® manual by Fronius)
 Page 15
VW 01105-2: 2013-05

3.3.3 Weld bonding

If adhesive is used (insulating effect), a shunt must be generated for the first weld spot of a row of
spots. This can be achieved by means the following measures:
– Locking pliers
– Fixture and/or gripper with clamp
– First spot without adhesive
If adhesive is used, the weld spot quality may be negatively affected by additional imperfections.

4 Basics
Depending on a part's structural design (section 2.4), different types of load affect the part:
– Shear specimen (figure 18)
– Cross-tension specimen (figure 19)
– Peeling tension specimen (figure 20)
– Torsion (figure 21)
– Quasistatic and cyclical load (figure 22).
If possible, spot-welded joints should only be loaded with shear since the highest forces per weld
spot can be transferred with this type of load. Therefore, pure cross-tension or peeling tension/tor‐
sion loads must be avoided.

4.1 Shear
The shear specimen is produced as per DIN EN ISO 14273 and/or DVS-EFB 3480-1 from two
sheet strips with a width of 45 mm and a free clamping length of 95 mm. Deviating from this stand‐
ard, the overlap length of the flange widths is minimized under the viewpoint of loading close to
vehicle loads. Table 1 lists the specimen dimensions and also reference values for the overlap
length as a function of the material thickness up to t = 4,5 mm. For combinations of different sheet
thicknesses, the specifications for the lowest sheet thickness must be used in each case. Depend‐
ing on the tip geometry and accessibility, the overlap length being used for the flange can be adap‐
ted, but a minimum of 16 mm is required. Figure 18 shows the sketch of the shear test specimen
with the most important dimensions. The longitudinal edges of the sheet strips must lie in the direc‐
tion of rolling. The sheet strips must be connected by a weld spot without a shunt (single weld spot
specimen) to form the shear test specimen. The weld spot is placed in the center of the overlap
region. The clamping length lc and the cut length li are dependent on the overlap length lÜ and the
clamping device being used in each case.
Page 16
VW 01105-2: 2013-05

Legend
t1, t2 Specimen thicknesses
l Total specimen length
li Cut length of individual sheet
lf Free clamping length
b Specimen width
lC Clamping length
lÜ Overlap length
Figure 18 – Shear specimen

Table 1 – Specimen dimensions of the shear specimen as a function of the sheet thick‐
ness
Sheet thick‐ t1, t2 ≤1,5 mm ≤2,5 mm ≤3,5 mm ≤4,5 mm
ness
Specimen b 45 mm
width
Overlap length lÜ 16 mm 18 mm 20 mm 22 mm
Free clamping lf 95 mm
length
Clamping lC ≥46 mm
length
Cut length li ≥100 mm

4.2 Cross-tension
The single-shear, overlapped cross-tension specimen is standardized for the evaluation of spot-
welded joints in DIN EN ISO 14272 and/or is described, as applicable, in DVS-EFB 3480-1. This
specimen geometry is used for the testing of spot-welded joints and in combination with adhesive
bonding. Figure 19 shows the sketch and the dimensions of the cross-tension specimen. The
cross-tension specimen is produced from two material cuts with dimensions l = 150 mm and
w = 50 mm by spot welding in the center of the overlap section. The holes for the standardized
 Page 17
VW 01105-2: 2013-05

clamping are formed by punching, drilling, lasering, or waterjet cutting prior to joining. Table 2 lists
the specimen dimensions that are independent of sheet thickness.

Legend
t1, t2 Specimen thicknesses
l Total specimen length
a Hole spacing
b Specimen width
lf Free clamping length
Figure 19 – Cross-tension specimen

Table 2 – Cross-tension specimen dimensions that are independent of sheet thickness

Specimen width b 50 mm
Specimen length l 150 mm
Hole spacing a 100 mm
Free clamping lf 2 mm
length

