Process Specification for the Resistance Spot Welding of Battery and
Electronic Assemblies

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| **Engineering Directorate**                                           |
|                                                                       |
| **Structural Engineering Division**                                   |
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| **February 2004**                                                     |
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| ![](media/image1.emf)                                                 |
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| National Aeronautics and                                              |
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| Space Administration                                                  |
|                                                                       |
| **Lyndon B. Johnson Space Center**                                    |
|                                                                       |
| Houston, Texas                                                        |
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**Process Specification for the Resistance Spot Welding of Battery and
Electronic Assemblies**

+-----------------+-------------------------------------+---+-----------+
| **Prepared by   | ***Signature on File***             |   | ***2      |
| :**             |                                     |   | /17/04*** |
+-----------------+-------------------------------------+---+-----------+
|                 | Daniel J. Rybicki                   |   | Date      |
|                 |                                     |   |           |
|                 | Materials and Processes Technology  |   |           |
|                 | Branch/ES4                          |   |           |
+-----------------+-------------------------------------+---+-----------+

+-----------------+-------------------------------------+---+-----------+
| **Approved      | ***Signature on File***             |   | ***2      |
| by:**           |                                     |   | /17/04*** |
+-----------------+-------------------------------------+---+-----------+
|                 | Jose' M. Hernandez                  |   | Date      |
|                 |                                     |   |           |
|                 | Materials and Processes             |   |           |
|                 |                                     |   |           |
|                 | Technology Branch/ES4               |   |           |
+-----------------+-------------------------------------+---+-----------+

  ------------ ----------------------------------------------- ------------
               REVISIONS                                       

  VERSION      CHANGES                                         DATE

  \--          Original version                                April 1996

  A            Expanded content throughout. Re-specify         10/29/97
               qualification requirements.                     

  B            Formatting changed process owner, rewrite       07/22/99
               numerous sections for clarification, deleted    
               requirement for WIR, deleted section 8.2 on     
               audits, added section 8.3 on WOPQ.              

  C            Add tolerance range to base material component  03/24/2000
               thickness(es), remove requirement for           
               certification of welding inspectors by the AWS, 
               remove NASA/MSFC reference documents in 4.0,    
               add item 21 to Table 1, revise 6.1, 7.0, 7.1,   
               7.3, 8.1, 8.2, and 8.3.                         

  D            Routine ISO review.                             02/17/2004
  ------------ ----------------------------------------------- ------------

**[1.0 SCOPE]{.underline}**

This process specification provides the requirements that govern the
Resistance Spot Welding (RSW) of battery tabs and component wires/leads
to batteries, battery tabs, or other associated electronic components.
Procedural and quality assurance requirements are given. All work
instructions and Weld Procedure Specifications (WPSs) used during
welding shall satisfy the requirements of this process specification and
it's applicable documents.

**[2.0 APPLICABILITY]{.underline}**

This process specification applies to the RSW of battery assemblies and
associated electronic flight and non flight hardware fabricated under
the control of the NASA/Johnson Space Center (JSC). RSW with opposed
electrodes (i.e., referred to herein as "opposed welding") is considered
as well as RSW with gapped electrodes (i.e., referred to herein as
"series welding"). Battery assemblies are considered to be non
structural with no load carrying capacity and shall be either potted,
taped, shrink wrapped, or installed in a rigid containment to preclude
stressing the tabs and lead wires.

**[3.0 USAGE]{.underline}**

This process specification shall be called out on the engineering
drawing by a drawing note with the following general format :

**WELD AND INSPECT PER NASA/JSC PRC-0009**

## **3.1 DESIGN REQUIREMENTS**

a)  The design of welded joints shall conform to the applicable hardware
    design handbooks contained in the Engineering Standards Library*.*

b)  All engineering drawings shall depict welded joints using the
    applicable symbols described in AWS A2.4.

c)  As required, all engineering drawings shall specify the minimum
    number and maximum number of resistance welded spots required for
    each connection. In any case, there shall be no less than two weld
    spots per connection. Connections which will accommodate only one
    spot shall be avoided where possible.

d)  As applicable, all engineering drawings shall specify the maximum
    electrical resistivity allowed for each connection. Where
    resistivity is not specified, measurements shall not exceed 1.0 mΩ.

e)  When welding occurs onto battery cells, the parts list shall contain
    the battery manufacturer, size, model/type no., and voltage rating.

f)  The parts list shall contain the tab or contact material,
    specification, thickness, width, metallurgical condition (e.g., ¼
    hard, ½ hard, etc.) and surface finish as applicable.

g)  The parts list shall contain component leads (i.e., diode leads)
    gage, material, and metallurgical condition (e.g., metallurgical,
    surface finish, etc.) and surface finish as applicable.

h)  Stranded wire shall not be resistance spot welded.

