AWS D8.

1M:2021
An American National Standard

Specification for
Automotive Weld
Quality Resistance
Spot Welding
of Steel

� p.11\erican Nationat

••
 AWS D8.1M:2021
An American National Standard

Approved by
American National Standards Institute
May 5, 2021

Specification for
Automotive Weld Quality­
Resistance Spot Welding of Steel

3rd Edition

Revises AWS D8. 1M:20 13

Prepared by the
American Welding Society (AWS) D8 Committee on Automatic Welding

Under the Direction of the

AWS Technical Activities Committee

Approved by the
Board of Directors

Abstract
This document contains both visual and measurable acceptance criteria for resistance spot welds in steels. The informa­
tion contained herein may be used as an aid by designers, resistance welding equipment manufacturers, welded product
producers, and others involved in the automotive industry and resistance spot welding of steels.

American Welding Society®

AWS 08 . 1 M :202 1

ISBN Print: 978-1 -64322-1 78-6

ISBN PDF: 978-1 -64322-1 79-3
©202 1 by American Welding Society
All rights reserved
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II
 AWS D8. 1 M :202 1

Statement on the Use of American Welding Society Standards

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

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

AWS disclaims liability for any injury to persons or to property, or other damages of any nature whatsoever, whether
special, indirect, consequential, or compensatory, directly or indirectly resulting from the publication, use of, or reliance
on this standard. AWS also makes no guarantee or warran ty as to the accuracy or completeness of any information pub­
lished herein.

In issuing and making this standard available, AWS is neither undertaking to render professional or other services for or
on behalf of any person or entity, nor is AWS undertaking to perform any duty owed by any person or entity to someone
else. Anyone using these documents should rely on his or her own independent judgment or, as appropriate, seek the
advice of a competent professional in determining the exercise of reasonable care in any given circumstances. It is
assumed that the use of this standard and its provisions is entrusted to appropriately qualified and competent personnel.

This standard may be revised, corrected through publication of amendments or errata, or supplemented by publication of
addenda. Information on the latest editions of AWS standards including amendments, errata, and addenda is posted on the
AWS web page (www. aws. org). Users should ensure that they have the appropriate edition, amendments, errata, and
addenda.

Publication of this standard does not authorize infringement of any patent or trade name. Users of this standard accept
any and all liabilities for infringement of any patent or trade name items. AWS disclaims liability for the infringement of
any patent or product trade name resulting from the use of this standard.

AWS does not monitor, police, or enforce compliance with this standard, nor does it have the power to do so.
Official interpretations of any of the technical requirements of this standard may only be obtained by sending a request,
in writing, to the appropriate technical committee. Such requests should be addressed to the American Welding Society,
Attention: Managing Director, Standards Development (see Annex B). With regard to technical inquiries made concern­
ing AWS standards, oral opinions on AWS standards may be rendered. These opinions are offered solely as a convenience
to users of this standard, and they do not constitute professional advice. Such opinions represent only the personal opin­
ions of the particular individuals giving them. These individuals do not speak on behalf of AWS, nor do these oral opin­
ions constitute official or unofficial opinions or interpretations of AWS. In addition, oral opinions are informal and should
not be used as a substitute for an official interpretation.

This standard is subject to revision at any time by the AWS D8 Committee on Automotive Welding. It must be reviewed
every five years, and if not revised, it must be either reaffirmed or withdrawn. Comments (recommendations, additions,
or deletions) and any pertinent data that may be of use in improving this standard are requested and should be addressed
to AWS Headquarters. Such comments will receive careful consideration by the AWS D8 Committee on Automotive
Welding and the author of the comments will be informed of the Committee's response to the comments. Guests are
invited to attend all meetings of the AWS D8 Committee on Automotive Welding to express their comments verbally.
Procedures for appeal of an adverse decision concerning all such comments are provided in the Rules of Operation of the
Technical Activities Committee. A copy of these Rules can be obtained from the American Welding Society, 8 669 NW 3 6
St, # 1 30, Miami, FL 33 1 66.

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IV
 AWS D8. 1 M :202 1

Personnel
AWS DS Committee on Automotive Welding

R. Ruokolainen, Chair FCA USALLC

H. Ghassemi-Armaki, Vice Chair ArcelorMittal - USA
A. Orr, 2nct Vice Chair Ford Motor Company
M. Diaz, Secretary American Welding Society
J. Beckham Fiat Chrysler Automobiles USLLC
D. Bellish Ohara Corporation
T. Coon Ford Motor Company
E. Cross Meggitt Aircraft Braking Systems
M. Gugel US Steel
F. W. Hunt Hitachi Automotive Systems Americas
J. G. Hunt AET International
D. R. Kolodziej Ford Motor Company (Retired)
D. F. Maatz R & E Engineering Services
J. S. Noruk Servo Robot Corporation
W. F. Qualls Consultant
M. D. Tumuluru Consultant
Z. Wang ArcelorMittal R&D
A. Young KUKA Robotics

Advisors to the DS Committee on Automotive Welding

W. H. Brafford Consultant
J. W. Dolfi Consultant
W. W. Doneth Fronius USALLC
D. L. Galiher Tower International (Retired)
S. C. Kelley Arce/or Mittal Global R & D
D. P. Kelly Fusion Welding Solutions
T. W. Morrissett Consultant

AWS DSD Subcommittee on Automotive Resistance Spot Welding

W.F. Qualls, Chair Consultant

M. Diaz, Secretary American Welding Society
D. Bellish Ohara Corporation
J. Beckham Fiat Chrysler Automobiles USLLC
E. Biro University of Waterloo
T. Coon Ford Motor Company
P. Edwards II R & D for Joining Technology
M. Gugel US Steel
M. Kuo Automotive Product Applications
D. F. Maatz R & E Engineering Services
C. Orsette Fusion Welding Solutions
E. Pakalnins R & E Engineering Services
W. Peterson United Technical
A. Orr Ford Motor Company

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AWS 08 . 1 M :202 1

M. D. Tumuluru Consultant
Z. Wang ArcelorMittal R&D
A. Young KUKA Robotics

Advisors to the DSD Subcommittee on Automotive Resistance Spot Welding

W. H. Brafford Consultant
M. Herbert General Motors (Retired)
J. G. Hunt AET International
D. P. Kelly Fusion Welding Solutions
M. Kimchi Edison Joining Technology Center
T. Morrissett Consultant
T. Natale A K Steel Corporation
N. Scotchmer Huys IndustriesL imited
D. Spinella Arconic
W. H. Trojanowski FCA Metallic Materials Engineering
H. Zhang University of Toledo

VI
 AWS D8. 1 M :202 1

Foreword
This foreword is not part of this standard, but is included for informational purposes only.

