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PRC-0009 Rev. D

Process Specification for the Resistance SpotWelding of Battery and Electronic Assemblies

Engineering Directorate

Structural Engineering Division

February 2!

National Aeronautics and

Space Administration

"yndon B# $ohnson Space %enter Houston, Texas

&erify correct version before use#

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PRC-0009 Rev. D

Process Specification for the Resistance SpotWelding of Battery and Electronic Assemblies

Prepared by ' Signature on File 2/17/04

Daniel #. R$%ic&i'aterials and ProcessesTec(nolo$ )ranc(*+S

Date

Approved by' Signature on File 2/17/04

#ose '. Hernande'aterials and ProcessesTec(nolo$ )ranc(*+S

Date

R+/S1NS

/+RS1N CHAN2+S DAT+-- 1riinal version April !993

A +xpanded content t(rou(out. Re-speci"$ 4uali"icationre4uirements.

!0*59*96

) 7ormattin c(aned process o8ner, re8rite numeroussections "or clari"ication, deleted re4uirement "or R,deleted section :.5 on audits, added section :.; on1P<.

06*55*99

C Add tolerance rane to %ase material component

t(ic&ness=es>, remove re4uirement "or certi"ication o" 8eldin inspectors %$ t(e AS, remove NASA*'S7Cre"erence documents in .0, add item 5! to Ta%le !,revise 3.!, 6.0, 6.!, 6.;, :.!, :.5, and :.;.

0;*5*5000

D Routine S1 revie8. 05*!6*500


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(# S%)PE

T(is process speci"ication provides t(e re4uirements t(at overn t(e Resistance Spoteldin =RS> o" %atter$ ta%s and component 8ires*leads to %atteries, %atter$ ta%s, or ot(er associated electronic components. Procedural and 4ualit$ assurancere4uirements are iven. All 8or& instructions and eld Procedure Speci"ications

=PSs> used durin 8eldin s(all satis"$ t(e re4uirements o" t(is process speci"icationand its applica%le documents.

2# APP"*%AB*"*+,

T(is process speci"ication applies to t(e RS o" %atter$ assem%lies and associatedelectronic "li(t and non "li(t (ard8are "a%ricated under t(e control o" t(eNASA*#o(nson Space Center =#SC>. RS 8it( opposed electrodes =i.e., re"erred to(erein as ?opposed 8eldin@> is considered as 8ell as RS 8it( apped electrodes=i.e., re"erred to (erein as ?series 8eldin@>. )atter$ assem%lies are considered to %enon structural 8it( no load carr$in capacit$ and s(all %e eit(er potted, taped, s(rin&8rapped, or installed in a riid containment to preclude stressin t(e ta%s and lead

8ires.

-# .SA/E

T(is process speci"ication s(all %e called out on t(e enineerin dra8in %$ a dra8innote 8it( t(e "ollo8in eneral "ormat

WE"D A0D *0SPE%+ PER 0ASA1$S% PR%3

-#( DES*/0 RE4.*RE5E0+S

a> T(e desin o" 8elded Boints s(all con"orm to t(e applica%le (ard8are desin(and%oo&s contained in t(e +nineerin Standards i%rar$.

%> All enineerin dra8ins s(all depict 8elded Boints usin t(e applica%le s$m%olsdescri%ed in AS A5..

c> As re4uired, all enineerin dra8ins s(all speci"$ t(e minimum num%er andmaximum num%er o" resistance 8elded spots re4uired "or eac( connection. nan$ case, t(ere s(all %e no less t(an t8o 8eld spots per connection.Connections 8(ic( 8ill accommodate onl$ one spot s(all %e avoided 8(erepossi%le.

d> As applica%le, all enineerin dra8ins s(all speci"$ t(e maximum electricalresistivit$ allo8ed "or eac( connection. (ere resistivit$ is not speci"ied,measurements s(all not exceed !.0 mΩ.

e> (en 8eldin occurs onto %atter$ cells, t(e parts list s(all contain t(e %atter$manu"acturer, sie, model*t$pe no., and voltae ratin.


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"> T(e parts list s(all contain t(e ta% or contact material, speci"ication, t(ic&ness,8idt(, metallurical condition =e.., (ard, E (ard, etc.> and sur"ace "inis( asapplica%le.

> T(e parts list s(all contain component leads =i.e., diode leads> ae, material, andmetallurical condition =e.., metallurical, sur"ace "inis(, etc.> and sur"ace "inis(

as applica%le.

(> Stranded 8ire s(all not %e resistance spot 8elded.

-#2 W)R6 *0S+R.%+*)0S

or& instructions s(all %e enerated "or implementin t(is process speci"ication. T(e8or& instructions s(all contain su""icient detail to ensure t(at t(e manu"acturin processproduces consistent, repeata%le products t(at compl$ 8it( t(is speci"ication. At #SC,t(ese 8or& instructions are approved as Detailed Process nstructions =DPs> t(atdescri%e in a detailed, step-%$-step "ormat t(e re4uired procedures, e4uipment, andmaterials to %e used "or conductin a iven process.

" t(is manu"acturin process is to %e per"ormed %$ an outside vendor, 8or& instructiondevelopment s(all %e t(e responsi%ilit$ o" t(e vendor. T(e contractor s(all ensure t(att(e 8or& instructions meet t(e re4uirements o" t(is process speci"ication.

-#- DEF*0*+*)0S

Essential &ariable F An identi"ied varia%le in t(e 8eldin process t(at must %econtrolled to ensure repeata%le 8eld 4ualit$.

