Special Process: Welding System Assessment

Version 1, 3/2010

Special Process: Welding System Assessment 特殊过程：焊接系统评估

Facility Name:设备名称
Address:地址

Phone Number:联系电话 Type(s) of Weld Processing at this Facility:此设备焊接加工型号

Fax Number:传真 Process Table A - Arc Welding 过程表A-弧焊
Arc Stud/Fastener Welding 电弧螺柱/紧固焊接
Number of Welding Employees at this Facility:此设备焊接人数 Flux Cored Arc Welding 焊剂空心弧焊
Gas Metal Arc Welding 气体金属电弧焊接
Captive Weld Organization (Y/N) 焊接组织 Submerged Arc Welding 埋弧焊
Shielded Metal Arc Welding 屏蔽金属电弧焊接
Commercial Weld Organization 焊接组织 Plasma Arc Welding 等离子弧焊
(Y/N) Gas Tungsten Arc Welding 气体钨弧焊
Date of Assessment: 评估日期 Gas Metal Arc Braze Welding 气体金属电弧Braze焊接
Process Table B - Resistance Welding 过程表B-电阻焊
Resistance Spot Welding 点焊
Date of Previous Assessment: 前期评估日期 Projection Welding 投影焊接
Resistance Seam Welding 电阻缝焊
High-frequency Seam Welding 高频缝焊
Induction Seam Welding 诱导缝焊
Mash Seam Welding 滚压电阻缝焊
Flash Welding 闪光焊接
Process Table C - Laser Welding 过程表C-激光焊接
Nd YAG Welding Nd YAG焊接
CO2 Welding CO2焊接
Diode Welding 二极管焊接
Wire Fed
Process Table D - Solid State Welding 过程表D-固态焊接
Inertia Friction Welding 惯性摩擦焊接
Direct Drive Friction Welding 直接驱动摩擦焊接
Friction Stir Welding 搅拌摩擦焊接
Flash Butt Welding 闪光对焊
Resistance Butt Welding 电阻对焊
Ultrasonic Welding 超声波焊接
Current Quality Certification(s)当前质量
认证
Date of Re-assessment (if necessary):再次评估日期（如有需要）
Personnel Contacted:
Name Title Phone Email

Auditors/Assessors审计师/评估员
Name Company Phone Email

Number of "Not Satisfactory" Findings不满意数量

Number of "Needs Immediate Action" Findings需立即实施数量

Number of "Fail" Findings in the Job Audit(s)废品数量

© 2010 Automotive Industry Action Group (AIAG)

1
 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

Section 1 - Management Responsibility & Quality Planning

To ensure readily available expertise, there shall be a 为了确保有技术可用，现场应有专业的焊接人员。这个
dedicated and qualified welding person on site. This 人应是下列之一：焊接工程师或者同等学历、国际公认
individual shall be one of the following: Degreed Welding 的焊接检查人员或客户或供应商批准的人员。此人必须
Engineer, or equivalent science degree, Certified Welding 是全职员工，且职位必须体现在组织结构图中。工作描
Inspector from approved internationally recognized body, 述应以冶金和焊接的资格鉴定为准。资格应包括至少有
or person agreed upon between customer and supplier. 五年焊接经验或至少有五年正规冶金教育和焊接经验。
This person shall be a full-time employee and the position
Is there a dedicated and shall be reflected in the organization chart. A job
1.1 qualified technical welding description shall exist identifying the qualifications for the
person on-site? position including metallurgical and welding knowledge.
The qualifications shall include a minimum of 5 years
experience in welding operations or a combination of a
minimum of 5 years of formal metallurgical education and
welding experience.

The organization shall maintain a responsibility matrix 此组织应具备一份责任矩阵图来鉴别所有重要管理和监

identifying all key management and supervisory functions 督人员的职能以及执行该职能的资深人员。需确定首要
Is there a responsibility matrix
and the qualified personnel who may perform such 及次要（备份）重要职能人员（由该组织规定）。此图
to ensure that all key
functions. It shall identify both primary and secondary 需随时为管理和客户可用。
1.2 management and supervisory
(backup) personnel for the key functions (as defined by
functions are performed by
the organization). This matrix shall be readily available to
qualified personnel?
management and customer at all times.

The organization shall provide employee training for all 此组织应为员工提供焊接操作有关知识的培训。所有焊

welding operations specific to their job function. All 接工人，包括储备人员以及临时员工都需培训。所有这
welding employees, including backup and temporary 些培训应以文件形式存在，这些文件包括培训效率的评
employees, shall be trained. Documented evidence shall 估，必须证明客户具体要求和内在标准。并在适当的时
be maintained showing the employees were trained; the 候给予资格证书，如焊接工人。管理和客户应规定每项
evidence shall include an assessment of the effectiveness 职能的具体要求，后续培训也应被落实。
Do you use only qualified of the training, must prove knowledge of the customer's
1.3 specific requirements and internal standards, and where
welders (personnel)?
appropriate, employee certification, such as for a manual
welder. Management and customer shall define the
qualification requirements for each function and ongoing
or follow-up training shall also be addressed.

Required qualification maintenance. If the welder has not 所需资格的保持。在六个月里，如果一个焊工在某一特

welded in the specific operation in a 6 month time frame, 定的操作中没有作业，那么他必须重新进行资格认证。
the welder must be requalified to that operation. Based 基于该焊工的工作表现，要进行资格认证该焊工必须接
How do you maintain welder
1.4 on the welder's quality performance, it must be 受在培训。
certification?
established when retraining and requalification of the
individual must be performed.

Set-up verification to the procedures (as example: 设置符合验证程序的作业指导书（设备设置，夹紧设置

Is set-up practice in equipment settings, clamping sequence, weld sequence, ，焊接设置，旅游和其他方向的过程设置记录）
1.5 compliance with documented direction of travel and other process controls) in
work instructions? compliance to documented work instructions.

© 2010 Automotive Industry Action Group (AIAG) 2 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

The organization shall incorporate a documented

advance quality planning procedure. A feasibility study
shall be performed and internally approved for each part.
Similar parts can be grouped into part families for this
effort as defined by the organization. After the part 组织应有一份记录质量推进计划进程的文件。实施一
Does the welding organization approval process is approved by the customer, no 份可行性研究并适用于各个部件。相似零件可根据组织
1.6 perform advanced quality process changes are allowed unless approved by the 规定划分到同一系。部分审批被客户认同以后，没有客
planning? customer. The welding organization shall contact the 户的同意不能够修改。当过程需要改变时，焊接组织应
customer when clarification of process changes is 及时与客户联系。这一改变应被记录。
required. This clarification of process changes shall be
documented.

The organization shall incorporate the use of a

documented Failure Mode and Effects Analysis (FMEA)
procedure and ensure the FMEA's are updated to reflect
current part quality status.
The FMEA shall be written for each part or part family or 组织应包括使用FMEA程序的记录，并确保更新反
they may be process-specific and written for each 映出部件的质量状态。FMEA可被记录于每一部件
process. In any case, they shall address all process steps 或同一种，也可是特定的过程或者每一过程。在任何情
Are welding FMEA's up to
from part receipt to part shipment and all key welding
1.7 date and reflecting current 况下，应按照组织所规定的参数处理好从订单到装运以
process parameters as defined by the organization. A
processing? 及重要焊接的所有进程。跨职能团队应用于FMEA
cross-functional team shall be used in the development of
the FMEA. All special characteristics, as defined by the 的发展。所有被组织和客户所认定的特性应在
organization and its customers, shall be identified, FMEA中有所鉴定、规定和处理。
defined, and addressed in the FMEA.