This publication supersedes the second edition of the D 8 . 1 M :20U, Specification.for Automotive Weld Quality-Resistance
Spot Welding of Steel. The content of the standard has changed in the areas with vertical lines adjacent to the text.

This document has been prepared to establish acceptance criteria for resistance spot welds in automotive structures fab­
ricated from steels including the Advanced High Strength Steels (AHSS). As a specification, the criteria and techniques
contained are obligatory when cited as a normative reference on a drawing or in a contract.

This specification was prepared by the D8D Subcommittee on Automotive Resistance Spot Welding of the AWS D8
Committee on Automotive Welding. This publication is issued under the auspices of the AWS D8 Committee on
Automotive Welding.

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 AWS D8. 1 M :202 1

Table of Contents
Page No.

Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
L ist of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
L ist of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
1. General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 . 1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 .2 Units of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1 .3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. .1
2. Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3. Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

4. Weld Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

5. Spot Weld Acceptance Criteria . . . . . . . . . 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. 1 Non-destructive Examination (NDE)- Visual Inspection Criteria 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Destructive Examination-Metallographic Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5.3 Destructive Examination-Peel and Chisel Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5.4 Destructive Examination-Shear and Cross Tension Criteria 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Annex A (Informative) -Informative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Annex B (Informative) - Requesting an Official Interpretation on an AWS Standard . . . . . . . . . . . . . . . . . . . . . . . . 2 7
List of AWS Documents on Automotive Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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AWS 08 . 1 M :202 1

List of Tables
Table Page No.

Classification of Steels for Resistance Spot Welding Purposes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2 Minimum Acceptable Weld Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Shear Tension Sample Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4 Cross Tension Sample Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

List of Figures
Figure Page No.

Examples of Edge Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2 Surface Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. . . . . . .

3 Indentation Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Attributes of a Spot Weld Measured from a Cross Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5 Penetration Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
6 Example of Discrepant Pores and Cavities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
7 Example of Discrepant Internal Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
8 Measurement Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
9 Example of Measuring a Crescent Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 Fracture Mode I-Button Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11 Fracture Mode 2 -Partial Thickness Fracture with Button Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12 Fracture Mode 3 -Partial Thickness Fracture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13 Fracture Mode 4 -Interfacial Fracture with Button Pull and Partial Thickness Fracture . . . . . . . . . . . . . . 14
14 Fracture Mode 5-Interfacial Fracture with Button Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
15 Fracture Mode 6-Interfacial Fracture with Partial Thickness Fracture . . . . . . . . . . . . . . . . . . . . . . . . . . .16
16 Fracture Mode 7 -Interfacial Fracture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
17 Fracture Mode 8 -No Fusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
18 Representative Minimum Shear Tension Strength Values for Group 2 Steels . . . . . . . . . . . . . . . . . . . . . . . 19
19 Representative Minimum Shear Tension Strength Values for Group 3 Steels . . . . . . . . . . . . . . . . . . . . . . . 19
20 Representative Minimum Shear Tension Strength Values for Group 4 Steels . . . . . . . . . . . . . . . . . . . . . . . 20
21 Minimum Cross Tension Strength Values for Group_s_ 2 , 3 , and 4 Steels . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
22 Schematic for Shear Tension Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
23 Metrics Monitored in Shear and Cross Tension Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
24 Schematic for Cross Tension Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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 AWS D8. 1 M :202 1

Specification for Automotive Weld Quality-Resistance

Spot Welding of Steel

1. General Reguirements
1.1 Scope This specification defines quality characteristics and metrics pertinent to resistance spot welds on steels used in
automotive applications. The evaluation methods and inspection criteria specified herein can be used to evaluate the
effectiveness of particular welding equipment and procedures used to weld a particular base material combination. The
criteria and metrics are the same for all welds regardless of the service load. The quality standards established by this
specification do not constitute a lower bound of suitability for service; welds that do not meet the weld quality criteria of this
specification may be satisfactory for certain applications. The acceptance criteria of this standard are not intended for
applications outside this scope (such as post-crash weld quality assessment): attempts to do so may lead to an erroneous result.

The specific type and number of tests that are required shall be at the discretion of the specifying party. While the test
methods were developed to compare the welding behavior of different steel grades. they can be judiciously applied to
evaluate other aspects of welding behavior. Not all of the above mentioned tests are required to establish the resistance
spot welding behavior of a given grade of steel.

1.2 Units of Measurement This standard makes sole use of the International System of Units (SI).

1.3 Safety Safety issues and concerns are addressed in this standard, although health issues and concerns are beyond the
scope of this standard. Safety and health information is available from the following sources:

American Welding Society:

(1 ) ANSI Z49 . l, Safety in Welding, Cutting, and Allied Processes

(2) AWS Safety and Health Fact Sheets

(3 ) Other safety and health information on the AWS website

Material or Equipment Manufacturers:

(I) Safety Data Sheets (SDS) supplied by materials manufacturers

(2) Operating Manuals supplied by equipment manufacturers

Applicable Regulatory Agencies

Work performed in accordance with this standard may involve the use of materials that have been deemed hazardous, and
may involve operations or equipment that may cause injury or death. This standard does not purport to address all safety
and health risks that may be encountered. The user of this standard should establish an appropriate safety program to
address such risks as well as to meet applicable regulatory requirements. ANSI Z49.l should be considered when devel­
oping the safety program.