)pposed Welding - RS 8(ic( utilies t8o electrodes positioned exactl$ opposite,and in line 8it( eac( ot(er =electrodes s(are a common axis>. See 7iure 5. +ac(electrode contacts a sinle piece o" %ase material. +ac( 8eld c$cle produces onl$ one

"used spot.Series Welding - RS 8(ic( utilies t8o electrodes positioned adBacent to eac( ot(er %ut separated %$ an air ap or ot(er dielectric. See 7iure 5. +ac( electrode contactst(e same sur"ace o" %ase material. T(is t$pe o" 8eldin is utilied 8(ere access to%ot( sides o" t(e 8eld Boint is p($sicall$ restricted or i" component damae 8ould resulti" t(e 8eldin current 8ere allo8ed to s(unt t(rou( t(e s$stem circuit or electricalcomponent. Support toolin opposin t(e "orce o" t(e electrodes is insulated "rom t(e8eldin circuit and t(ere"ore does not s(unt current "rom t(e 8eldin circuit. +ac( 8eldc$cle produces t8o "used spots. T(e electrodes can %e positioned parallel or at a "ixedanle to eac( ot(er.

.ni7ue Weld +ype - T(ose 8eld Boint con"iurations t(at di""er "rom one anot(er in an$

o" t(e "ollo8in respects

!. )atter$ anode and*or cat(ode cross sectional t(ic&ness =±!0G>,5. Anode and*or cat(ode material, metallurical condition, and sur"ace "inis(,;. #umper ta% cross sectional t(ic&ness =±!0G>,. #umper ta% material or metallurical condition,. Component lead*8ire material, metallurical condition, and sur"ace "inis(,3. Component lead material*8ire cross sectional diameter =±!0G>.


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PRC-0009 Rev. D

Figure 2 )pposed and Series Welding

+lectrodes

)PP)SED WE"D*0/

Ta%, ire

or ead 89

8:9

SER*ES WE"D*0/

8:9

Support 7ixturin Support 7ixturin

+lectrodes

Ta%, ire

or ead

89

898:9

!# REFERE0%ES

T(e standards listed %elo8 s(all %e considered a part o" t(is speci"ication to t(e extentspeci"ied (erein. Inless ot(er8ise indicated, t(e revision t(at is in e""ect on t(e date o" invitation "or %ids or t(e date o" re4uest "or proposals s(all appl$.

a# American Welding Society 8AWS9 Standards

ANS*AS A5. Standard Symbols for Welding, Brazing and Nondestructive Testing

ANS*AS A;.0 Standard Welding Terms and Definitions

b# 0ASA1$S% Documents

#P2 !600.!2 NASA/JS !e"uirements #andboo$ for Safety, #ealt%and &nvironmental 'rotection

+'-006.! 're(aration and !evision of 'rocess S(ecifications

T-0000-0 Training )or Welders and Welding *(erators

c# RW5A Documents

No Document Num%er !esistance Welding +anual !esistance Welder +anufacturers- Association !W+A


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d# SAE1Aerospace 5aterial Specification 8A5S9 Documents

A'S 5390 'arallel 0a( Welding

;# 5A+ER*A" A0D E4.*P5E0+ RE4.*RE5E0+S

All materials used in t(e 8eldin o" electronicall$ related "li(t (ard8are s(all meet t(ere4uirements o" an applica%le #SC material speci"ication unless ot(er8ise speci"ied. " a #SC material speci"ication is not availa%le, an applica%le commercial speci"ication or a manu"acturerJs speci"ication s(all %e used.

;#( E4.*P5E0+

T(e e4uipment used to produce t(e 8elds s(all consist o" an electrical ener$ source,electrodes, and a means o" appl$in mec(anical pressure to t(e materials to %e8elded.

;#(#( P)WER S.PP",

T(e po8er suppl$ s(all (ave an ade4uate means o" controllin and indicatin t(eener$ applied to t(e 8eld one. T(e po8er suppl$ s(all (ave means "or internalvoltae reulation i" t(ere is no suc( reulation on t(e primar$ AC po8er line source.Reulation s(all %e 8it(in ±5G "or line voltae variations o" ±!0G. +ner$ sourcemeters s(all (ave a minimum accurac$ o" ±5G.

;#(#2 WE"D*0/ <EAD

T(e 8eldin (ead s(all %e o" lo8-inertia desin and provide a means o" e""icientl$controllin electrode "orce. T(e electrode "orce s(all %e repeata%le to 8it(in ±G.

;#(#- E"E%+R)DES

T(e composition o" electrodes s(all con"orm to t(e Resistance elder 'anu"acturers Association =R'A> allo$ classi"ications or t(e electrode manu"acturersclassi"ications. +ac( electrode s(all %e identi"ied accordin to t(e R'A cateor$ or manu"acturers classi"ication, %od$ sie, con"iuration, and tip sie. Custom electrodesare allo8ed (o8ever, t(e speci"ic electrode materials and con"iuration s(all %econsidered an essential varia%le.

;#(#! +))"*0/ A0D F*=+.RES

Toolin re4uired to locate or assist in t(e assem%l$ o" %atteries to %e 8elded s(all %edesined to preclude an$ secondar$ current pat( t(at 8ill allo8 current to %e s(unted

a8a$ "rom t(e electrodes or t(rou( %atter$ cells.


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PRC-0009 Rev. D

;#(#; WE"D*0/ E4.*P5E0+ 4.A"*F*%A+*)0

T(e 8eldin e4uipment s(all %e 4uali"ied as a s$stem t(at includes at a minimum, t(epo8er suppl$, 8eld (ead, electrodes, and interconnectin ca%les. <uali"ication o" aeldin Procedure Speci"ication also 4uali"ies t(e s$stem. 1t(er8ise, 4uali"ication o" a s$stem s(all %e per 3.5.5.