The organization shall incorporate the use of a

documented Control Plan procedure and ensure the
Control Plans are updated to reflect current controls. The
Control Plans shall be written for each part or part family
or they may be process-specific and written for each
process. They shall address all process steps from part
receipt to part shipment and identify all equipment used
and all essential welding process parameters as defined 组织应包括文件型控制计划的使用来确保控制计划的随
by the relevant individual process tables or non-essential 时更新。控制计划可被记录于每一部件或同一种，也可
as agreed upon between supplier and customer. A cross- 是特定的过程或者每一过程。他们将按照供应商和客户
functional team, including a production operator, shall be 之间达成的相关参数从订单到装运到鉴定所有使用设备
Are welding process control
used in the development of Control Plans, which shall be 再到焊接过程中处理好所有的程序。一个跨职能团队,
1.8 plans up to date and reflecting
consistent with all associated documentation such as 包括生产制造操作工,应当用于控制计划的发展,符合
current processing?
work instructions, shop travelers, and FMEA's. All special 所有相关的文档,如工作指令,商店旅客,FMEA。
characteristics, as defined by the organization and its 所有被组织和客户所认定的特性应在控制计划中有所鉴
customers, shall be identified, defined, and addressed in 定、规定和处理。过程中和产品特性的样本大小和评估
the Control Plans. Sample sizes and frequencies for 频率应依靠在程序表中所列的对应的最低要求来解决。
evaluation of process and product characteristics shall
also be addressed consistent with the minimum
requirements listed in the Process Tables.

© 2010 Automotive Industry Action Group (AIAG) 3 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

To ensure all customer requirements are both understood

and satisfied, the organization shall have all specifically
related welding and customer referenced standards and
specifications available for use and a method to ensure
that they are current. Such standards and specifications
may include, but are not limited to, those relevant
documents published by SAE, AIAG, ASTM, ASME, 为确保所有的客户需求被理解和满足，组织应有相关专
AWS, ISO, General Motors, Honda, Ford, Toyota, and 业的焊接和客户参考标准以及可利用的规范方法，来确
Chrysler. The organization shall have a process to ensure 保他们的通用性。这些标准和规格包含
Are all welding related and the timely review, distribution, and implementation of all SAE、AIAG、ASTM、ASME、AW
referenced specifications customer and industry engineering S、ISO、美国通用汽车、Honda、Ford、
current and available? For standards/specifications and changes based on Toyota、以及Chrysler发表的相关文件。
1.9 example: SAE, AIAG, ASTM, customer-required schedule. Timely review should be as 根据客户需求，组织应有一个确保及时反馈、分布、和
ASME, AWS, ISO, General soon as possible and shall not exceed two working 实施所有客户和工厂工程标准/规格的程序。及时反馈
Motors, Honda, Ford, Toyota weeks. The organization shall document this process of 应尽快，不得超过两个工作周。组织应记录该反馈和实
and Chrysler. review and implementation, and it shall address how 施过程，还应解决客户和工厂的文件被吸收的问题、解
customer and industry documents are obtained, how they 决如何在组织中保持的问题、解决如何建立当前状态的
are maintained within the organization, how the current 问题、以及解决在两周内如何将相关信息与车间串联起
status is established, and how the relevant information is 来的问题。组织应规定谁对实施这些工作负责任。
cascaded to the shop floor within the two-week period.
The organization shall identify who
is responsible for performing these tasks.

The welding organization shall have written process

specifications for all active processes and repair
processes which identify all steps of the process including
relevant operating parameters. Examples of operating
parameters as defined by the relevant process tables. 焊接组织应具备成文的活动进程与修复进程的规划，此
Such parameters shall not only be defined, they shall 规划规定了相关操作参数的所有步骤。操作参数举例参
Is there a written process
have operating tolerances as defined by the organization 考相关进程表。为了保持进程受控，这些参数不仅要规
1.10 specification for all active
in order to maintain process control. 定好，还要有组织规定的操作宽度。这些进程规范可根
processes?
据工作指令、工作卡、设置表以及其它相似文件而有所
These process specifications may take the form of work 不同。
instructions, job card, set-up sheets, or other similar
documents.

© 2010 Automotive Industry Action Group (AIAG) 4 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

The organization shall perform product capability studies

for the initial validation of each process, after relocation of
any process equipment, and after a major process
change of any equipment or parameter. The organization
and customer shall define what constitutes a major
process change. Initial product capability studies shall be
conducted for all welding processes per each process
path defined in scope of work and in accordance with
customer requirements. In the absence of customer 组织应实行每一进程初步验证的产品性能研究，这一研
requirements, the organization shall establish acceptable 究在任何进程设备迁出以后以及在任何设备参数的主要
ranges for measures of capability. An action plan shall 进程改变后。组织和客户规定主要进程改变的组成。初
exist to address the steps to be followed in case capability 步的产品性能研究应按照客户的要求，实施于每段进程
Has a valid product capability indices fall outside customer requirements or established 的工作和承受范围的焊接工艺过程中。在缺乏客户要求
1.11 study been performed initially ranges. 的情况下，组织应建立可接受的能力测量范畴。应有一
and after process changes? 个行动计划来解决接下来的步骤，以防能力指数偏离客
户需求和确定的范围。/每一过程都包括焊接中作业的
Each process path includes all combinations of 所有设备的结合。性能研究技术应包含由控制计划所规
equipment that are integrated in the performance of a 定的样本状态并且满足客户的需求。例如：进程表所规
welding process, e.g., weld cell with A and B side fixture 定的任意公差的组合。
feeding another weld cell with A and B side fixture or
multiple machines. Capability study techniques shall
include boundary sample conditions as defined by the
control plan that are robust and meet all customer
requirements. Example, any combination of tolerances as
defined by Process Tables.

The analysis of products or processes over time can yield

vital information for defect prevention efforts. The
organization shall have a system to collect, analyze, and 随着时间的推移，产品及进程的分析会得到失误预防的
Does the welding organization react to product or essential process data over time.
重大信息。组织应有一个系统来搜集、分析、及应对产
monitor and analyze data over Methods of analysis shall include ongoing trend or
1.12 品或重要进程数据。分析方法应包括当前或过去的产品
time, and react to this data? historical data analysis of product or process parameters.
数据以及进程参数的分析。组织还应决定分析所包含的
The organization shall determine which parameters to 参数。
include in such analysis.

Is management reviewing the Management shall review the weld process control
weld control system at a systems. The management review shall include efforts to 管理者应审查焊接过程控制系统。管理审查应包括努力
1.13 frequency determined by the detect out-of-control conditions or alarm conditions. The 失控的条件或检测报警条件。回顾的过程控制系统应形
control plan? process of reviewing the control system shall be 成文件,并记录在控制计划中。
documented and recorded in the control plan.

Are internal assessments The organization shall conduct internal assessments on

being completed on an annual an annual basis, at a minimum, using the AIAG WSA. 组织应用AIAG(WSA)至少一年进行一次内部评
1.14
basis, at a minimum, using Concerns shall be addressed in a timely manner. 估，应及时处理问题。
AIAG WSA?