2. Normative References
The documents listed below are referenced within this publication and are mandatory to the extent specified herein. For
undated references, the latest edition of the referenced standard shall apply. For dated references, subsequent amendments
to, or revisions of, any of these publications do not apply.
AWS 08 . 1 M :202 1

American Welding Society (AWS) standards:

AWS A3 .0M/A3 .0, Standard Welding Terms and Definitions Including Terms for Adhesive Bonding, Brazing,
Soldering, T hermal Cutting, and T hermal Spraying;

AWS D 8 . 9M, Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behavior of
Automotive Sheet Steel Materials.

3. Terms and Definitions

AWS A3 .0M/A3 .0, Standard Welding Terms and Definitions, provides the basis for terms and definitions used herein.
However, the following terms and definitions are included below to accommodate usage specific to this document.

aspect ratio. The ratio of the maximum dimension to the minimum dimension of the fused area.

button pull. A fracture mode of a spot weld where separation occurs through the heat-affected zone (HAZ) of the weld,
resulting in a button (see example in Figure 1 0 ) .

button size. The average of the maximum and minimum dimensions of the button.

edge weld (resistance welding). A spot weld area, as defined by the impression left by the electrodes, which is not fully
contained within all original edges of the sheet metal.

fracture mode. The appearance of the weld after destructive testing as categorized in Figures I0 through 1 7 .

fused area. The area of the nugget at the faying surface (interface between the metals being joined). The fused area may
result in button pull, partial thickness fracture, interfacial fracture, or combinations thereof.

fusion zone. The volume of fused base metal resulting from the welding process. The fusion zone is visible when a weld
is cross-sectioned and suitably etched.

governing metal thickness (GMT). The metal gauge in a stack-up on which the minimum acceptable weld size is based.
The GMT for a two-sheet stack-up is the metal thickness of the thinner of the two sheets. The GMT for a three-sheet
stack-up is the metal thickness of the thinner sheet at each interface.

indentation. Indentation is the ratio of the amount of weld depression to the pre-welded sheet thickness, expressed as a
ratio (see example in Figure 3 ).

interfacial fracture. A fracture mode of a spot weld where all of the weld nugget separates through the plane of the weld
at the faying surface. If less than approximately 20% of the mating sheet thickness is removed, the fracture is interfacial
(see example in Figure 1 6).

partial thickness fracture. A fracture mode of a spot weld where a part of the weld nugget shows removal of parent
metal by the weld from the mating sheet. The portion removed must be at least approximately 20% of the mating sheet
thickness (such that the partial thickness fracture can be measured with a caliper), otherwise the fracture is interfacial. A
cavity is left in the mating sheet (see example in Figure 1 2 ) .

penetration. Penetration i s the ratio of the nugget's maximum depth of fusion to the pre-welded sheet thickness, expressed
as a percentage.

stack-up. The number of sheets and materials being joined by the spot weld.

weld size. The average of the maximum and minimum dimensions of the fused area in destructive inspection or the nug­
get width in metallographic inspection.

4. Weld Process Control

Production-welded parts being joined by the resistance spot welding process have inherent variability of weld quality
characteristics. The welding process must be controlled to meet or exceed the minimum weld quality level of the product
requirements. Information and guidance pertaining to supplier requirements for process and product control are contained

2
 AWS D8. 1 M :202 1

in IATF 1 6949:20 1 6 (published by the Automotive Industry Action Group (AIAG)); ISO 900 1 :20 1 5; or ASTM E2587
Practice for Use of Control Charts in Statistical Process Control.

5. Spot Weld Acceptance Criteria

The intended use of this specification is to satisfy the needs of both shop floor and laboratoiy applications to define auto­
motive weld quality. Not all inspection methods of this specification need to be applied simultaneously to determine weld
quality. Rather. the test method(s) must be appropriate for the application. as determined by an agreement between the
customer and supplier and shall be considered adequate to define the weld quality for a specific application.

This specification addresses four (4) major areas/methods of assessing weld quality, based on the method of inspection:
(1 ) Non-destructive Examination (NDE) Methods - Surface Inspection (see 5. 1 )

(2) Destructive Examination Methods

(a) Metallographic (see 5.2)

(b) Peel and Chisel (see 5. 3 )

(c) Shear and Cross Tension (see 5.4)

Automotive welds are defined as having acceptable weld quality if the welds satisfy the established acceptance criteria
using one or more of the specified method(s) of assessment.
The specific type and number of tests required shall be at the discretion of the specifying party. Not all of the above men­
tioned tests are required to establish the resistance spot welding behavior acceptance criteria.

For this specification, steels are classified into four groups according to minimum ultimate tensile strength as shown in
Table 1 .

Table 1
Classification of Steels for Resistance Spot Welding Purposesa
Group: 2 3 1
Tensile Strength (MPa): <350 350--500 501-800 >80.Q
Typical Materials: Mild 140YS/270TS BH 260YS/370TS DP 350YS/600TS DP 700YS/1000TS
BH 180YS/300TS HSLA 280YS/350TS TRIP 350YS/600TS MS 950YS/1200TS
BH 210YS/320TS HSLA 350YS/450TS DP 500YS/800TS MS 1150YS/1400TS
BH 240YS/340TS DP 300YS/500TS TRIP 500YS/800TS MS 1250YS/1520TS
CP 700YS/800TS HF 950YS/1300TS
a BH: Bake Hardenable, HSLA: High Strength Low Alloy, DP: Dual Phase, TRIP: Transformation Induced Plasticity, MS: Martensitic, CP: Complex
Phase, YS: Yield Strength, TS: Tensile Strength. HF: Hot-Formed

Note: Steels with a minimum tensile strength above 500 MPa (Groups 3 and 4) are generally considered Advanced High Strength Steels (AHSS).
Adopted from: WorldAutoSteel, Advanced High Strength Steel (AHSS) Application Guidelines, Version 6 April 2 0 1 7. Table 4.C-5 .