;#(#> F)R%E /A./E

Devices used to determine electrode "orce s(all (ave a minimum accurac$ o" ±G.

># PR)%ESS RE4.*RE5E0+S

All 8eldments s(all %e "a%ricated accordin to t(e re4uirements o" t(is processspeci"ication. T(e re4uirements o" t(e applica%le codes and standards listed in Section.0 s(all %e met as speci"ied %$ t(is PRC %ased on t(e desin and intended "unction o" t(e (ard8are. Certain pararap(s o" t(is process speci"ication are a%%reviated re-statements ta&en "rom t(e applica%le standards and are included (ere "or t(e

clari"ication. T(e remainin pararap(s o" t(is process speci"ication ma$ representre4uirements imposed in addition to t(e %asic re4uirements o" t(e applica%le codes andstandards.

All resistance 8eldin s(all %e per"ormed usin eldin Procedure Speci"ications=PS> t(at (ave %een 4uali"ied in accordance 8it( t(e re4uirements o" Section 3.5.

>#( PR)%ESSSPE%*F*% RE4.*RE5E0+S

>#(#( WE"D S,S+E5 *0SPE%+*)0 A0D %<E%6 ).+

Prior to t(e start o" eac( 4uali"ication, preproduction, production, or re4uali"ication lot,

and at an$ interval=s> deemed necessar$ %$ t(e operator or enineerin, t(e "ollo8initems s(all %e addressed and an$ discrepant condition corrected as re4uired. eldcircuit interconnections s(all %e inspected to ensure t(at t(e$ are ti(t, clean andcorrosion "ree. +lectrode alinment s(all %e c(ec&ed per t(e PS re4uirements andadBusted. +lectrode tips and contact sur"ace condition s(all %e inspected andcontinuousl$ monitored "or conditions 8(ic( ma$ impede 8eldin tec(ni4ues and*or 8eld 4ualit$. T(e electrodes and related essential components s(all %e cleaned,dressed, or replaced. +lectrodes s(all %e dressed 8it( num%er 300 or "iner rita%rasive paper or e4uivalent. +lectrode "orce s(all %e c(ec&ed 4uantitativel$ %$ acali%rated "orce aue and adBusted. 7or applications 8(ere eac( electrode iscontrolled individuall$ =e.., series 8eldin>, t(e "orce o" eac( electrode s(all %edetermined and adBusted individuall$.

>#2 WE"D 4.A"*F*%A+*)0

A eldin Procedure Speci"ication =PS> s(all %e 4uali"ied "or eac( uni4ue 8eld t$peto %e produced %$ con"ormin to t(e re4uirements %elo8, %e"ore t(e production 8eldsare made. An existin 4uali"ied PS "or one uni4ue 8eld t$pe ma$ %e used "or a ne8enineerin dra8in provided t(e resistivit$ determined durin 4uali"ication meet t(ere4uirements o" t(e ne8 dra8in as applica%le, and it is demonstrated t(at t(eessential 8eld varia%les 8ill %e met. Demonstration s(all constitute all t(e


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re4uirements o" Section 3.5.5 except t(at no additional documentation is re4uired=existin P<R and PS records s(all %e accepta%le documentation>.

>#2#( 4.A"*F*%A+*)0 )F WPS

T(e actual 8eldin varia%les, met(ods, practices, speci"ic toolin re4uirements, and

test results used durin PS 4uali"ication s(all %e recorded on a Procedure<uali"ication Record =P<R>.

>#2#2 RE4.A"*F*%A+*)0 )F WPS

Re4uali"ication o" t(e PS s(all %e re4uired 8(en an$ o" t(e "ollo8in conditions exist

a> T(e 8eld s$stem (as %een placed on a di""erent external po8er sourceexcept 8(en t(e po8er suppl$ (as a means "or internal po8er reulation,

%> A PS is proposed to %e used on a 8eld s$stem or s$stems ot(er t(an t(atused "or t(e initial 4uali"ication,

c> 'aBor maintenance (as %een per"ormed on t(e 8eld s$stem. 'aBor

maintenance includes replacement o" t(e po8er suppl$, maBor repair o" t(e po8er suppl$ re4uirin entrance into t(e controller or trans"ormer ca%inet, replacement o" t(e 8eld (ead, or replacement or c(ane inlent( %$ more t(an !0G o" an$ o" t(e interconnectin ca%les,

d> Preproduction 8eld samples do not meet re4uirements and no assina%lecause "or t(e "ailure can %e determined.

Re4uali"ication ma$ %e per"ormed 8it( less total test sample re4uirements t(an t(atre4uired "or an initial 4uali"ication "or a uni4ue 8eld t$pe. 7or re4uali"ication, total8eld samples s(all %e produced and su%mitted as a lot. All samples s(all %esu%Bected to visual inspection and conductivit$ and destructive peel testin and s(allmeet t(e applica%le re4uirements speci"ied (erein. No re4uali"ication specimens "romt(e su%mitted s(all "ail an$ o" t(e re4uirements as stated (erein. Re4uali"icationresults s(all %e documented on a P<R 8it( a speci"ic notation made indicatin?re4uali"ication@. " t(e re4uali"ication activities result in an$ 8eldin parameter deviations t(at exceed t(e rane speci"ied in Ta%le ! "or t(at parameter, t(en t(e levelo" testin in 3.5. s(all %e re4uired.