4.3 Peeling tension

The single-shear, overlapped peeling-tension specimen is standardized for the evaluation of resist‐
ance spot-welded joints in DIN EN ISO 14270 and/or is described, as applicable, in DVS-
EFB 3480-1. Deviating from this standard, for hybrid joints the overlap length is minimized under
the viewpoint of smaller flange widths to be used. In comparison to the shear specimen, the usable
area is limited to materials that can be formed through bending. Figure 20 shows a sketch of the
peeling-tension specimen with the most important dimensions. The clamping area is marked in
gray. Table 3 lists the specimen dimensions and also reference values for the overlap length as a
function of the material thickness for an area up to t = 4,5 mm. For combinations of different sheet
Page 18
VW 01105-2: 2013-05

thicknesses, the specifications for the lowest sheet thickness must be used in each case. For spe‐
cial joining elements, greater sheet thicknesses, and modes of failure not related to practice, the
specimen dimensions and overlap length must be adapted in consultation with the supplier of the
joining system against the background of these results. Especially when determining the stiffness
of joints, an optimized overlap length can be selected that examines the advantages specific to the
type of joint, such as stiffness and weight of the joining parts, in optimized constructions.

Figure 20 – Peeling-tension specimen

Table 3 – Specimen dimensions of the peeling-tension specimen as a function of the

sheet thickness
Sheet thick‐ t1, t2 ≤1,5 mm ≤2,5 mm ≤3,5 mm ≤4,5 mm
ness
Specimen b 45 mm
width
Overlap length lÜ 16 mm 18 mm 20 mm 22 mm
Inner bending ri 2 – 4 mm 4 – 6 mm 6 – 8 mm 8 – 10 mm
radius
Free clamping lf 95 mm
length
Cut length li ≥100 mm

The free clamping length of the specimen equals lf = 95 mm. A sufficient clamping area must be
ensured so that there is no slipping during the test. To be able to compare the determined results,
it is important that the free clamping length and overlap are kept constant.
 Page 19
VW 01105-2: 2013-05

4.4 Torsion
A durable joint is achieved with at least two weld spots, because in the event of torsion around one
spot, the transferable torque Mt is too low. Designs with only one load-carrying spot are not per‐
missible.

Figure 21 – Torsion

4.5 Quasistatic and cyclical load

A basic distinction is made between loading a specimen as per static or cyclical loads (figure 22).
The following information applies to the proof of sufficient strength for dynamically loaded compo‐
nents:
– Due to as yet inadequate knowledge about the influence of the design of the joint and the un‐
certainties in calculation, the load-carrying capacity of the joints for vibration loads must al‐
ways be verified through testing.
– For a given material thickness, the service life of a joint is dependent on the load height, the R
value (stress ratio Fmin/Fmax), and the type of load. The type of load may be shear or peeling
tension. Cross tension and torsion usually do not occur. Generally no type of load occurs
alone and in pure form.
– The single-row, single-shear joint is preferred.
– Dynamic cross-tension and torsion loads must be avoided due to the low permissible stress.
Further information – including information on calculation of simple design parts – is included in the
list of references in DVS 2902-3. With respect to component dimensioning, ensure that under dy‐
namic oscillating loads (structural durability), no better strength values are achieved with spot-wel‐
ded, self-hardening, or hardened aluminum alloys than with soft or non-hardened aluminum alloys.
Page 20
VW 01105-2: 2013-05

Figure 22 – Load amplitudes

To determine the cyclic load capacity in the fatigue strength range, the H-shaped shear specimen
and, if necessary, the H-shaped peeling-tension specimen are used as per DIN EN ISO 18592
and/or DVS-EFB 3480-1. For an S-N curve in the fatigue strength range, at least 12 test speci‐
mens are welded as per the string of pearls method. Of these test specimens, the first and last
welded specimens are subjected to destructive chisel testing to verify the required weld spot diam‐
eter prior to cyclic testing.
Figure 23 shows a sketch of the H-shaped shear specimen and Figure 24 shows the H-shaped
peeling-tension specimen. Table 4 lists the sheet-thickness-dependent dimensions and cut dimen‐
sions for the specimen blanks for the H-shaped shear specimen and Table 5 lists these dimen‐
sions for the H-shaped peeling-tension specimen.
The specimen sheets must be joined in suitable tensioning devices, in order to guarantee an exact
positioning of the parts. The joining points are placed starting from the center of the specimen al‐
ternately on the outsides of the specimens.