The quality management system shall include a process 质量管理体系应包括记录、评论、解决客户问题和组织

Does the Quality Department for documenting, reviewing, and addressing customer 内部问题。会使用一个有纪律的解决问题的方法。
review, address, and concerns and any other concerns internal to the
1.15
document customer and organization. A disciplined problem-solving approach shall
internal concerns? be used.

© 2010 Automotive Industry Action Group (AIAG) 5 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

The welding organization shall define a process for

continual improvement for their welding processes
identified in the scope of the WSA. The continual
Is there a continual 组织应确定焊接工艺过程的持续改进,因为焊接过程确
improvement process shall be designed to bring about
improvement plan applicable improvements in quality and productivity. Identified 定在WSA的范围内。持续改进过程的设计应提高质
1.16
to each process defined in the actions shall be prioritized and shall include timing 量和生产率。应优先考虑识别措施并且应当包含计时
scope of the assessment? (estimated completion dates). The organization shall (预计完成日期)。组织应说明程序的成效。
show evidence of program effectiveness.

Does the Quality Manager or The Quality Manager or designee is responsible for
designee authorize the authorizing and documenting the disposition of 质量部门经理或设计人员负责批准和记录处理待验物料
1.17
disposition of material from quarantined material. 。
quarantine status?
There shall be procedures or work instructions available
to welding personnel covering the welding process. These
procedures or work instructions shall include methods of
焊工进行焊接工艺需有可行的工作指导和程序。这些程
Are there procedures or work addressing potential emergencies (such as power failure),
序或作业指导书应包括潜在突发事件应对的方法(如停
instructions available to the equipment start-up, equipment shut-down, product
1.18 电),设备启动,设备停机、产品隔离(见2.8),产品检
welding personnel that define segregation (See 2.8), product inspection, safety, house-
keeping, and general operating procedures. These 验、安全、做家务的问题,和一般操作程序。这些程序
the welding process?
procedures or work instructions shall be accessible to 或工作说明书应放在车间的人员可见之处。
shop floor personnel.

The organization shall have a documented preventive

maintenance program for process equipment (as
identified by the Process Tables). The program shall be a
closed-loop process that tracks maintenance efforts from
request to completion to assessment of effectiveness.
Is there a preventive Equipment operators shall have the opportunity to report 组织应有一个可以记录 "机构应是否有记录的预
maintenance program? Is problems, and problems shall also be handled in a
防性维修程序对工艺设备鉴定的过程(如表。程序应该
maintenance data being closed-loop manner.
1.19 是闭环过程追踪努力维护要求完成评估的有效性。设备
utilized to form a predictive Company data, e.g., downtime, quality rejects, first-time-
through capability, recurring maintenance work orders, 操作人员将有机会来报告问题,也要处理问题的方式。
maintenance program?
and operator-reported problems, shall be used to improve 一个闭环系统
the preventive maintenance program.
Maintenance data shall be collected and analyzed as part
of a predictive maintenance program.

© 2010 Automotive Industry Action Group (AIAG) 6 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

Has the welding organization The welding organization shall develop and maintain a
developed a critical spare part critical spare parts list and shall ensure the availability of 公司的数据,例如、停机时间、质量first-
1.20 list and are the parts available such parts to minimize production disruptions. time-through能力绝的,,复发的命令,一个维修
to minimize production 工作
disruptions?

How does the organization Reaction plans are to be followed per the control plan and
document and respond to PFMEA or, in the case of newly indentified issues PFMEA 反应计划必须遵循控制计划和PFMEA,或者新鉴
1.21 quality spills, and control plan must be updated to reflect the new 定的PFMEA。控制计划必须及时更新以反映新的
nonconformance, customer failure mode and reaction steps taken.
失效模式和采取的反应措施。
concerns?

If there are to be changes in process outside of the

current control plan and last agreed upon process and 如果再加工过程中有不同于当前控制计划的变化或者不
What is the process deviation parts sign off, do you know what your customer
同于已经签署的有关工艺和零件的合同，那么，你知道
1.22 requirements of your requirements are, have you notified your customer, and
你的客户要求吗？你通知了客户吗？你在修改之前的到
customer? do you have customer approval prior to making the
change? 客户的允许了吗？

The quality management system shall include a 质量管理体系应有一个文件性的程序以便用来再加工和

documented process for reprocessing and repair that 修补还应包括顾客指定的人员批准。这个过程应描述产
shall include authorization from a customer designated 品的是否被再加工的特征。任何再加工活动需要一份新
individual. The process shall describe product 的由资深技术人员发布的焊接改性加工控制表。记录应
characteristics for which reprocessing is allowed as well 当清楚的反应材料再加工的时间和方式。由质量经理或
as those characteristics for which reprocessing is not 设计人员授权再加工产品的出厂。
Is there a system in place to permissible. Any reprocessing activity shall require a new
1.23 authorize reprocessing and processing control sheet issued by qualified technical
repair? Is it documented? personnel denoting the necessary welding modifications.
Records shall clearly indicate when and how any material
has been reprocessed. The Quality Manager or a
designee shall authorize the release of reprocessed
product.

© 2010 Automotive Industry Action Group (AIAG) 7 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

Section 2 - Floor and Material Handling Responsibility

It is critical that all customer requirements and lot
identification be adequately transferred to internal welding
documents. The facility shall ensure that the data entered
in the receiving system match the information on the
customer's shipping documents. Documented processes
and evidence of compliance shall exist, e.g., shop 将客户所有的需求和货物识别写入内部焊接文件中是十
Does the facility ensure that travelers, work orders, etc. Sometimes the material 分必要的。工厂应当确保接收系统中的数据与客户装船
the data entered in the received does not precisely correspond to customer 文件相匹配。记录的过程和合格证明应当存在于例如,
2.1 receiving system matches the shipping documents. The facility shall have a detailed 车间巡视，工作秩序等中。有时，收到的材料与客户的
information on the customer's process in place to resolve receiving discrepancies. 装船单据并不完全吻合。工厂应有一个细致的方案来解
shipping documents? The requirements stated above also apply to captive 决这种差异。上述的要求也同样适用于静态焊接部门。
welding departments. This process refers to receiving 这一过程是指从焊接部门接收和装运零件。
and shipping the parts in and out of the welding
department.

Procedures for part and container identification help to

avoid incorrect processing or mixing of lots. Appropriate
location and staging within the facility also help to ensure 与部件的有关程序和集装箱识别都可以帮助避免错误的
that orders are not shipped until all required operations 加工和货物的混合。设备中适当的定位和分工也有助于
Is product clearly identified are performed. Customer product shall be clearly 确保在所有运算完成之后才进行装运。整个焊接的过程
2.2 and staged throughout the identified and staged throughout the welding process. 应当明确客户的产品需求。非焊接品，加工品以及成品
welding process? Non-welded, in-process, and finished product shall be 都应当明确分离和标识。所有的材料都应该在一个精密
properly segregated and identified. All material shall be 的规定明确的区域里进行。
staged in a dedicated and clearly defined area.

Out-going lot(s) shall be traceable to the incoming lot(s).