>#2#- ESSE0+*A" &AR*AB"ES

All essential varia%les s(all %e addressed and identi"ied on a 4uali"ied PS and t(esupportin P<R. T(ese essential varia%les are listed in Ta%le ! %elo8. 1t(er varia%lesdetermined to %e essential to maintainin t(e 4ualit$ o" t(e process output ma$ %ere4uired to %e controlled, as determined %$ t(e 'KP oraniation.


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+AB"E ( ESSE0+*A" WE"D*0/ &AR*AB"ES

0.5BER ESSE0+*A" &AR*AB"ES &AR*AB"E RA0/E! A c(ane in t(e input line voltae source N1N+=!>

5 Po8er suppl$ - ma&e and model N1N+

; eld (ead - ma&e and model N1N+ nterconnectin ca%le sie and lent( ±!0G Ta% material t$pe N1N+3 Ta% material metallurical condition N1N+6 Ta% material t(ic&ness ±!0G: )atter$ material t$pe N1N+9 )atter$ material metallurical condition N1N+!0 )atter$ anode t(ic&ness ±!0G!! )atter$ cat(ode t(ic&ness ±!0G!5 Component lead material t$pe N1N+!; Component lead metallurical condition N1N+! Component lead diameter ±!0G

! Sur"ace condition o" %ase materials N1N+!3 +lectrode R'A cateor$ or ot(er

classi"icationN1N+

!6 +lectrode con"iuration K dimensions N1N+!: +lectrode tip spacin ±50G!9 +lectrode tip contact sur"ace s(ape N1N+50 +lectrode tip contact sur"ace area ±!0G5! Process F a c(ane "rom opposed to

series 8eldin or vice versaN1N+

55 eld G po8er or 8att*sec =all pulses> ±!0G5; Num%er o" 8eld pulses N1N+5 eld pulse 8idt( N1N+

5 +lectrode tip "orce =pounds> ±!0G53 Current t$pe =AC or DC> N1N+56 DC polarit$ current direction =1pposed

eldin onl$>N1N+

=!> Inless t(e po8er suppl$ (as internall$ reulated voltae capa%ilit$.

>#2#! 4.A"*F*%A+*)0 SA5P"ES

>#2#!#( /E0ERA"

T(e manu"acturin oraniation is responsi%le "or 4uali"$in t(e 8eldin process.

Actual cat(ode and anode ends "or t(e same ma&e, sie, and model*t$pe %atter$ usedin t(e desin s(all %e o%tained "or use as 4uali"ication and preproduction controlsamples. Actual %atteries ma$ %e also used "or 4uali"ication and*or preproductioncontrol samples. ire*leads o" t(e same material and construction as componentleads, or actual components used in t(e desin, s(all also %e supplied 8(enappropriate.


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>#2#!#2 4.A"*F*%A+*)0 5A+ER*A"S

7or eac( uni4ue t$pe o" 8eld to %e produced, a minimum o" ! sample 8eldedconnections s(all %e produced "or an initial procedure 4uali"ication and su%mitted as alot. 7or eit(er o" t(e "ollo8in 8eld conditions, an additional sample s(all %e producedand su%mitted "or metallurical examination %rinin t(e minimum total to !3 !> t(e

"a$in sur"aces at t(e 8eld Boint are o" essentiall$ di""erent materials, or 5> 8(ere it isdetermined t(at an$ o" t(e %ase materials =plated or not> are &no8n to experiencesini"icant deradation or ot(er pro%lems caused %$ t(e 8eld (eatin. eld controlsettins s(all not %e varied nor s(all an$ maintenance, except cleanin and*or polis(in o" electrodes, %e per"ormed on t(e e4uipment durin t(e production o" t(e4uali"ication samples. T(e num%er o" 8eld spots on eac( 4uali"ication sampleconnection s(all not exceed t(e minimum num%er re4uired per t(e enineerin dra8inor i" not speci"ied s(all %e no reater t(an 5 spots per connection or t(at planned "or production 8or&. T(e 4uali"ication sample set s(all %e accepta%le to all o" t(e "ollo8in levels o" 4ualit$ control as applica%le, "or success"ul 4uali"ication !> visualinspection, 5> conductivit$ =resistivit$> testin, ;> destructive peel testin, and >metallurical examination =8(en re4uired>.

>#2#!#- &*S.A" *0SPE%+*)0 A0D E"E%+R*%A" %)0D.%+*&*+, +ES+*0/

All 8eld specimens s(all %e visuall$ inspected per 6.; and tested "or electricalconductivit$ =resistivit$>. T(e resistivit$ o" eac( connection s(all meet t(e dra8inre4uirements or i" not speci"ied %$ t(e dra8in, s(all measure less t(an !.0 mΩ. " an$o" t(e individual samples "rom t(ose su%mitted "ail to pass t(e visual or resistivit$re4uirements, an additional sample s(all %e allo8ed to %e 8elded and su%mitted toreplace it, one time onl$. " more t(an 5 samples "rom t(e oriinal lot "ail t(e visual or resistivit$ re4uirements "urt(er 8eld parameter development or process anal$sis todetermine t(e cause "or t(e reBection=s> is re4uired prior to su%mittin anot(er lot o" samples "or testin to t(e re4uirements o" t(is speci"ication.