Figure 23 – H-shaped shear specimen

 Page 21
VW 01105-2: 2013-05

Table 4 – Dimensions and cut dimensions of the H-shaped shear specimen

H-shaped shear specimen geometry
Sheet thickness t [mm] 1,0 1,5 2,0 3,0 4,0
Edge distance v1 [mm] 8 8 8 8 8
Overlap c (16 + r) [m] 18 19 20 22 24
Interior bending radius r (2 x t) [mm] 2 3 4 6 8
Leg length lleg [mm] 67 69 70 73 76
Not-clamped length f [mm] P1 203 203 203 203 203
Effective lengths leff. [mm] P2 67 69 70 73 76

Figure 24 – 10 weld spot, H-shaped peeling-tension specimen

Table 5 – Dimensions and cut dimensions of the 10 weld spot, H-shaped shear speci‐
men
H-shaped shear specimen geometry
Sheet thickness t [mm] 1,0 1,5 2,0 3,0 4,0
Edge distance v1 [mm] 8 8 8 8 8
Overlap c (16 + r) [m] 18 19 20 22 24
Interior bending radius r (2 x t) [mm] 2 3 4 6 8
Leg length lleg [mm] 49 49,5 50 51 52
Not-clamped length f [mm] P1 64 64 64 64 64
Effective lengths leff. [mm] P2 167 165 163 159 155

4.6 Process assurance

Each spot-welded joint is characterized by the sum of its individual characteristics and their influen‐
ces on manufacturing. These characteristics and influences will be evaluated as per the quality re‐
quirements by means of measurable or countable values as test characteristics.
Page 22
VW 01105-2: 2013-05

4.6.1 Weld spot geometry

Nugget diameter dL
The nugget diameter dL is the diameter of the area in the joining plane (perpendicular to the joint
plane) of the workpiece parts that was molten during the welding process and is distinguished from
the base material by a different microstructure (figure 25).
The measurement of the nugget diameter dL in the joining plane and the evaluation of the weld
nugget for weld defects are carried out by means of metallographic testing (macrosection, see
figure 26). The minimum nugget diameter is calculated using the following formula:

dLmin = 5 x (1)

Deviations from the minimum nugget diameter must be specified in the finished part drawing.

Legend
1 Weld nugget
2 Joining plane
3 Heat-affected zone (HAZ)
dE1, dE2 Indentation ∅
dL Nugget ∅
tL Weld nugget penetration depth
tS Gap width
tE1; tE2 Indentation depth
t1; t2 Material thickness (t1 ≤ t2)
tr Minimum remaining sheet thickness in area of electrode indentation
Figure 25 – Schematic representation of a weld spot

A high contact resistance between the electrode and sheet surface may lead to the weld nugget
fusing to the sheet surface when the electrode tip is placed in contact (figure 27). The resulting
Al‑Cu phases on the weld spot surface can be critical in terms of corrosion.
 Page 23
VW 01105-2: 2013-05

Figure 26 – Microsection of a weld spot (conventional), on the right with fused weld nugget

The use of resistance spot welding with intermediate process tape electrodes (DeltaSpot®) can re‐
sult in barrel-shaped weld nuggets due to the additional resistances of the process tapes. Due to
the process tape, no Al-Cu phases are created on the weld spot surface.

Figure 27 – Microsection of a weld spot with DeltaSpot® technology (barrel-shaped weld nugget)

Weld nugget penetration depth tL

The weld nugget penetration depth must be tL ≥ 0,2 mm. It may be less than 0,2 mm, if the
strength of the joint is proven (e.g., by determining the spot weld shear diameter in a chisel test).
Indentation diameter dE1, dE2
The indentation diameter dE is the mean diameter of an indentation caused by the electrode.
Indentation depth tE1, tE2
The indentation depth tE is the greatest depth of the indentation caused by the electrode (see also
surface quality classes in section 4.6.3).
Page 24
VW 01105-2: 2013-05

Sheet thickness t1
t1 is the thickness of the thinnest sheet that is part of the joint. The achievable strength is deter‐
mined by the thinnest sheet.
Gap width tS
The gap width tS is the measure of spread-apart sheets in the joining plane next to or between the
weld spots (see figure 23).
Spot diameter dP
In the case of an interfacial failure (figure 28) or in the case of a shear fracture (fused area), the
spot diameter dP is the mean diameter of the fracture surface in the interfacial failure surface of the
workpiece parts.
In the case of a pullout failure, dP is the average diameter of the base surface of the sheared but‐
ton.
In the case of a mixed fracture, dP is the mean diameter of the base surface of the sheared button,
including the fraction portion of the interfacial failure (d1, not d3, see figure 28).
The spot weld shear diameter dp in aluminum spot welding is usually less than or equal to the di‐
ameter of the weld nugget dL (DIN EN ISO 18595).
Reference value:

dP min ≈ dLmin (2)

dP min = 5 x (3)