5.1 Non-destructive Examination CNDE) - Visual Inspection Criteria

5.1.1 Edge Weld. Spot welds fully contained within all original edges of the sheet are acceptable. Spot welds distorting
and/or breaking the original edges of the sheet are discrepant (see Figure 1 ).

5.1.2 Surface Cracks. The acceptability of surface cracks, found when visually inspecting welds without a
magnification device, depends on the steels being welded and the position of the cracks. The following acceptance
criteria should be applied (see Figure 2).;.

Discrepant Conditions:

(1 ) Spot welds with surface cracks in the area defined by the outside 1 5% of the linear distance between the interior
peripheiy line and the center of electrode impression.
(2) Spot welds with surface cracks adjacent to the periphery of the electrode impression.

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AWS D8. 1 M :202 1

EDGE WELD WITH EXPULSION-DISCR E PANT

EDGE WELD WITH BULGE-D I SCR E PANT

NON D I SCRE PANT

Figure 1-Examples of Edge Welds

5.1.3 Holes. A weld is discrepant when, upon visual inspection without a magnification device, any opening contained
within the electrode impression is found extending through the stack-up.

5.1.4 Indentation. Indentation should be less than 30% of the thickness of each outside sheet of the welded joint (see
Figure 3 ) . Care must be taken during measurement if distortion is present. Distortion must not add to the value of the
impression.
5.2 Destructive Examination-Metallographic Criteria

5.2.1 Nugget Width. An acceptable weld has a nugget width greater than or equal to the minimum weld size shown
in Table 2 unless specified otherwise on the controlling engineering documents. An illustration of nugget width is shown
in Figure 4. Information on weld specimen preparation for nugget width measurement is contained in AWS D 8 . 9M,
Recommended Practices for Test Methods for Evaluating the Resistance Spot Welding Behavior of Automotive Sheet Steel
Materials. When determining the nugget width of a weld already destructively tested, the cross section must be taken
through what appears to be the minimum dimension of the fused area.

5.2.2 Penetration. Penetration must exceed 20% of the pre-welded sheet thickness into each sheet of the weldment
(see Figure 5). Note: Full penetration is undesirable and may result in other discrepancies.
5.2.3 Porosity. Pores, cavities or voids observed in a weld cross section meeting any one of the following criteria are
considered discrepant. Examination shall occur at a magnification of lOX (see Figure 6).

Discrepant Conditions:
(1 ) Sum of all areas (e. g., Area Pol+Area Po2 +Area Po3 ) > 1 5% of Nugget Area.

(2 ) Sum of all lengths (e. g.. Ll+ L2 + L3 ) > 25% of Nugget Width.

(3 ) Pores or cavities in area defined by the outside 1 5% of the linear distance between the fusion zone periphery and
its center (e. g.. Area Pol).

5.2.4 Internal Cracks. Cracks observed in a weld cross section are considered internal cracks. Welds with cracks
located in the nugget or HAZ meeting any one of the following criteria are considered discrepant. Examination shall
occur at a magnification of lOX (see Figure 7).

4
 AWS D8. 1 M :202 1

I MAGI NARY CI RCLE OF

RAD I U S 1 5% SMALLER THAN
THE I N T E R I O R P E R I PH E RY
EXT E R I O R P E R I PH E RY OF OF E LECTROD E I N DENTATION
E LECTRODE I N D ENTATION

I NT E R I O R P E R I P H E RY OF
E LECTRODE I N D ENTATION

N O N D I SCRE PANT CRACK

Figure 2-Surface Cracks

Discrepant Conditions:

(1 ) Sum of all lengths in the fusion zone (e. g. , Ll+ L2 + L3 ) > 25% of Nugget Width.

(2 ) Cracks in the HAZ or nugget area defined by the outside 1 5% of the linear distance between the fusion zone
periphery and its center (e. g. , Ll and L4).

5.3 Destructive Examination-Peel and Chisel Criteria. Destructive testing will result in different fracture modes
depending on the material thickness, material composition, steel strength, part geometry or the type and rates of loading.
The basic fracture modes are interfacial fracture, partial thickness fracture, button pull, or combinations thereof.

Peel and chisel testing of resistance spot welds in Advanced High Strength Steel (AHSS groups 3 and 4 of Table 1 ) may
produce fracture through the weld, resulting in interfacial or partial thickness fractures. These fractures become more
common with increasing sheet thickness and base material strength. Judgment of weld quality should incorporate the
amount of deformation of the metal adjacent to the weld and the level of effort required to produce fracture. Note: Low
ductility or thick gage steels might not exhibit deformation.

Nondestructive chisel or prybar testing is commonly used in production environments to check for fusion between welded
steels without producing permanent damage to the components. However, because of the inherent stiffness of AHSS
sheets, prybar testing on AHSS spot welded panels will deform the panel permanently and may inadvertently promote
weld metal fracture. Therefore, prybar testing is not acceptable for AHSS unless specifically approved by authorized
personnel.

5.3.1 Weld Size. In destructive testing, weld size is determined by measuring the known fused area. In most instances
this means measuring only button and partial thickness fractures (i. e. , material protruding from one of the previously
welded sheets). Interfacial fractures can be included in the measurement only when proven to be part of a nugget by other
means such as metallographic inspection.
The weld size is calculated as the average of the maximum dimension and the minimum dimension, which may not
always be 90° from each other. These measurements are typically made with calipers. Irregular shaped welds are meas­
ured as shown in Figures 8 and 9. All welds must not exceed an aspect ratio of 2 to 1 . A tail might be formed on a button
by destructively tearing the two sheets apart, and shall not be included in the button measurement.