>#2#!#! DES+R.%+*&E PEE" +ES+*0/

7i"teen =!> 8eld samples s(all %e peel tested. T(e edes o" a spot 8elded sampleconnection s(all %e ripped and pulled apart to "ailure. T(e 8elded connection =lap

Boint> s(all %e pulled in tension at an approximate 90 0 anle to t(e plane o" t(e "a$in Boint sur"aces. See 7iure ;. T(e lent( o" t(e rip sections on t(e samples s(all %elon enou( to preclude an$ inter"erence o" t(e rippin (ard8are 8it( t(e 8eldedconnection. 7or a procedure 4uali"ication or preproduction veri"ication sample set to %econsidered accepta%le, t(e result o" t(e peel test must %e a plu pull-out in a minimumo" 6G o" t(e total num%er o" individual spots in t(e sample set "or connections 8it( or more spots, :G "or connections 8it( ; spots onl$, and !00G "or connections 8it( 5or less spots. " an$ o" t(e individual samples "rom t(e ! peel tests "ail to result in atleast 5 plu pull-outs "rom t(e total num%er o" 8eld spots on t(e individual connection,

5 additional 8elded sample connections ma$ %e 8elded and su%mitted "or inspectionand testin as part o" t(e initial sample set, one time onl$. T(ese 5 samples s(all t(en%e "actored into t(e a%ove acceptance criteria. " more t(an 5 samples "rom t(e oriinallot "ail t(e peel test as descri%ed a%ove, "urt(er 8eld parameter development or process anal$sis to determine t(e cause "or t(e "ailure=s> is re4uired prior to su%mittinanot(er !3 samples "or testin to t(e re4uirements o" t(is speci"ication. " t(e minimumplu pull-out re4uirement "or t(e total num%er o" individual spots in t(e sample set =i.e.,6G, :G, or !00G "or t(e respective condition> can not %e met as descri%ed a%ove,"urt(er 8eld parameter development or process anal$sis to determine t(e cause "or t(e


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"ailure is re4uired prior to su%mittin anot(er lot o" samples "or testin to t(ere4uirements o" t(is speci"ication.

Direction o"

Tension

#oint 7a$in

Sur"ace

Ta%*9ire*ead

Direction o"

Tension

~90O

Ta%*9ire*ead

Component=e.., )atter$>

#oint 7a$in

Sur"ace

Figure - 2 Peel +est E?amples

~90O

Figure ! 5etallurgical Sectioning Re7uirements

eld Spot Pair 7romSeries eldin C$cle

on Ta% to )atter$ or Ta%

to ot(er 7lat Sur"ace

=L>

=->=L>=->

eld Spots Sectioned

90o 7rom +ac(ot(er on

ire * ead to Ta% or ead

or 1t(er Component

>#2#!#; 5E+A"".R/*%A" E=A5*0A+*)0

(en re4uired, one =!> o" t(e !3 samples su%mitted s(all %e cross-sectioned,mounted, polis(ed, and etc(ed "or metallurical examination. 7or samples involvin a

8ire or component leads, one eac( 8eld spot on t(e connection 8ill %e cross sectionedtransverse to t(e 8ire diameter and lonitudinal to t(e 8ire diameter axis and "or Serieselded samples, cross sections o" %ot( 8eld spots produced %$ one 8eld c$cle =8eldsproduced under eac( electrode contact> s(all %e ta&en. See 7iure .

T(e 8elds s(all %e "ree o" crac&s or voids open to an$ exterior sur"ace. Pore and voidscontained 8it(in t(e 8eld one %ut not open to an exterior sur"ace, and are notdetermined to (ave s(arp notc( li&e c(aracteristics, s(all %e accepta%le. (enexaminin 8elds intended "or %atter$ cells, an$ anomal$ 8(ic( is determined to %e a


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potential "or %reac(in or deradin t(e %atter$ (ousin and t(ere"ore potentiall$causin a lea&, s(all %e cause "or reBection. n addition, a metallurical "usion %onds(all %e visi%le at eac( 8eld spot inter"ace. " t(is criteria cannot %e met, "urt(er 8eldparameter development or process anal$sis to determine t(e cause "or t(e reBecta%lecondition, is re4uired prior to su%mittin anot(er lot o" samples "or testin to t(ere4uirements o" t(is speci"ication. P(otomicrorap(s s(all %e ta&en o" t(e prepared

samples and retained 8it( t(e P<R.

@# PR)%ESS &ER*F*%A+*)0

Process veri"ication s(all consist o" visual examination and*or nondestructiveinspection, as descri%ed "urt(er in sections 6.! to 6.;. n addition, at t(e appropriatetime durin t(e "a%rication activities, t(e manu"acturin activit$ s(all assure t(e"ollo8in items

a> T(e operator is certi"ied "or t(e speci"ic 8eldin operation,%> A valid PS exists,c> T(e essential varia%le ranes "or t(e PS are %ein ad(ered to.

@#( PREPR)D.%+*)0 WE"D*0/ &ER*F*%A+*)0

Prior to t(e start o" a production run, a minimum o" ! preproduction 8eld sample "or eac( uni4ue t$pe o" 8eld s(all %e prepared usin t(e appropriate 4uali"ied PS.

Actual %atteries and component leads or simulated ones, as descri%ed in section3.5..!, s(all %e used "or t(is preproduction 8eld sample. T(e sample s(all %e visuall$inspected, in accordance 8it( Section 6.;, and peel tested, in accordance 8it( Section3.5... T(e preproduction sample s(all %e made and tested %e"ore t(e 8eldin o" t(eproduction 8elds and under t(e "ollo8in conditions

a> At t(e start o" a production s(i"t or t(e c(ane o" production s(i"ts,%> Ipon replacement o" eit(er or %ot( o" t(e 8eldin electrodes,c> 7ollo8in metal expulsion or severe metal deposits on t(e electrode "ace=s>,d> 7ollo8in t(e mis"ire or no 8eld condition 8(ere a 8eld (as %een attempted %ut not

made and no assina%le cause can %e determined,e> 7ollo8in a dela$ in 8eldin o" more t(an (ours and 8(ere t(e 8eldin s$stem

8as re4uired to %e po8ered do8n durin t(is period,"> (ere a di""erent operator 8as assined to t(e 8or&station to continue a Bo%.