NOTE 3: Any "flag"-shaped sheet metal residues remaining after shearing/uncoiling must be re‐
moved. One exception to this rule is a joint with aluminum die casting and aluminum wrought alloy,
i.e., dP > dL.
 Page 25
VW 01105-2: 2013-05

Figure 28 – Spot diameter dP; weld with pullout failure

When determining the spot diameter (figure 29), the primary and secondary axes d1 and d2 of the
button are determined using a caliper (second measurement offset by 90°), and the mean value is
determined from the two measurements. If a precise measurement in two directions is not possi‐
ble, the smaller diameter must be used as dP.
Page 26
VW 01105-2: 2013-05

Legend
1 Fused area
2 Adhesion zone
d1, d2 Axes of the spot diameter
Figure 29 – Spot diameter; interfacial fracture

Table 6 – Determining the minimum nugget and spot diameters and the minimum shear
force via the sheet thickness
Minimum sheet thick‐ Nugget diameter Spot diameter Minimum shear force
ness t1 dLmin ≥ 5 x dPmin ≈ 1,0 x dLmin Fmin.
mm mm mm kN
1,0 5,0 5,0 1,5
1,2 5,5 5,5 2,0
1,5 a) 6,1 6,1 2,5
1,7 6,5 6,5 2,8
2,0 7,1 7,1 3,1
2,4 7,8 7,8 4,0
3,0a) 8,7 8,7 5,0
a) Fmin values interpolated/extrapolated
The table applies to parallel joints and lap joints.
The shear force applies to the materials of the 6xxx series in the state T4.

With different sheet thicknesses, the thinner sheet t1 is decisive for determining the nugget and/or
spot diameter.
NOTE 4: In destructive testing, the type of fracture is dependent on the nugget penetration depth
and is not in direct relationship with the weld spot diameter!

4.6.2 Number of weld spots

The determined number and position of weld spots and the determined minimum nugget diameter
must be complied with. If there are deviations, a new release by the appropriate Testing depart‐
ment is absolutely necessary. This must be noted separately in the assembly drawing.
 Page 27
VW 01105-2: 2013-05

4.6.3 Surface quality class for spot-welded sheets

Surface spatter must be avoided, because this negatively affects the surface appearance.
Surface spatter increases the wear of the electrode tip through electrode pick-up and this has a
negative effect on the surface quality of subsequent spot welds.
Erosion and strong electrode pick-up must be avoided on the electrode tip (figure 30) because
these also negatively affect the surface quality.

Figure 30 – Erosion on the electrode tip

Spatter between the sheets can increase the electrode indentation depth and therefore exceed the
permissible dimension. This must be avoided especially when surface quality class 1 is required.
Surface quality class OG1
This surface quality class applies to sheet metal surfaces that, after the "metal finish", must be free
enough from marks and impurities that they are invisible after painting (visible area). However, the
"metal finish" must not remove more than 10% of the sheet thickness. Marks >10% of the sheet
thickness must be filled before the "metal finish".
Surface quality class OG2
This surface quality class includes a minimum of marks on the surface and is used where minimum
indentations up to 15% of the sheet thickness below the normal surface will still be accepted (e.g.,
insides of lids).
Surface quality class OG3
This surface quality class characterizes an indentation on the sheet surface up to 20% of the re‐
spective sheet thickness. Here, adhering weld spatter is also permitted unless the drawing speci‐
fies freedom from burrs and spatter.
Surface quality class OG4
This surface quality class characterizes surfaces without special quality requirements. If no quality
class is specified in the drawing, quality class 4 applies.
Page 28
VW 01105-2: 2013-05