Is lot traceability and integrity The discipline of precisely identifying lots and linking all 出货对进料来说应该是可塑的。精细的货物识别以
2.3 maintained throughout all pertinent information to them enhances the ability to do 及与之相关的信息可以加强对根源的分析和不断的提高
processes? root cause analysis and continual improvement. 。

The control of suspect or non-conforming product is 对不合格的产品必须进行控制以避免装货的疏忽和其他

required to prevent inadvertent shipment or contamination 产品的污染。程序应当足以防止不合格产品进入到生产
of other lots. Procedures shall be adequate to prevent 系统中。程序应存在适当的配置,以解决产品识别、和
movement of non-conforming product into the production 材料输入和运出追踪问题。不合格物品暂放地就是用来
Are procedures adequate to system. Procedures shall exist addressing proper 分离这些不合格材料的。
prevent movement of non- disposition, product identification, and tracking of material
2.4
conforming product into the flow in and out of the hold area. A non-conforming hold
production system? area shall be clearly designated to maintain segregation
of such material.

© 2010 Automotive Industry Action Group (AIAG) 8 of 34

 Special Process: Welding System Assessment
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Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

Containers handling customer product shall be free of

inappropriate material and contaminants. After emptying
and before re-using containers, containers shall be
inspected to ensure that all parts and inappropriate 处理客户产品的容器不应选用不合格材料且应当远离污
Are containers free of material have been removed. The source of 染。。排空后或再利用容器前,都应当检查所有零件，
2.5 inappropriate material and inappropriate material shall be identified and addressed. 以及是否不合格材料和污染物都被处理。不合格材料应
contaminants? This is to ensure that no nonconforming welded parts or 当特别标识。这是为了保证没有不合格的焊件和材料污
inappropriate material contaminate the finished lot. 染成品。

Loading parameters shall be specified, documented, and

Is part loading specified, controlled. Examples include part load sequence and 振动荷载参数有明确规定,存档,并且控制。例子包括部
2.6
documented and controlled? clamp sequence. 件负荷序列和夹具序列。

Operators shall be trained in material handling,

containment action, and product segregation in the event
of an equipment emergency including power failure.
Training shall be documented. Work instructions 操作人员应当接受在包括停电等突发事件时有关材料处
specifically addressing potential types of equipment 理、隔离行为和产品隔离的培训。培训应形成文件。作
Is there a containment emergencies and failures shall be accessible to and 业指导书专门说明潜在突发事件的类型，应该放在设备
reaction plan and are understood by equipment operators. These instructions
2.7 操作人员可见之处，并易于他们理解。这些指导书应解
operators trained in the shall address containment/reaction plans related to all 决有关焊接加工过程中出现的污染和反映计划等问题。
process? elements of the welding process. Evidence shall exist 还应有可以说明产品可塑性和配置的文件。意外事件和
showing disposition and traceability of affected product. 停工加大了错误加工的出现。
Unplanned or emergency downtime greatly raises the risk
of improper processing.

The welder’s loading system, in-process handling, and

对焊工的加载系统、过程处理和运输过程应进行评估，
Is the handling, storage and shipping process shall be assessed for risk of part
damage or other quality concerns. 因为在这些过程中，有零件损坏的风险以及其他质量问
2.8 packaging adequate to
preserve product quality? Other practices such as stacking of overloaded containers 题。例如集装箱重叠的其他一些事故也会提高低部件损
can also increase the risk of part damage. 坏的风险。

Plant cleanliness, housekeeping, environmental, and

working conditions shall be conducive to controlling and
improving quality. The welding organization shall
Are plant cleanliness, evaluate such conditions and their effect on quality. A 植物清洁、卫生、环境和工作条件,应当有利于控制和
housekeeping, environmental housekeeping policy shall be clearly defined and 提高质量。焊接组织应评估这些条件及其对质量的影响
2.9 and working conditions executed. The facility shall be reviewed for conditions 。一条明确的卫生条例应该被执行。应有一个可以反映
conducive to control and that are detrimental to quality processing such as loose 不利于加工质量的设备。这些不利因素包括，部件松落
improved quality? parts on floor, contaminants, oil, inadequate plant lighting, ,污染物,石油，不充足的照明等。
fumes, etc.

© 2010 Automotive Industry Action Group (AIAG) 9 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

Are parts free from Parts shall be free from contaminants that are detrimental
contaminants that would be to the quality of the welding processes, subsequent
processes, or the product. If applicable, pre-wash and 部件应该远离污染，这些污染对焊接过程的质
detrimental to the quality of
2.10 post-wash parameters shall be monitored and 量，随后的工艺，或者产品都是不利的。如果适用,预
the welding processes,
documented. 洗和后洗参数都应该受监测和记录在案。
subsequent processes, or the
product?

Section 3 - Equipment / Facilities/Controls

This could include but is not limited to, facilities
capabilities such as safely, environmental
regulations/practice, sufficient incoming power (balance 这可能包括但不仅限于设备能力,如安全、环保及相关
的公司规定,足够的进料/实践能力(平衡),空气和加载
Are the facilities sufficient for and loading), air (sizing, filtering and cleanliness), water,
3.1 power supply grounding per OEM and regulatory 时,过滤和清洁)、水、供电接地/ OEM和定期的监
the welding operation?
specifications, gas mixing system (equipment and sizing), 督管理、气体混合系统(设备和上浆)、通风、和充足
ventilation, and adequate lighting. 的照明。

The power supply should be adequate for the

Are the power supplies manufacturing process with consideration not limited to 加工过程的电源应充足，也应考虑到不限制输出能量责
3.2 output energy, duty cycle, cooling, flow rates and
sufficiently sized? 任周期、冷却、流速和接地。
grounding.
The calibration and certification of the process equipment
Are process equipment shall be checked at regular specified intervals. Refer to
calibrations and/or verification the applicable Process Tables.
3.3 应定期检查工艺设备的校验和认证。参照适用工艺表。
certified, documented,
available, and current?

Supplier shall have a preventative maintenance program

Has a preventative that is documented and implemented. Refer to Section 供应商必须有一个可以记录和实施的预防性维护计划。
3.4 maintenance program been 1.19 and the applicable Process Tables.
参照1.19节和适用工艺表。
established and documented?

The replacement parts and process consumables shall be 部件的更换和加工的耗材应以合适的数量和存储来识别

identified, maintained in the appropriate volumes and 。耗材必须存在于客户的材料清单中(如适用)。参阅
proper storage. Consumables must be on the customer's 适用工艺表,2.0节和1.19节。这将被储存在工具
Have the necessary approved source list (if applicable). Refer to the applicable 加工中,如设置程序,PFMEA、控制计划。它应包
replacement parts and Process Tables, Section 2.0 and Section 1.19. This shall 含在分层过程审核或其他类似的质量审核过程中。
3.5 process consumables been be captured in tools such as the set up procedure,
identified and made readily PFMEA and Control Plans. It should be included in the
available? layered process audit or other similar type quality review
process.

The welding operation shall have a list of welding

Are the process, equipment, process, equipment, and safety alarms. These alarms
and safety alarm checks shall be individually tested at the required frequency as 焊接作业有一大串焊接工艺、设备、安全警报器。这些
3.6 being tested at the required listed in the control plan, and after any repair, process 警报应在特定的时间例如，在控制计划中，修理后，工
frequency or after any repair change or rebuild. These checks shall be documented. 艺改变或者工艺重建。这些检查应形成文件。
or rebuild?