Di""erent PSs ma$ %e alternated 8it(in a production 8eldin session provided t(ea%ove re4uirements are met.

@#2 WE"D &ER*F*%A+*)0

Prior to encapsulation, pottin, or an$ process 8(ic( 8ould preclude inspection o" t(e8elds, all 8elds and 8or&mans(ip s(all %e inspected "or con"ormance to t(ere4uirements o" t(is standard and t(e enineerin dra8in. " a noncon"ormance isidenti"ied it s(all %e documented appropriatel$. " t(e 8elds o" a completed 8eldedmodule or assem%l$ cannot %e inspected a"ter t(e assem%l$ is complete, t(e module or assem%l$ must %e inspected at selected points durin assem%l$ to assure inspection o" eac( 8eld in t(e module.


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@#- &*S.A" *0SPE%+*)0

All 8elds s(all %e inspected visuall$ at a mani"ication o" ;0M. T(e 8elds s(all con"ormto t(e "ollo8in visual inspection criteria

a> %raced Weld - An$ 8eld t(at ex(i%its a crac& in t(e 8eld one s(all %e reBected.

%> Pitted1Deformed Weld - An$ 8eld t(at ex(i%its pits, (oles or voids open to t(esur"ace, in eit(er o" t(e materials %ein s(all %e reBected. Sur"ace de"ormationor upset "rom electrode contact s(all not %e considered unless t(e area in4uestion ex(i%its s(arp notc( li&e c(aracteristics, severe oxidation due toover(eatin, or 8(ere eit(er o" t(e elements (as %een de"ormed*upset %$ moret(an 0G o" t(e material t(ic&ness.

c> 5etal E?pulsion - An$ 8eld t(at ex(i%its metal expulsion 8(ere t(e molten metal(as %ecome separated "rom t(e 8eld area s(all %e reBected.

d> Electrode Deposit - Sini"icant deposits o" t(e electrode tip %ein le"t on t(e 8eldsur"ace s(all %e reBected. Topical s(allo8 deposits and super"icial mar&s s(allnot %e considered.

e> )pen Weld - An open 8eld s(all %e reBected. An open 8eld is one in 8(ic( a 8eld(as %een attempted %ut no %ondin (as occurred.

"> 5issed Weld - An$ 8eld t(at (as %een speci"ied on t(e dra8ins %ut (as %eenoverloo&ed %$ t(e 8eldin operator s(all %e identi"ied and 8elded to meet t(edra8in re4uirements.

@#! WE"D REPA*RS A0D REW)R6

An$ 8eld t(at (as %een indicated as (avin a de"ect =8it( t(e exception o" an 1peneld or a 'issed eld> as listed in 6.;, or as not meetin t(e re4uirements speci"iedon t(e dra8in, ma$ %e re8elded no more t(an ! time at t(e same location 8(ere t(eoriinal 8eld 8as attempted. An 1pen or 'issed eld s(all %e re8or&ed to provide aninitial 8eld per t(e enineerin dra8in. " a re8eld attempt is unsuccess"ul, unless amis"ire condition occurs, a discrepanc$ report s(all %e enerated and s(all re4uiredispositionin %$ t(e responsi%le enineerin oraniation. T8o unsuccess"ul re8eldattempts s(all re4uire dispositionin %$ t(e 'aterial Revie8 )oard ='R)>. T(e level o" documentation o" repair 8elds s(all, at a minimum, %e consistent 8it( t(at re4uired "or t(e oriinal production 8eld. All re8elds s(all %e per"ormed usin t(e PS used "or t(e oriinal 8eld or a speci"ic 4uali"ied PS "or t(at repair and s(all meet all o" t(ere4uirements o" t(e oriinal dra8in and an$ additional re4uirements t(at aredocumented in t(e PS.

# PR)%ESS D)%.5E0+A+*)0 RE4.*RE5E0+S

T(e PS, P<R, and 1P< s(all %e prepared and retained as a permanent recordand made availa%le upon re4uest to t(e NASA*#SC 'KP oraniation "or revie8.

T(ese procedures must contain, at a minimum, all o" t(e essential 8eldin parameters,an identi"ication o" t(e 8eldin e4uipment, and include an$ pertinent toolinin"ormation. 1ne cop$ o" t(e PS s(all %e maintained in t(e vicinit$ o" t(e 8eldinstation and s(all %e readil$ accessi%le %$ t(e 8elders, inspectors, supervision, and*or enineerin.


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#( WE"D*0/ PR)%ED.RE SPE%*F*%A+*)0

A eldin Procedure Speci"ication =PS> is a 4uali"ied 8ritten 8or&in procedure t(atmust %e developed %e"ore %einnin production "or eac( uni4ue 8eld t$pe to %eproduced. <uali"ication support documentation in t(e "orm o" a Procedure <uali"icationRecord =P<R> s(all %e maintained on "ile to s(o8 proo" o" process*procedure capa%ilit$

usin t(e PS. T(e PS s(all %e tracea%le %$ means o" serialied nomenclature ands(all s(o8 tracea%ilit$ to t(e applica%le P<R=s>. T(e PS used "or production 8eldins(all meet t(e re4uirements o" t(is process speci"ication and s(all %e certi"ied %$ t(eresponsi%le 'KP oraniation at t(e operatin "acilit$, prior to use in production.