5 Drawing specifications
The general tolerances as per DIN ISO 2768-1, medium, apply to the dimensions b, c, e, g, k and v
as well as a, f, h, l (see section 3.2.4.1 to section 3.2.4.8).
The dimensions and symbols in assembly drawings and/or PDM drawings are based on
DIN EN 22553. In addition, the following reference is required in the "Documents" column:
VW 01105-2
DIN EN ISO 17659 contains further information and general principles for the definition of welds.
NOTE 5: The meaning of the symbols as per DIN EN 22553: The weld nugget diameter dL min must
lie between the sheets t1 and t2 in the joining plane. For the exact definition and transfer of the posi‐
tion of the weld spots within the "Body" process chain, the applicable requirements for CAD/CAM
data must be considered in the relevant parts of the series of standards VW 01059 "Requirements
for CAD/CAM data". Surface quality class for spot-welded sheets, see section 4.6.3. The surface
quality class always applies to the indicated side only. If no surface quality class is specified, quali‐
ty class 4 is applicable. See DIN EN 22553.

Table 7 – References for quality levels

Quality level Load
B Dynamic load, crash
C Predominantly static load
or in case of documented
tolerance regarding defects
D Minor load, auxiliary spots

The following supplementary terms are defined as per figure 31:

 Page 29
VW 01105-2: 2013-05

Legend
dL Nugget diameter
dE Indentation diameter
1 "Edge area" of the weld spot, from 0,9 dL to 1,1 dE, area of the weld spot which is rele‐
vant to strength
2 "Center" of the nugget, area 0,5 dL, non-load-bearing area of the weld spot
3 "Transition zone", from 0,5 dL to 0,9 dL, area between the center and edge area
Figure 31 – Supplementary definitions

Legend
1 Edge area
2 Center
3 Transition zone
h Length of the irregularity
Figure 32 – Evaluation of imperfections in the transition area between the center and edge area

Requirements
– The edge area must be OK as per the evaluation criteria of tables 8 and 9.
– The sum of the imperfections in the transition area and in the center must not exceed 0,5 dL,
Σ h ≤ 0,5 dL.
The requirements must be tested.
Page 30
VW 01105-2: 2013-05

6 Applicable documents
The following documents cited in this standard are necessary to its application.
Some of the cited documents are translations from the German original. The translations of Ger‐
man terms in such documents may differ from those used in this standard, resulting in terminologi‐
cal inconsistency.
Standards whose titles are given in German may be available only in German. Editions in other
languages may be available from the institution issuing the standard.

VW 01059 Requirements for CAD/CAM data

DIN EN 22553 Welded, brazed and soldered joints - Symbolic representation on draw‐
ings
DIN EN 573-3 Aluminium and aluminium alloys - Chemical composition and form of
wrought products - Part 3: Chemical composition and form of products
DIN EN ISO 14270 Specimen dimensions and procedure for mechanized peel testing resist‐
ance spot, seam and embossed projection welds
DIN EN ISO 14272 Specimen dimensions and procedure for cross tension testing resistance
spot and embossed projection welds
DIN EN ISO 14273 Specimen dimensions and procedure for shear testing resistance spot,
seam and embossed projection welds
DIN EN ISO 17659 Welding - Multilingual terms for welded joints with illustrations
DIN EN ISO 18592 Resistance welding - Destructive testing of welds - Method for the fati‐
gue testing of multi-spot-welded specimens
DIN EN ISO 18595 Resistance welding - Spot welding of aluminium and aluminium alloys -
Weldability, welding and testing
DIN ISO 2768-1 General tolerances; tolerances for linear and angular dimensions without
individual tolerance indications
DIN Technical Weldability - Metallic materials - General principles
Report ISO/TR 581
DVS-EFB 3480-1 Testing of properties of joints - Testing of properties of mechanical and
hybrid (mechanical/bonded) joints
DVS 2902-3 Resistance spot welding of steels of an individual thickness of up to 3
mm; design and calculation
DVS 2932-1 Resistance spot welding and resistance roller seam welding of alumini‐
um, and aluminium alloys of an individual thickness of 0.35 to 3.5 mm -
weldability
DVS 2932-3 Resistance point and seam welding of aluminium and aluminium alloys
of an individual thickness from 0.35 to 3.5 mm; preparation and execu‐
tion of welding
 Page 31
VW 01105-2: 2013-05

7 Bibliography
[1] DIN EN 573-4 Aluminum and aluminum alloys – Chemical composition and form of
wrought products – Part 4: Forms of products
[2] DVS 2936 Resistance projection welding of aluminum materials from 0,35 to 3,5 mm in‐
dividual thickness