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 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

Section 4 - TOOLING/FIXTURING
Supplier shall have documentation of the fixture design,
that are stored properly and accessible. Proper 供应商有可以记录夹具设计的文件,该文件必须合理的
Is there a record of the design identification and revision level on the fixture or related to
4.1 存储和易于拿取。正确的标识和修订应与夹具一致或与
and set-up of the fixture? the fixture. Documented fixture set-up (i.e., clamps, pins, 其相关。夹具安装文件(例如,夹、别针、定位设备)
locating devices)
A method to detect proper fixture and part position is
一个可以侦夹具和部件位置的方法对每一个部件来是必
Is the positioning of each part required for each part, such as the use of proximity
4.2 switches, optical sensors, mechanical probes, part 须的如使用接近开关、光传感器、机械探针,部分存在
being controlled?
presence or poke yokes., etc. 或轭等

Supplier shall have a preventative maintenance program

Has fixturing/tooling that is documented and implemented. Refer to Section 供应商必须有一个实时性和记录性强的预防性维护计划
4.3 preventative maintenance 1.18 and the applicable Process Tables. Examples: 。可参阅1.18节和适用工艺表。例如：进行清洗、
program been established? cleaning, degreasing, and fixturing integrity. 脱脂以及夹具的完整性。

Are the fixture components Gas, air, sensors, control cables, etc. are adequately 煤气、空气、传感器、控制电缆等在加工过程需充分的
4.4 protected for the process environment. 保护。
robust?
Fixturing/tooling was developed considering movement,
Are the tooling components reach, accessibility, tool center point, maintenance, and
4.5 designed for the welding ergonomics (manual, automatic, and robotics) 夹具/模具的开发需要考虑到运动、易操作、工具中心
process?
点、维护,和工效学（人，自动化，和机器人）
Section 5 - PROCESS CONTROLS AND CONFIRMATION
Identify the process control equipment necessary to
monitor, control and provide feedback on all essential 识别过程控制设备对监测、控制十分重要，它可以为所
Does welding operation
5.1 process variables as listed below and in the applicable 有必须的过程变量提供反馈。过程变量如下所列或在进
include the following?
Process Tables. 程表中。

Logic has been established to effectively identify and

5.1.1 address process or equipment faults. 应有逻辑以有效地识别和处理过程或设备故障。
5.1.2 With over rides or resets, logs must be maintained. 由于超额负载或休眠，原木必须经常维修。

5.1.3 Weld faults audible, visible and line shut down. 焊缝断裂声、可见光和线关闭。
At weld cycle interrupt, part must not be removed or 在焊接循环中断过程中，直到适当的人处理时，部件才
5.1.4 passed until dispositioned by appropriate personnel. 能够被移走。
5.1.5 Calibration of meters and system controls. 米和系统控制的校准。
Inter-locking of previous operations have occurred and 结合业已发生的操作和在下个操作开始前已经检测的部
5.1.6 quality of parts has been verified before the next 件的质量。
operation begins.
Secure backups of all programs and procedures 确保所有的项目和程序的备份(电子的最好)。
5.1.7 (electronic preferred).

5.1.8 High/Low limit alarms established by actual data. 高/低限告警由实际数据来确定。

Process variables have been defined and developed by 过程变量由统计数据来鉴定和开发并具有统计能力

5.1.9 data and shown to be statistically capable.

5.1.10 Acceptable traceability (sequence/date coding) 可接受的可塑性（序列/日期编码）

© 2010 Automotive Industry Action Group (AIAG) 11 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Special Process: Welding System Assessment

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a
violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group
Assessment

Question Needs Immediate

Question Requirements and Guidance Objective Evidence N/A Satisfactory Not Satisfactory
Number Action

5.1.11 All tooling and process changes are documented. 记录所有模具和加工的变化

Documented welding procedures for each weld location 记录每一焊焊接工艺位置和每个过程变量

5.1.12 and each process variable.

5.1.13 Change over procedure (filler material, fixtures) 修改程序(填充材料、装置)

Must have documented start-up and shut-down

5.1.14 procedure. 必须有书面的启动和关闭手续。
Process control parameters shall be monitored per
Are process control frequencies established in the control plan. An 监控工艺控制参数应经常性的在控制计划中建立。由一
5.2 parameters monitored at appropriate person shall verify the process control 个合适的人来审核过程控制参数。管理评审的每题需要
established frequencies? parameters. Management review is required per 1.13。
Question 1.13.

How does the organization Are there documented reaction plans with appropriate
levels of containment for both out of control and out of 是否有反应计划的记录，该记录可用来适时遏制失控和
review and react to out of
5.3 tolerance process parameters? Is there documented 工艺参数的公差?是否有明确的记录可以说明即将实施
control/specification
evidence that reaction plans are followed? 的反应计划？
parameters?

How does the organization There shall be a hierarchy established for making and
approving process changes. Each process should be 应建立一个分层结构用来的制作和批准过程的变化。每
handle changes to process
5.4 acted on according to the level of change. Review 个过程应根据变化水平的变化而实施。评审过程的变化
control parameters after initial
process changes with your customer. 随客户变化。
customer approval?

Are In-Process and Final In-Process and Final Tests shall be performed per
frequencies in the control plan as agreed upon between 过程和最终测试应在供应商和客户双方同意的控制计划
5.5 Tests performed at
the supplier and the customer. 的频率中进行。
established frequencies?

Are weld quality requirements Weld quality requirements per internal and customer 每个客户的焊接质量要求标准,如不限于如下的测试方
5.6 clearly defined per customer specifications, such as but not limited to the following 法。
specifications? testing methodology:

5.6.1 Cut and etch 切割和蚀刻

Part location, warping, gap, and dimensional 零件位置，翘曲，差距和尺寸要求
5.6.2
requirements
5.6.3 Correct number of welds 焊缝正确号
5.6.4 Weld length/size 焊缝长度/尺寸
5.6.5 Weld location 焊缝位置
5.6.6 Non Destructive Testing (NDT) 非破换性测试
5.6.7 Spatter, undercut, porosity, discontinuities,… 溅出,削弱、孔隙度、间断,
5.6.8 Weld direction confirmation 焊缝方向确认
5.6.9 Destructive testing 破坏性测试
5.6.10 Additional testing 额外的测试

© 2010 Automotive Industry Action Group (AIAG) 12 of 34

 Special Process: Welding System Assessment
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Section 6 - Job Audit

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered
or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Base Metal Specifications:
Filler Metal Specification (if required):
Welding Process(es):
Job (Shop) Order or
Related Customer or Internal Actual Condition Pass /
Question # Job Audit Question作业审计问题 Reference Documentation
WSA Question # Requirement (Objective Evidence) Fail / N/A
Requirement
1.8
Has the welding operation identified the 5.1
process control equipment necessary to 5.2
6.1 monitor, control and provide feedback on all
essential process variables as listed in the
applicable Process Tables?

Has the logic been established to effectively 5.1

6.2 identify and address process or equipment
faults?
Are over rides or resets logs maintained? 5.1.2
6.3

Are weld faults audible, visible and does the 5.1.3

6.4
line shut down?
2.7
If the weld cycle is interrupted, is the part 5.1.4
6.5 controlled or contained until dispositioned
by appropriate personnel?

Are the meters and feed back controls 5.1.5

6.6 3.3
calibrated per established frequencies?
If applicable, is there an inter-locking of the 5.1.6
6.7 previous operation and has the quality of
parts been verified?