Appendix ) is an example o" a eldin Procedure Speci"ication (o8ever, an$ "ormat isconsidered accepta%le provided all t(e in"ormation and data necessar$ to success"ull$per"orm t(e 8eldin activit$ is availa%le and displa$ed clearl$.

#2 PR)%ED.RE 4.A"*F*%A+*)0 RE%)RD

A Procedure <uali"ication Record =P<R> is documentation to support t(e 8eldinprocedure speci"ication to s(o8 proo" o" process*procedure capa%ilit$. A P<R s(all %euni4ue and tracea%le, %$ means o" serialied nomenclature. T(e P<R s(all %e process

speci"ic and speci"ic to a uni4ue 8eld t$pe. Data re4uired in t(e P<R s(all includedetailed descriptions o" t(e test coupon con"iurations and Boint desins, all pertinentmaterial speci"ications, all pertinent essential process varia%les used, all destructiveand nondestructive test results "rom t(e 4uali"ication sample set, and all re4uiredcerti"ications "rom t(e approvin oraniation. T(e P<R s(all %e approved %$ t(eresponsi%le 'KP oraniation at t(e operatin "acilit$. Appendix A is an example o" aProcedure <uali"ication Record (o8ever, an$ "ormat is considered accepta%le providedall t(e in"ormation and data necessar$ to accuratel$ document t(e process is madeavaila%le and displa$ed clearl$.

#- WE"D*0/ )PERA+)R PERF)R5A0%E 4.A"*F*%A+*)0

A eldin 1perator Per"ormance <uali"ication =1P<> is documentation t(at s(o8st(at a 8elder (as %een tested in accordance 8it( t(is PRC and s(o8n competent toproduce a sound 8eld "or a speci"ic 8eldin process*%ase material*e4uipmentcom%ination. An$ "ormat is considered accepta%le provided all t(e in"ormation anddata necessar$ to accuratel$ document t(e operators per"ormance 4uali"ication ismade availa%le and displa$ed clearl$.

#! DE&*A+*)0S A0D WA*&ERS

An$ deviations or 8aivers reardin t(e use o" t(is process speci"ication s(all %ere4uested in 8ritin %$ t(e outside vendor. T(is re4uest s(all %e directed to t(e

NASA*#SC 'KP oraniation 8it( t(e appropriate Busti"ication and rationale. A 8rittenresponse 8ill %e provided upon suc( a re4uest.


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3# +RA*0*0/ A0D %ER+*F*%A+*)0 )F PERS)00E"

3#( +RA*0*0/

At #SC, i" 8eldin operator trainin is considered necessar$ prior to4uali"ication*re4uali"ication o" existin #SC 8eldin operator personnel or t(e initial

4uali"ication o" ne8 (ires, it s(all %e conducted in accordance 8it( T-0000-0. 7or anoutside #SC vendor, 8eldin operator trainin =8(en necessar$> s(ould consist o" practice usin t(e "acilit$ 8eldin e4uipment 8it( a speci"ic PS to demonstratepro"icienc$, under t(e supervision o" a 4uali"ied*certi"ied 8eldin operator or desinatedtrainin personnel. Speci"ic development o" an appropriate trainin proram s(all %et(e responsi%ilit$ o" t(e vendor. RS is a potentiall$ (aardous Boinin process%ecause o" t(e (i( eneries involved. Trainin s(all include ade4uate exposure to allspot 8eldin e4uipment manu"acturers instructions and applica%le industr$ standardsrelatin to sa"et$ and 8(ere applica%le, to t(e speci"ic (aards related to %atteries. All#SC oraniations and t(eir contractors 8(o enae in (andlin %atteries s(all %etrained in all approved uidelines and procedures "or 8or&in 8it( and (andlin%atteries. Sa"et$ related documents listed in Section .0 o" t(is PRC "orm a part o" t(ese sa"et$ precautions and notes to t(e extent speci"ied (erein.

3#2 WE"D*0/ )PERA+)R 4.A"*F*%A+*)0

Resistance spot 8eldin o" %atter$ and related electronic assem%lies s(all %eper"ormed %$ a 8eldin operator 4uali"ied and certi"ied in accordance 8it( NASA*#SCPRC-0009. Su""icientl$ detailed records s(all %e maintained %$ t(e manu"acturinoraniation executin t(e process=es>. T(ese records s(all %e made availa%le to t(eNASA*#SC 'KP oraniation upon re4uest. 'inimum re4uirements "or 4uali"ication*certi"ication s(all %e demonstrated %$ eit(er o" t(e "ollo8in

a> t(e operator must (ave success"ull$ per"ormed a P<R 4uali"ication or re4uali"ication to a 8ritten PS per t(is speci"ication, or

%> t(e operator must (ave %een Buded competent in t(e process and use o" t(ee4uipment, %$ t(e responsi%le 'KP enineerin representative, %$ success"ull$demonstratin t(e application o" a 4uali"ied PS. T(is s(all include demonstrationto t(e 4uali"ier =certi"$in representative>, mac(ine operation, sc(edule*parameter selection, electrode setup, and 8eld c$cle execution.


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APPE0D*= A$ndon ). #o(nson Space Center

R+SSTANC+ SP1T +DN2O PR1C+DIR+ <IA7CAT1N R+C1RD =P<R>

E4.*P5E0+ *DE0+*F*%A+*)0 E"E%+R)DE %)0F*/.RA+*)0 A0D SE+.P

Date nitial <uali"ication Re4uali"ication P<R No.