5
AWS DB 1 M :202 1
.

D IAL O R
DIGITAL
I N D I CATO R

I N D I CATO R
POS I T I O N I N G
FIXTU R E
I N D I CATO R
ROTATION
WHEEL

ln1
S H E ET 1 t1
f

S H E ET 2 t2

ln2

% I N D E NTATION S H E ET 1 = ln1 /t1 x 1 00

% I N D E NTATION S H E ET 2 = ln2/t2 x 1 00

Figure 3-Indentation Measurement

Table 2
Minimum Acceptable Weld Size;!_
Governing Metal Thickness (t) (mm) Weld Size l1 (mm)
0.50-0.60
0.61-0.80
0.81-1.00
1.01-1.30
1.31-1.60
1.61-1.90
1.91-2.30
2.31-2.70
2.71-3.10
3.11-3.60
•Weld sizes are calculated to ensure that weld size will always exceed 4 · w
l> For sheet thicknesses greater than 3 .60 mm. the minimum weld size is 4 ·W

6
 AWS D8 . 1 M :202 1

I N D ENTATION
,________ I N D ENTATION W I DTH ------ D E PTH

\------ _l_

i-.---- N U GGET WI DTH----

Figure 4- Attributes of a Spot Weld Measured from a Cross Section

P1

P2

% P E N ETRATION SHEET 1 = P 1 /t1 x 1 00

% P E N ETRATION SHEET 2 = P2/t2 x 1 00

Figure 5-Penetration Measurement

MAGN IFICATION: 1 OX FUSION ZON E 1 5% I N BOARD OF

P E R I P H E RY FUSION ZON E P E R I P H E RY

,____ N U GGET WI DTH----

Figure 6-Example of Discrepant Pores and Cavities

7
AWS DB . 1 M :202 1

MAGN IFI CATION: 10X FUSION ZON E 1 5% I N BOAR D OF

P E R I P H E RY FUSION ZON E P E R I P H E RY

i------ N U GGET W I DTH ___ ___,..i

Figure 7-Example of Discrepant Internal Cracks

An acceptable weld size is defined by Table 2. As with nugget width, the governing metal thickness (GMT) determines
the minimum acceptable weld size unless specified otherwise in the controlling engineering documents.

5.3.2 Fracture Mode. Eight combinations of fracture modes are described in Figures 1 0 through 1 7, where their weld
quality acceptance criteria are also summarized. When interpretation of weld size is disputed, metallographic inspection
must be used to measure nugget width. When determining the nugget width of a weld that has already been destructively
tested, the cross section must be taken through what appears to be the minimum dimension of the fused area.

5.4 Destructive Examination-Shear and Cross Tension Criteria. The mechanical properties to be considered when
evaluating weld quality are weld strength and weld energy. Weld mechanical performance of Advanced High Strength
Steels (AHSS) may depend upon the loading mode, loading rate and degree of constraint. The strength of a weld is
quantified by the peak load achieved during shear or cross tension testing. Weld strength shall be recorded using the test
methods described in 5.4 . 3 . While only values for the minimum strength are used to quantitatively describe weld quality
in this specification, weld energy values may be qualitatively considered.

Both shear and cross tension strength are measures of weld mechanical strength. Equations for these tests are used to
describe the minimum expected values for steels in WorldAutoSteel Groups 2, 3 , and 4 from Table 1 . Welds with strengths
below those computed by the equations are considered discrepant. The values determined by these equations must come
from weld specimen designs described in 5.4. 3 . The equations for each test were determined from comparing formulas
and data from other industry specifications, corporate research, and open literature. The equations are applicable to welds
between two sheets of the same grade and gauge. They are applicable to sheet thicknesses between 0 . 6 mm and 3 . 0 mm,
with weld size assumed to be at the minimum per Table 2 .

5.4.1 Minimum Shear Tension Strength. The minimum shear tension strength is computed using Equation (1 ).

ST= (-8.83 x 10-7 x S2 + 1.34 x 10-3 x S+ 1.514) x Sx 411.s Equation (1 )

1000

where:

ST=Shear Tension Strength (kN)

S =Base Metal Tensile Strength (MPa)
t =Material Thickness (mm)

Graphs of Equation (1 ) for representative steels in Groups 2 through 4 are given in Figures 1 8 through 20. Equation (1 )
should be computed for each specific weld under consideration.

8
 AWS D8. 1 M :202 1

�-- M AX I M U M
D I M ENSION

�-- M I N I M U M
D I M ENSION

�-- M AX I M U M
D I M ENSION

,____ MINIMUM
D I M ENSION

--- M AX I M U M
D I M ENSION

.---- M I N I M U M
D I M EN S I O N

Figure 8--Measurement Method

5.4.2 Minimum Cross Tension Strength. The minimum cross tension strength is computed using Equation (2 ).
Cross tension strength has not been conclusively found to be a function of base metal strength. This equation represents
a lower bound for all material strengths as a function of material thickness.

CT= 1 .25 x t22 Equation (2 )

where:

CT=Cross Tension Strength (kN)

t =Material Thickness
(mm)

A graph of Equation (2 ) for steels in Groups 2 through 4 is given in Figure 2 1 . Equation (2 ) should be computed for each
specific weld under consideration.

5.4.3 Test Methods

5.4.3.1 Shear Tension Test. A shear tension test is a quasi-static test performed by pulling lap-joined specimens
on a tensile testing machine. The procedure documented in AWS D 8 . 9M shall be followed. The sample geometry is
shown in Figure 22 with coupon sizes listed in Table 3 . The metrics which can be monitored include the peak value of
load (peak load), displacement up to the peak load, energy defined by the area under the load- displacement curve up to
the peak load, and fracture mode. These metrics are defined further in Figure 23 . Fracture modes are characterized in
Figures 1 0 through 1 7 . The equation for determining minimum tensile strength values is given in 5.4. 1 .