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 Special Process: Welding System Assessment
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Section 6 - Job Audit

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered
or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Base Metal Specifications:
Filler Metal Specification (if required):
Welding Process(es):
Job (Shop) Order or
Related Customer or Internal Actual Condition Pass /
Question # Job Audit Question作业审计问题 Reference Documentation
WSA Question # Requirement (Objective Evidence) Fail / N/A
Requirement
5.1.7
Are there secure backups of all programs
6.8
and procedures (electronic preferred)?

Are high/low limit alarms established by 5.1.8

6.9 actual data. 5.1.1

Have process variables been defined and 5.1.9

6.10 developed by data and shown to be
statistically capable?
5.1.10
Is there acceptable traceability 5.1.11
6.11 2.3
(sequence/date coding)?
2.7
4.1
Is there traceability of all process and 5.1.11
6.12
tooling changes? 5.4

5.1.12
Are there documented welding procedures 1.5
6.13 for each weld location and each process 1.10
variable?

1.5
Is there a documented change over 5.1.13
6.14
procedure (filler material, fixtures)? 3.6

1.5
Is there a documented start-up and shut- 1.10
6.15
down procedure? 5.1.14

© 2010 Automotive Industry Action Group (AIAG) 14 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

Section 6 - Job Audit

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered
or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Base Metal Specifications:
Filler Metal Specification (if required):
Welding Process(es):
Job (Shop) Order or
Related Customer or Internal Actual Condition Pass /
Question # Job Audit Question作业审计问题 Reference Documentation
WSA Question # Requirement (Objective Evidence) Fail / N/A
Requirement
5.2
Are process control parameters monitored
6.16
at established frequencies?

5.3
Are there documented reaction plans with 1.21
appropriate levels of containment to both 5.6
6.17 out of control and out of tolerance process 1.8
parameters and provide documented 2.7
evidence that reaction plans are followed?

1.6
How does the organization handle changes 5.4
to process control parameters after initial 1.22
6.18
customer approval and how do you notify 1.16
your customer?

Are In-Process and Final Tests performed 1.8

6.19 5.5
at established frequencies?

Are weld quality requirements clearly 1.9 Each part may have one or more requirements determined by the welding specification.
6.20 5.6
defined per customer specifications? Parts must meet each requirement. List requirements below and validate.
6.20.1 Test Type:
Test Method:
Test Frequency and Quantity:
Specification:

6.20.2 Test Type:

Test Method:

© 2010 Automotive Industry Action Group (AIAG) 15 of 34

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Section 6 - Job Audit

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered
or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Base Metal Specifications:
Filler Metal Specification (if required):
Welding Process(es):
Job (Shop) Order or
Related Customer or Internal Actual Condition Pass /
Question # Job Audit Question作业审计问题 Reference Documentation
WSA Question # Requirement (Objective Evidence) Fail / N/A
Requirement
Test Frequency and Quantity:
Specification:

© 2010 Automotive Industry Action Group (AIAG) 16 of 34

 Special Process: Welding System Assessment
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Section 6 - Job Audit

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered
or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group

Job Identity:
Customer:
Shop Order Number:
Part Number:
Part Description:
Base Metal Specifications:
Filler Metal Specification (if required):
Welding Process(es):
Job (Shop) Order or
Related Customer or Internal Actual Condition Pass /
Question # Job Audit Question作业审计问题 Reference Documentation
WSA Question # Requirement (Objective Evidence) Fail / N/A
Requirement
6.20.3 Test Type:
Test Method:
Test Frequency and Quantity:
Specification:

6.20.4 Test Type:

Test Method:
Test Frequency and Quantity:
Specification:

© 2010 Automotive Industry Action Group (AIAG)

© 2010 Automotive Industry Action Group (AIAG) 17 of 34

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PROCESS TABLE A- Arc Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The
information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service
marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming
to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Gas
Arc Stud/ Flux- Gas Metal Shielded
Submerged Plasma Arc Tungsten Gas Metal
Related WSA Fastener Cored Arc Arc Metal Arc
Item # Category/Process Steps Arc Welding Welding Arc Arc Braze
Question # Welding Welding Welding Welding
(SAW) (PAW) Welding Welding
(SW) (FCAW) (GMAW) (SMAW)
(GTAW)

1.0 1.7, 1.8 Arc welding specific essential variables which shall be
addressed in the FMEA, control plan and welding
procedures

A1.1 Arc voltage x x x x x x

A1.2 Amperage x x x x x x x x
A1.3 Current type (AC/DCEN/DCEP) x x x x x x x x
A1.4 Wire feed speed x x x x1 x1 x
A1.5 Pulse setting variables specific to the OEM of the welding
equipment must be documented and controlled. x x x x
A1.6 Stud gun/torch position work angle, travel angle x x x x x x x x
A1.7 Contact tip-to-work distance x x x x
A1.8 Electrode-to-work distance ü x x
A1.9 Lift height of stud x
A1.10 Fastener coating (determines current type) x
A1.11 Plunge control mode force or position x
A1.12 Flux classification and depth x
A1.13 Flux removal and reclaimation plan x
A1.14 Gas flow pre-flow, post-flow, rate and type(s) x2 x2 x x x x
A1.15 Electrode and/or filler metal type, diameter, and x
classicifacation x x x x x1 x1 x
A1.16 Travel speed x x x ü x x x
A1.17 Gas nozzle size and type x2 x2 x x x x
A1.18 Arc starting parameters x x x ü x x x

© 2010 Automotive Industry Action Group (AIAG) 18 of 34

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PROCESS TABLE A- Arc Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The
information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service
marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming
to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Gas
Arc Stud/ Flux- Gas Metal Shielded
Submerged Plasma Arc Tungsten Gas Metal
Related WSA Fastener Cored Arc Arc Metal Arc
Item # Category/Process Steps Arc Welding Welding Arc Arc Braze
Question # Welding Welding Welding Welding
(SAW) (PAW) Welding Welding
(SW) (FCAW) (GMAW) (SMAW)
(GTAW)

A1.19 Arc end parameters x x x x x x

A1.20 Wire burnback settings x x x x
A1.21 Plunge depth x
A1.22 Arc time x x3 x3 x3 x3
A1.23 Fastener geometry per material type x
A1.24 What are your Nozzle cleaning and cleaners, replacement ü ü ü ü ü ü
A1.25 procedures for: Tip changes ü ü ü ü ü
A1.26 Wire liners/conduits cleaning and replacing ü ü ü ü
A1.27 Drive roll changes ü ü ü ü
A1.28 Wire guide tube change ü ü ü ü
A1.29 Antispatter Application (spray/dip and equipment) ü ü ü
A1.30 Electrode and stud collet change ü ü
A1.31 O rings in gas system maintenance ü ü ü ü ü ü
A1.32 Gas delivery and mixing system x 2
x 2
x x x x
A1.33 Flux delivery systems maintenance ü
A1.34 Flux removal (screens size and magnetic separators) ü
A1.35 Electrode sharpening ü ü
A1.36 Slag removal x x x
A1.37 Wire dereelers maintenance ü ü ü ü
A1.38 Wire brake adjustment ü ü ü ü
A1.39 Integrity of ground system ü ü ü ü ü ü ü ü
x : Processes can be used both with and without filler metal.
1

x2: These welding processes are designated for either gas shielded, self shielded or gasless.