E"E%+R)DES

)$

)$

Date

Date

PA/E ( of -

e certi"$ t(at t(e statements and p(otomicrorap(s in t(is data s(eet

are correct and t(e test 8elds 8ere 8elded and tested in accordance

8it( #SC PRC-0009. T(e p(otomicrorap(s s(all "orm a part o" t(is

P<R to t(e extent speci"ied in #SC PRC-0009, Revision.

&AR*AB"ES

No. o" eld C$cles Per ocation

Polarit$, 7irst C$cle

Polarit$, Second C$cle

Pulse idt(

Num%er o" Pulses

Total +lectrode Tip 7orce =l%s>

e"t +lectrode Tip 7orce =l%s>

Ri(t +lectrode Tip 7orce =l%s>

7irin 7orce Settin

Approx Av Pea& Amperae

Response =re"erence onl$>

18ner * ocation

Po8er Suppl$ * 'odel

Serial Num%er

eld Head * 'odel

Serial Num%er

nterconnectin Ca%le Sie * ent(

5A+ER*A"S

BA++ER,

'anu"acturer

T$pe * Sie

'aterial T$pe * 'etallurical Cond

Anode T(ic&ness

Cat(ode T(ic&ness

Sur"ace Condition

'anu"acturer T$pe * Temper

Heat Num%er

T(ic&ness * idt(

Sur"ace Condition

Component ead 'aterial

Component ead 2ae

%)00E%+*0/ 1 %)5P)0E0+ 5A+ER*A"S

R'A Cateor$

1t(er Cateor$ * Descip

Distance )et8een +lectrode Tips

+lect Tip Con"i * Sie

Contact Tip Sur"ace S(ape

+lectrode )od$ Dimensions

1t(er

Pulse !

Pulse 5

8att seconds

8att seconds

G po8er or

G po8er or


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$ndon ). #o(nson Space Center

CRES*S+A0%E SP)+ WE"D*0/ PR)%ED.RE 4.A"*F*%A+*)0 RE%)RD 8P4R9


)$

)$

Date

Date

Peel Test

Sample %athode or &isual Resistivity Peel +est ITS =l%s.>

0umber Anode Results 8mohms9 Plug Pull )uts 1 +otal =Re"erence 1nl$>

!

5

;

3

6

:

9

!0

!!

!5

!;

!

!

!3

!6

!:

!9

505!

55

5;

5

5

53

56

5:

59

;0

*0SPE%+*)0 A0D +ES+*0/ RES."+S

e certi"$ t(at t(e statements and p(otomicrorap(s in t(is data s(eetare correct and t(e test 8elds 8ere 8elded and tested in accordance

8it( #SC PRC-0009. T(e p(otomicrorap(s s(all "orm a part o" t(isP<R to t(e extent speci"ied in #SC PRC-0009, Revision.

PA/E 2 of -


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PRC-0009 Rev. D

$ndon ). #o(nson Space Center

CRES*S+A0%E SP)+ WE"D*0/ PR)%ED.RE 4.A"*F*%A+*)0 RE%)RD 8P4R9


)$

)$

Date

Date

5E+A"".R/*%A" +ES+*0/ RES."+S

e certi"$ t(at t(e statements and p(otomicrorap(s in t(is data s(eet

are correct and t(e test 8elds 8ere 8elded and tested in accordance8it( #SC PRC-0009. T(e p(otomicrorap(s s(all "orm a part o" t(is

P<R to t(e extent speci"ied in #SC PRC-0009, Revision.

PA/E - of -


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PRC-0009 Rev. D

APPE0D*= B$ndon ). #o(nson Space Center

CRES*S+A0%E SP)+ WE"D*0/ WE"D*0/ PR)%ED.RE SPE%*F*%A+*)0 8WPS9

E4.*P5E0+ *DE0+*F*%A+*)0

18ner * ocation

Po8er Suppl$ * 'odel

Serial Num%er

eld Head * 'odel

Serial Num%er

5A+ER*A"S

%)00E%+*0/ 1 %)5P)0E0+ 5A+ER*A"S

E"E%+R)DE %)0F*/.RA+*)0 A0D SE+.P

e certi"$ t(at t(e statements in t(is speci"ication s(eet

are correct and t(e test 8elds 8ere 8elded and tested in

accordance 8it( #SC PRC-0009, Revision.

)$

)$

Date

Date

RS Procedure Speci"ication Num%er

Applica%le #SC P<R Num%er=s>

Date n +""ect

Revision

BA++ER,'anu"acturer

T$pe * Sie

'aterial T$pe * 'etallurical Cond

Anode T(ic&ness

Cat(ode T(ic&ness

Sur"ace Condition

PA/E ( of (

'anu"acturer

T$pe * Temper T(ic&ness * idt(

Sur"ace Condition

Component ead 'aterial

Component ead 2ae

+ES+*0/

Detailed test results are documented in t(e "ollo8in

Procedure <uali"ication Record=s> =P<R>

No. o" eld C$cles Per ocation

Polarit$, 7irst C$cle

Polarit$, Second C$cle

Pulse idt(

Num%er o" Pulses

Total +lectrode Tip 7orce =l%s>

e"t +lectrode Tip 7orce =l%s>

Ri(t +lectrode Tip 7orce =l%s>

7irin 7orce Settin

Approx Av Pea& Amperae

Response =re"erence onl$>

Pulse !

Pulse 5

G po8er or

G po8er or

8att seconds

8att seconds

&AR*AB"ES

E"E%+R)DES

R'A Cateor$

1t(er Cateor$ * Comp

Distance )et8een +lectrode Tips

+lect Tip Con"i * Sie

Contact Tip Sur"ace S(ape

+lectrode )od$ Dimensions


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