9
AWS DB . 1 M :202 1

DO NOT I NC L U D E TH I S LENGTH
OF "TAIL:' OF THE WELD BUTTON
I N THE M EAS U R E M ENT

KNIFE EDGE VERN I E R CALI P E R

ROTATE CALI P E R T O M EASU R E "I N S I DE"

T H E CONCAVE AREA OF T H E WELD

Figure 9-Example of Measuring a Crescent Button

5.4.3.2 Cross Tension Test. A cross tension test is a quasi-static test performed by pulling two coupons having
been spot welded together perpendicular to each other on a tensile testing machine. The procedure documented in AWS
D8.9M shall be followed. The sample geometry is shown in Figure 24 with coupon sizes listed in Table 4. The metrics
that can be monitored include the peak value of load (peak load), displacement up to the peak load, energy defined by the
area under the load- displacement curve up to the peak load, and fracture mode. These metrics are defined further in
Figure 23 . Fracture modes are characterized in Figures 1 0 through 1 7 . The equation for determining minimum cross
tension values is given in 5.4.2.

10
 AWS D8. 1 M :202 1

4�---- HOLE P U LLED BY BUTTON

I
WELD BUTTON--------- �
"°"'
PULLED FROM �
� /
O P POS I N G S H E ET -

L FUSION ZON E OF N U GGET

�
IN BOTTOM S H E ET

WELD FRACT U R E PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
Round Oval Hollow Area Crescent Shape I rregular Button/ Multiple Button/
Fused Area Fused Area

• • • 0 Q @
Accept if the indicated Notes are satisfied (independent of the loading method):
a a+b a a+b a+b Discrepant
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b. Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.

Weld Fracture Plan View Shading Area Legend

Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

� ® • 0
Figure 10- Fracture Mode 1- Button Pull

11
AWS DB . 1 M :202 1

�---

y--- - --
CAVITY AND HOLE LEFT IN OPPOSING S H E ET
I
.---------:;;i
---. ,�--------. ......
PARTIAL T H I CKNESS PARTIAL WELD BUTTON
OF WELD FROM
OPPOS I N G S H E ET c:==: � FROM OPPOS I N G S H E ET

FUSION ZON E OF N U GGET

IN BOTTOM S H E ET

WELD FRACT U R E PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
I rregular Button/ Multiple Button/
Round Oval Hollow Area Crescent Shape Fused Area Fused Area

• • 8 • • •
Accept if the indicated Notes are satisfied (independent of the loading method):
a+c a+b+c a+c a+c a+c a+c
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b. Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.
Weld Fracture Plan View Shading Area Legend
Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

� ® • 0
Figure 11- Fracture Mode 2-Partial Thickness Fracture with Button Pull

12
 AWS D8. 1 M :202 1

5---....
=1
CAVITY LEFT I N PARTIAL T H ICKNESS
�
�------

OPPOS I N G S H E ET
:=:---__
OF WELD FROM
BY PARTIAL ------- OPPOSING S H E ET
T H I C KN ESS WELD � -----_:::;
FUSION ZON E OF N U GGET
IN BOTTOM S H E ET

WELD FRACT U R E PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
I rregular Button/ Multiple Button/
Round Oval Hollow Area Crescent Shape Fused Area Fused Area

• • 8 c Q @
Accept if the indicated Notes are satisfied (independent of the loading method):
a+c a+b+c a+c a+b+c a+b+c Discrepant
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b. Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.
Weld Fracture Plan View Shading Area Legend
Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

� ® • 0
Figure 12- Fracture Mode 3-Partial Thickness Fracture

13
AWS DB . 1 M :202 1

;; CAVITY AND HOLE LEFT I N OPPOS I N G S H E ET

_/c
PARTIAL THICKN ESS --------- � ,____
_______
I
PARTIAL WELD BUTTON

z
FRACT U R E AREA FROM OPPOSING S H E ET

I NTER FAC IAL

c::::== FUSION ZON E OF N U GGET
�
FRACTU R E AREA IN BOTTOM S H E ET

WELD FRACT U R E PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
Irregular Button/ Multiple Button/
Round Oval Hollow Area Crescent Shape Fused Area Fused Area

• • 8 • • •
.

Accept if the indicated Notes are satisfied (independent of the loading method):
a+b+c a+b+c a+b+c a+b+c a+b+c a+b+c
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b. Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.
Weld Fracture Plan View Shading Area Legend
Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

� @ @ 0
Figure 13- Fracture Mode 4-Interfacial Fracture with Button Pull and Partial
Thickness Fracture

14
 AWS D8. 1 M :202 1

HOLE PULLED BY PARTIAL BUTTON

I NTERFAC IAL---------�
F l
��-------- PARTIAL WELD BUTTON
I
FRACTU R E AREA FROM OPPOSING S H E ET

c::::::= ZON ZON E OF NUGGET

�
IN BOTTOM S H E ET

WELD FRACTURE PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
I rregular Button/ Multiple Button/
Round Oval Hollow Area Crescent Shape Fused Area Fused Area

Accept if the indicated Notes are satisfied (independent of the loading method):
a+b+c a+b+c a+b+c a+b+c a+b+c a+b+c
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b. Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.
Weld Fracture Plan View Shading Area Legend
Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

0
Figure 14- Fracture Mode 5-Interfacial Fracture with Button Pull

15
AWS DB . 1 M :202 1

r- I
'==---= CAVITY LEFT BY PARTIAL THICKNESS WELD
I NTERFACIAL----------- �
�
------- PARTIAL WELD BUTTON
FRACT U R E AREA FROM OPPOS I N G S H E ET

�
z:=<:: � ZON E OF N U GGET
IN BOTTOM S H E ET

WELD FRACTU RE PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
I rregular Button/ Multiple Button/
Round Oval Hollow Area Crescent Shape Fused Area Fused Area

Accept if the indicated Notes are satisfied (independent of the loading method):
a+ b+c a+b+c a+b+c a+b+c a+b+c a+b+c
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b. Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.
Weld Fracture Plan View Shading Area Legend
Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