© 2010 Automotive Industry Action Group (AIAG) 19 of 34

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PROCESS TABLE A- Arc Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The
information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service
marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is conforming
to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Gas
Arc Stud/ Flux- Gas Metal Shielded
Submerged Plasma Arc Tungsten Gas Metal
Related WSA Fastener Cored Arc Arc Metal Arc
Item # Category/Process Steps Arc Welding Welding Arc Arc Braze
Question # Welding Welding Welding Welding
(SAW) (PAW) Welding Welding
(SW) (FCAW) (GMAW) (SMAW)
(GTAW)

x3: Arc Spot welding applicactions only.

© 2010 Automotive Industry Action Group (AIAG)

© 2010 Automotive Industry Action Group (AIAG) 20 of 34

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PROCESS TABLE B- Resistance Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such
content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action
Group are registered service marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is
conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

High- Mash
Resistance Resistance Induction
Projection Frequency Seam Flash
Related WSA Spot Seam Seam
Item # Category/Process Steps Welding Seam Welding Welding*
Question # Welding Welding Welding
(PW) Welding (RSEW- (FW)
(RSW) (RSEW) (RSEW-I)
(RSEW-HF) MS)

2.0 1.7, 1.8 Resistance welding specific essential variables which

shall be addressed in the FMEA, control plan and
welding procedures

B2.1 Weld force X X X X X

B2.2 Clamp force ü ü ü
B2.3 Forge force ü ü ü
B2.4 Forge delay ü ü
B2.5 Amperage X X X X
B2.6 Voltage X X X X ü
B2.7 Power ü ü
B2.8 Frequency X X X X X X X
B2.9 Pulsation X X X X
B2.10 Squeeze time/cycles X X X X
B2.11 Weld time/cycles X X X X X
B2.12 Hold time/cycles X X X X X
B2.13 Quench time/cycles ü ü ü ü ü ü ü
B2.14 Temper time ü ü ü ü ü ü ü
B2.15 Cool time/cycles X X X X
B2.16 Upslope time/cycles X X X X X X X

© 2010 Automotive Industry Action Group (AIAG) 21 of 34

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PROCESS TABLE B- Resistance Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such
content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action
Group are registered service marks of the Automotive Industry Action Group
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify welding is
conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

High- Mash
Resistance Resistance Induction
Projection Frequency Seam Flash
Related WSA Spot Seam Seam
Item # Category/Process Steps Welding Seam Welding Welding*
Question # Welding Welding Welding
(PW) Welding (RSEW- (FW)
(RSW) (RSEW) (RSEW-I)
(RSEW-HF) MS)

B2.17 Stepper programs X

B2.18 Tip/electrode/wheel dressing X X X X X X
B2.19 Weld travel speed X X X X
B2.20 Adequate electrode follow up in weld force / distance X X X
B2.21 System cooling-transformers, electrodes, etc. X X X X X X X
B2.22 Tip/electrode/wheel/coil change frequency X X X X X X X
B2.23 Tip/electrode/wheel/coil alignment X X X X X X X
B2.24 What are your Electrode selection/type (material type etc.) ü ü ü ü ü ü
B2.25 procedures for: Electrode geometry ü ü ü ü ü ü
B2.26 Induction coil geometry ü
B2.27 Secondary loop electrical conductors (cables, leaf shunts, ü ü ü ü ü ü ü
etc.) and mechanical joints maintenance
B2.28 Projection weld geometry and size ü

*Flash Welding is a Solid State process, however, the process controls most resemble a resistance weld process.
Refer to Table D for other requirements on Flash Welding

© 2010 Automotive Industry Action Group (AIAG)

© 2010 Automotive Industry Action Group (AIAG) 22 of 34

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PROCESS TABLE C- Laser Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

With Wire
Related WSA Nd YAG CO2 DIODE
Item # Category/Process Steps Feed
Question # (LBW) (LBW) (LBW)
System

3.0 1.7, 1.8 Welding specific essential variables which shall be

addressed in the FMEA, control plan and welding
procedures

Equipment
C3.1 Beam quality X X X X
C3.2 Optic cleanliness X X X X
C3.3 Cross jet or laser knife X X X X
C3.4 Beam configuration (split, single) X X X X
C3.5 Focal length X X X X
C3.6 Beam spot size X X X X
C3.7 Gas tube angle/arrangement X X X X
C3.8 Optics purge gas (flow and quality) X X
C3.9 Mirror cleanliness X X X
C3.10 Mirror degradation X X X
C3.11 Beam sharing X X X X
C3.12 Split beam X X X X
C3.13 Tip changes X
C3.14 O rings in gas system X

© 2010 Automotive Industry Action Group (AIAG) 23 of 34

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PROCESS TABLE C- Laser Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

With Wire
Related WSA Nd YAG CO2 DIODE
Item # Category/Process Steps Feed
Question # (LBW) (LBW) (LBW)
System

C3.15 Gas nozzle X

C3.16 Torch angles X
C3.17 Chillers (internal - external) X X X X
C3.18 - Flow rate X X X X
C3.19 - Water quality X X X X
C3.20 - Type of coolant X X X X
C3.21 - Additive concentration X X X X
C3.22 - Temperature control (rate of change and range) X X X X
C3.23 Wire feed system X
C3.24 - Wire feed speed X
C3.25 - Wire liners/conduits cleaning and replacing X
C3.26 - Drive roll changes X
C3.27 - Wire guide tube X
C3.28 - Wire derealers X
C3.29 - Wire brake adjustment X
C3.30 - Wire cleaners/wipers X
C3.31 - Contact tip to work distance X
C3.32 - Wire position to laser focal point X

© 2010 Automotive Industry Action Group (AIAG) 24 of 34

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PROCESS TABLE C- Laser Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

With Wire
Related WSA Nd YAG CO2 DIODE
Item # Category/Process Steps Feed
Question # (LBW) (LBW) (LBW)
System

Beam Delivery
C3.33 Direct X X
C3.34 Fiber X X X
C3.35 - Fiber diameter X X X
C3.36 - Fiber lengths X X X
C3.37 - Bend radius X X X
C3.38 - Condition of fiber X X X
C3.39 - Fiber ends (condition of fiber ends) X X X
C3.40 - Fiber end cooling X X X
C3.41 Mirror X X
C3.42 - Power loss though the delivery system X X
C3.43 - Alignment X X
C3.44 - Cleanliness X X
C3.45 - Coatings of mirror X X
C3.46 - Mirror type X X
C3.47 - Optic and mirror cooling X X
Process Variables
C3.48 Shielding gas type - flow rate X X X X
C3.49 Weld travel speed control (rate of change, and velocity X X
control) X X
C3.50 Power Output Control X X X X

© 2010 Automotive Industry Action Group (AIAG) 25 of 34

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PROCESS TABLE C- Laser Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or
disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright
infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action
Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit,
the auditor shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

With Wire
Related WSA Nd YAG CO2 DIODE
Item # Category/Process Steps Feed
Question # (LBW) (LBW) (LBW)
System

C3.51 Power ramping/program (start, weld, end) X X X X

C3.52 Power at the work piece X X X X
C3.53 Offset of beam to joint X X X X
C3.54 Continuous wave X X X X
C3.55 Pulsation X X X X
C3.56 Angle of Incidence X X X X
C3.57 Focus point X X X X
C3.58 Direction of welding (trailing or lead) X X X X
C3.59 Beam quality burn-in X X X X
C3.60 Power output control calibration X X X X
C3.61 Plasma suppression X X
C3.62 - Monitoring Back scatter for control process ü ü ü ü