0
Figure 1 5- Fracture Mode 6-Interfacial Fracture with Partial Thickness Fracture

16
 AWS D8. 1 M :202 1

FUSED AREA -----��

OF N U GGET

F U S I O N ZON E OF N U GGET
IN BOTTOM S H E ET

WELD FRACT U R E PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
Irregular Button/ Multiple Button/
Round Oval Hollow Area Crescent Shape Fused Area Fused Area

rm
\V
Accept if the indicated Notes are satisfied (independent of the loading method):
a+c a+b+c a+c a+b+c a+b+c Discrepant
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b. Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.
Weld Fracture Plan View Shading Area Legend
Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

• 0
Figure 1 6- Fracture Mode 7-Interfacial Fracture

17
AWS DB . 1 M :202 1

NO FUSION IN WELD ZON E

<

WELD FRACTURE PLAN VI EW-BOTTOM SH EET

(Some may not appear as in side view)
I rregular Button/ Multiple Button/
Round Oval Hollow Area Crescent Shape Fused Area Fused Area

0 0 Q a ~ @
Accept if the indicated Notes are satisfied (independent of the loading method):
d d d d d d
Notes:
a. Average of the maximum and minimum dimension of the known fused area (see 5 . 3. 1 ) must be greater than or equal to the
minimum weld size specified in Table 2 .
b . Aspect ratio o f maximum dimension t o the minimum dimension i s less than o r equal t o 2 t o 1 .
c. Evidence of metal deformation due to the existence of a weld. Note that low ductility or thick gage steels might not exhibit
deformation.
d. Metallographic inspection only. Cross section must be taken through what appears to be the minimum dimension of the fused area.
Weld Fracture Plan View Shading Area Legend
Through Sheet Button Partial Thickness Fracture lnterfacial Fracture No Fusion

� ® • 0
Figure 1 7- Fracture Mode 8- No Fusion

18
 AWS D8. 1 M :202 1

GRO U P 2 STE E LS (350 M Pa-500 M Pa)

18

z I ..,. 350 M Pa I
I � 480 M Pa I
_ _
16
�
I
I- 14
��
0
z
w 12 ./
a:
I-
(/) 10
Jr" �
..
z
Q 8 � I
.,,, .

(/) .... )J'

z ,.,,, • ""
w 6
I-
a: 4
� - ,,,,. '"
<t ......
w
I
(/) 2
· --
� . ....

0
0 0.5 1 .0 1 .5 2.0 2.5 3.0
T H I CKNESS (mm)

Figure 18- Representative Minimum Shear Tension Strength Values for Group 2 Steels

GRO U P 3 STE E LS (>500 M P a-800 M Pa)

30

z _. 600 M Pa
_ _

� 25 -+------<

I
� 800 M Pa
I-
0
z 20
w
a:
I-
(/)
z 15
Q
(/)
z
w 10
I-
a:
<t
w
I 5
(/)

0
0 0.5 1 .0 1 .5 2.0 2.5 3.0
T H I CKN ESS (mm)

Figure 19- Representative Minimum Shear Tension Strength Values for Group 3 Steels

19
AWS 08 . 1 M :202 1

GRO U P 4 STEELS (>800 M P a)

40

z 35 -+-------1 - � - 1 000 M Pa >-- - --+--- --+--- -�------1

�
� 1 200 M Pa
I
I- 30
CJ
z
w 25
a:
I-
Cf)
z 20
Q
Cf)
z 15
w
I-
a: 10
<(
w
I
Cf) 5

0
0 0.5 1 .0 1 .5 2.0 2.5 3.0
T H I CKNESS (mm)

Figure 20- Representative Minimum Shear Tension Strength Values for Group 4 Steels

GRO U PS 2, 3, AND 4

z 25 -+- ---- -+-

---- +- --- ----!
---- +-+ -------<
�
I
0 20 -+------+---+--!---<
z
w
a:
� 1 5 -1- ---- -+-
---- +- --- ----!-+- --- --+ ----�
z
Q
Cf)
z 1 0 -1- ---- -+-
---- +- - --.._----!- --- --+ ----�
w
I-­
Cf)
� 5 -1- ---- -+-
-- �.,C..T-- --- ----!
---- --+ ----�
a:
()

0 2 3 4 5
T H I C KN ESS (mm)

Figure 2 1- Minimum Cross Tension Strength Values for Group� 2, 3, and 4 Steels

20
 AWS D8. 1 M :202 1

---- SL ----.. 1
--������ U L ��������---<�

I w

���____.__��� _l_
�GL� W E L D I S CENTERED
AT 0/2 AND W/2

Figure 22-Schematic for Shear Tension Samples

Table 3
Shear Tension Sample Dimensions
Gripped
Sheet Thickness Coupon Length Coupon Width Overlap Sample Length Undamped Length GL"
(mm) L" (mm) wb (mm) Oh (mm) SL" (mm) Length ULh (mm) (mm)

0.50-1.29 105 45 35 175 95 40

1.30--:!..00 138 60 45 230 105 62.5
• Lengths may be increased to accommodate gripping fixtures.
b Tolerance: ± 1 .0 mm.

21
AWS DB . 1 M :202 1

PEAK
LOAD

0
<l'.
g

/ D I S P LAC E M E NT
AT P EAK LOAD

D I S PLAC E M ENT

Figure 23- Metrics Monitored in Shear and Cross Tension Tests

22
 AWS D8. 1 M :202 1

�-- - - - - - - - - - - ----� 20 m m ; +0.2, -0

T
HS
0 • w L

_______. _J_
----EB WELD IS CENTERED
AT 0/2 AND W/2
I
I
I
I

�
I

� W/2

Figure 24-Schematic for Cross Tension Samples

Table 4
Cross Tension Sample Dimensions
Sheet Thickness Coupon Length Coupon Width Overlap Hole Spacing
(mm) L• (mm) Wb (mm) O (mm) Hsc (mm)

0.50--1:.00 150 50 50 100

" Tolerance: +O, -0 . 5 mm.
b Tolerance: +O, - 1 .0 nnn .
' Tolerance: ±0.2 mm.

23
AWS 08 . 1 M :202 1

This page is intentionally blank.

24
 AWS D8. 1 M :202 1

Annex A (Informative)
Informative References
This annex is not part of this standard, but is included for informational purposes only. For undated references, the
latest edition of the referenced standard shall apply.

Aerospace Material Specification (AMS), AMS W 6858D - Welding Resistance: Spot and Seam.
- ,

AWS Dl7.2/Dl7.2M, Specification.for Resistance Welding.for Aerospace Applications

AWS C 1 . lM/Cl. 1 , Recommended Practices.for Resistance Welding

AWS D 8 . 7M, Recommended Practices for Automotive Weld Quality-Resistance Spot Welding

AWS Safety and Health Committee, Effects on Welding and Health (I through XI) , Miami: American Welding Society.

ASTM E2587, Standard Practice for Use of Control Charts in Statistical Process Control

IATF 1 6949, Quality Systems - Automotive suppliers - Particular requirements for the application of ISO 900 l

ISO 900 1 , Quality Management Systems - Requirements

Occupational Safety and Health Administration (OSHA), Code of Federal Regulations, Title 29 Labor 1 9 1 0. l to
1 90 1 . 1 450.

Quality System Requirements, QS-9000, Third Edition.

WorldAutoSteel, Advanced High Strength Steel (AHSS) Application Guidelines

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Annex B (Informative)
Requesting an Official Interpretation
on an AWS Standard
This annex is not part of this standard, but is included for informational purposes only.

B l . Introduction
The following procedures are here to assist standard users in submitting successful requests for official interpretations to
AWS standards. Requests from the general public submitted to AWS staff or committee members that do not follow these
rules may be returned to the sender unanswered. AWS reserves the right to decline answering specific requests; if AWS
declines a request, AWS will provide the reason to the individual why the request was declined.

B2. Limitations
The activities of AWS technical committees regarding interpretations are limited strictly to the interpretation of provi­
sions of standards prepared by the committees. Neither AWS staff nor the committees are in a position to offer interpre­
tive or consulting services on (1 ) specific engineering problems, (2) requirements of standards applied to fabrications
outside the scope of the document, or (3 ) points not specifically covered by the standard. In such cases, the inquirer
should seek assistance from a competent engineer experienced in the particular field of interest.

B3. General Procedure for all Requests

B3.1 Submission. All requests shall be sent to the Managing Director of AWS Standards Development Division. For
efficient handling, it is preferred that all requests should be submitted electronically through standards@aws. org.
Alternatively, requests may be mailed to:

Managing Director
Standards Development Division
American Welding Society
8 669 NW 3 6 St, # 1 3 0
Miami, FL 33 1 66

B3.2 Contact Information. All inquiries shall contain the name, address, email, phone number, and employer of the
inquirer.

B3.3 Scope. Each inquiry shall address one single provision of the standard unless the issue in question involves two or
more interrelated provisions. The provision(s) shall be identified in the scope of the request along with the edition of the
standard (e. g . , D 1 . 1 :2006) that contains the provision(s) the inquirer is addressing.

B3.4 Question(s). All requests shall be stated in the form of a question that can be answered ' yes' or ' no'. The request
shall be concise, yet complete enough to enable the committee to understand the point of the issue in question. When the
point is not clearly defined, the request will be returned for clarification. Sketches should be used whenever appropriate,
and all paragraphs, figures, and tables (or annexes) that bear on the issue in question shall be cited.

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B3.5 Proposed Answer(s). The inquirer shall provide proposed answer(s) to their own question(s).

B3.6 Background. Additional information on the topic may be provided but is not necessary. The question(s) and
proposed answer(s) above shall stand on their own without the need for additional background information.

B4. AW S Policy on Interpretations

The American Welding Society (AWS) Board of Directors has adopted a policy whereby all official interpretations of
AWS standards are handled in a formal manner. Under this policy, all official interpretations are approved by the techni­
cal committee that is responsible for the standard. Communication concerning an official interpretation is directed through
the AWS staff member who works with that technical committee. The policy requires that all requests for an official
interpretation be submitted in writing. Such requests will be handled as expeditiously as possible, but due to the proce­
dures that must be followed, some requests for an official interpretation may take considerable time to complete.

BS. AW S Response to Requests

Upon approval by the committee, the interpretation is an official interpretation of the Society, and AWS shall transmit the
response to the inquirer, publish it in the Welding Journal, and post it on the AWS website.

B6. Telephone Inquiries

Telephone inquiries to AWS Headquarters concerning AWS standards should be limited to questions of a general nature
or to matters directly related to the use of the standard. The AWS Board Policy Manual requires that all AWS staff mem­
bers respond to a telephone request for an official interpretation of any AWS standard with the information that such an
interpretation can be obtained only through a written request. Headquarters staff cannot provide consulting services.
However, the staff can refer a caller to any of those consultants whose names are on file at AWS Headquarters.

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List of AWS Documents on Automotive Welding

Designation Title

D 8 . IM Specification.for Automotive Weld Quality -Resistance Spot Welding of Steel

D8 .2M Specification for Automotive Weld Quality-Resistance Spot Welding of Aluminum
D 8 . 8M Specification.for Automotive Components Weld Quality-Arc Welding of Steel
D 8 . 9M Recommended Practices.for Test Methods for Evaluating the Resistance Spot Welding Behavior
a/Automotive Sheet Steel Materials

D 8 . 1 0M Specification for Automotive Weld Quality -L aser Beam Welding of Steel

D 8 . 1 4M Specification for Automotive Components Weld Quality-Arc Welding of Aluminum

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