Fixtures/Part
C3.63 - Stability and/or vibration isolation X X X X
C3.64 - Articulation system (smoothness of motion and accuracy) X X X X
C3.65 What are your Part fit up ü ü ü ü
C3.66 procedures for ü ü ü ü
Seam tracking
controlling:
C3.67 Edge condition ü ü ü ü
C3.68 Coatings ü ü ü ü

© 2010 Automotive Industry Action Group (AIAG)

© 2010 Automotive Industry Action Group (AIAG) 26 of 34

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PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

4.0 1.7, 1.8 Welding specific essential variables which shall be

addressed in the FMEA, control plan and welding
procedures

D4.1 Tolerances on axial alignment X X X

D4.2 Faying surface area X X X
D4.3 Faying surface cleanliness X X X
D4.4 Initial spindal speed X X X
D4.5 Welding spindal speed X
D4.6 Spindal torque - to not damage equipment X X X
D4.7 Flywheels; total moment of inertia X
D4.8 Spindle clamp pressure X X X
D4.9 Fixture clamp pressure X X X
D4.10 Part stickout X X
Preheat (First friction phase) if needed
D4.11 -Projection on faying surface X1 X1
D4.12 -Preheat force X 1
X1
D4.13 -Preheat time or RPM X 1
X1
D4.14 Preheat burnoff length-amount of dimension loss during X1
preheat X X
Weld Heat (Second friction phase)
D4.15 -Friction weld force X X
D4.16 -Friction speed at which forging begins X X

© 2010 Automotive Industry Action Group (AIAG) 27 of 34

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PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

Forging Stage
D4.17 -Forging speed X X
D4.18 -Forge force X X
D4.19 -Forge time X
D4.20 -Forge length if limited upset is used X
D4.21 -Forge delay X
D4.22 -Upset distance X
D4.23 -Upset removal / management X X
D4.24 -Upset hold time X X
D4.25 -Upset rate X X
D4.26 -Friction upset distance and time X
D4.27 Brake setting or stopping time dimensions and tolerences X
D4.28 Brake force X
D4.29 Brake delay prior to upset X
D4.30 Final position X
D4.31 Postweld heat treatment if needed based on materials joined ü ü ü

D4.32 Protective atmosphere if necessary for the base material ü

D4.33 Total burnoff-amount of dimension loss during total process X
X X

© 2010 Automotive Industry Action Group (AIAG) 28 of 34

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PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

FSW
D4.34 Primary control (position or force) X
D4.35 Tool to weld joint alignment during length of travel X
Tool
D4.36 -Pin to shoulder ratio X
D4.37 -Pin length X
D4.38 -Included angle for pin X
D4.39 -Included angle for shoulder X
D4.40 -Thread on pin surface X
D4.41 -Pin material X
Plunge Practice
D4.42 -Speed of plunge X
D4.43 -Spindal speed during plunge X
D4.44 -Preheat dwell time after plunge X
D4.45 -Plunge force X
Weld
D4.46 -Weld force X
D4.47 -Travel speed X
D4.48 -Tool tilt angle X
D4.49 -Weld spindal speed X
Weld termination
D4.50 -Exit motion of tool such as tilt angle rotation X
D4.51 -Spindal speed at tool extraction X

© 2010 Automotive Industry Action Group (AIAG) 29 of 34

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Version 1, 3/2010

PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

D4.52 -Dwell at end of travel X

© 2010 Automotive Industry Action Group (AIAG) 30 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

FBW RBW
D4.53 Electrode design-eliminate die burns X X
D4.54 Electrode/Die cleanliness X X
D4.55 Electrode/Die clamping pressure X X
D4.56 Part cleanliness and scale removal X X
D4.57 Part alignment X X
D4.58 Joint geometry preporation X X
D4.59 Initial martial stickout or extension beyond electrodes X X
Preheat
D4.60 -Preheat force X X
D4.61 -Tap selection X X
D4.62 -Percent heat X X
D4.63 -Off time during initial die opening X
Initial Flashing
D4.64 -Initial die opening X
D4.65 -Initial flashing rate X
D4.66 -Type of platten movement (linear or parabolic) X
D4.67 -Voltage X
D4.68 -Initial flashing distance or time X
D4.69 -Percent heat X
D4.70 -Tap selection X

© 2010 Automotive Industry Action Group (AIAG) 31 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

Flashing
D4.71 -Flashing rate X
D4.72 -Type of platten movement (linear or parabolic) X
D4.73 -Voltage X
D4.74 -Flashing distance or time X
D4.75 -Percent heat X
D4.76 -Tap selection X
Weld Stage 1
D4.77 -Percent heat X
D4.78 -Tap selection voltage X
D4.79 -Force X
D4.80 -Pulsation (on, off and number of pulses) X
D4.81 -Off time before stage change X
Weld Stage 2 (can be multiple stages with different parameters)
D4.82 -Percent heat X
D4.83 -Tap selection voltage X
D4.84 -Force X
D4.85 -Pulsation (on, off and number of pulses) X

© 2010 Automotive Industry Action Group (AIAG) 32 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

Forge/Upset
D4.86 -Forge rate X X
D4.87 -Forge force X X
D4.88 -Forge distance / total upset X X
D4.89 -Upset time X X
D4.90 -Upset current X X
D4.91 -Flashing voltage cut off X
D4.92 -Flashing removal / management X X
Post weld heat treatment if needed
D4.93 -Heat treatment clamping distance ü ü
D4.94 -Quench time ü ü
D4.95 -Tap selection ü ü
D4.96 -Precent heat ü ü
D4.97 -Temper time ü ü
D4.98 Final die opening X X
Ultrasonic Metal weld
D4.99 Tap selection / design of ribbon structure ü
D4.100 Frequency of power supply for application (40/30/20kHz) ü
D4.101 Fixture & part design with max dimension deviation and material specs ü

© 2010 Automotive Industry Action Group (AIAG) 33 of 34

 Special Process: Welding System Assessment
Version 1, 3/2010

PROCESS TABLE D - Solid State Welding Processes

The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in
part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the
Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group.
All control of variables given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor
shall verify welding is conforming to the customer's requirements.

Dashes below indicate "not applicable".

X indicates an essential variable which shall be documented and controlled.
ü indicates that procedure should be reviewed and documented when necessary.

Inertia Direct Drive Friction Resistance

Flash Butt
Related WSA Friction Friction Stir Butt Ultrasonic
Item # Category/Process Steps Welding
Question # Welding Welding Welding Welding Welding
(FW)
(FRW-I) (FRW-DD) (FSW) (UW)

Upset and Monitoring (windowing)

D4.102 Welding-Energy X
D4.103 Welding-Time X
D4.104 Welding-Amplitude X
D4.105 Welding-Force X
D4.106 Welding-Current X
D4.107 Welding pre Height and travel (compaction) X
D4.108 Energy with height compensation X
D4.109 Weld Head Cooling ü
D4.110 Environmental conditions control (i.e., temperature, humidity, dust, etc.) ü
D4.111 TAP/Die cleanliness ü
D4.112 TAP/Die clamping pressure ü
D4.113 Part cleanliness and scale removal ü
D4.114 Part alignment ü
x1: If required to achieve heat balance. Example thin part to thick part or various hardnesses.

© 2010 Automotive Industry Action Group (AIAG)

© 2010 Automotive Industry Action Group (AIAG) 34 of 34