## **3.2 WORK INSTRUCTIONS**

Work instructions shall be generated for implementing this process
specification. The work instructions shall contain sufficient detail to
ensure that the manufacturing process produces consistent, repeatable
products that comply with this specification. At JSC, these work
instructions are approved as Detailed Process Instructions (DPIs) that
describe in a detailed, step-by-step format the required procedures,
equipment, and materials to be used for conducting a given process.

If this manufacturing process is to be performed by an outside vendor,
work instruction development shall be the responsibility of the vendor.
The contractor shall ensure that the work instructions meet the
requirements of this process specification.

**3.3 DEFINITIONS**

**Essential Variable** -- An identified variable in the welding process
that must be controlled to ensure repeatable weld quality.

**Opposed Welding** - RSW which utilizes two electrodes positioned
exactly opposite, and in line with each other (electrodes share a common
axis). See Figure 2. Each electrode contacts a single piece of base
material. Each weld cycle produces only one fused spot.

**Series Welding** - RSW which utilizes two electrodes positioned
adjacent to each other but separated by an air gap or other dielectric.
See Figure 2. Each electrode contacts the same surface of base material.
This type of welding is utilized where access to both sides of the weld
joint is physically restricted or if component damage would result if
the welding current were allowed to shunt through the system circuit or
electrical component. Support tooling opposing the force of the
electrodes is insulated from the welding circuit and therefore does not
shunt current from the welding circuit. Each weld cycle produces two
fused spots. The electrodes can be positioned parallel or at a fixed
angle to each other.

**Unique Weld Type** - Those weld joint configurations that differ from
one another in any of the following respects:

1.  Battery anode and/or cathode cross sectional thickness (±10%),

2.  Anode and/or cathode material, metallurgical condition, and surface
    finish,

3.  Jumper tab cross sectional thickness (±10%),

4.  Jumper tab material or metallurgical condition,

5.  Component lead/wire material, metallurgical condition, and surface
    finish,

6.  Component lead material/wire cross sectional diameter (±10%).

![](media/image2.wmf){width="6.439583333333333in"
height="3.745138888888889in"}

# **4.0 REFERENCES**

The standards listed below shall be considered a part of this
specification to the extent specified herein. Unless otherwise
indicated, the revision that is in effect on the date of invitation for
bids or the date of request for proposals shall apply.

**a. American Welding Society (AWS) Standards**

ANSI/AWS A2.4 *Standard Symbols for Welding, Brazing and Nondestructive
Testing*

ANSI/AWS A3.0 *Standard Welding Terms and Definitions*

# **b. NASA/JSC Documents**

JPG 1700.1G *NASA/JSC Requirements Handbook for Safety, Health and
Environmental Protection*

EM-007.1 *Preparation and Revision of Process Specifications*

TI-0000-04 *Training For Welders and Welding Operators*

# **c. RWMA Documents**

No Document Number *Resistance Welding Manual; Resistance Welder
Manufacturers' Association (RWMA)*

# **d. SAE/Aerospace Material Specification (AMS) Documents**

AMS 2690 *Parallel Gap Welding*

## 

## **5.0 [MATERIAL AND EQUIPMENT REQUIREMENTS]{.underline}**

All materials used in the welding of electronically related flight
hardware shall meet the requirements of an applicable JSC material
specification unless otherwise specified. If a JSC material
specification is not available, an applicable commercial specification
or a manufacturer\'s specification shall be used.

**5.1 EQUIPMENT**

The equipment used to produce the welds shall consist of an electrical
energy source, electrodes, and a means of applying mechanical pressure
to the materials to be welded.

**5.1.1 Power Supply**

The power supply shall have an adequate means of controlling and
indicating the energy applied to the weld zone. The power supply shall
have means for internal voltage regulation if there is no such
regulation on the primary AC power line source. Regulation shall be
within ±2% for line voltage variations of ±10%. Energy source meters
shall have a minimum accuracy of ±2%.

**5.1.2 Welding Head**

The welding head shall be of low-inertia design and provide a means of
efficiently controlling electrode force. The electrode force shall be
repeatable to within ±5%.

**5.1.3 Electrodes**

The composition of electrodes shall conform to the Resistance Welder
Manufacturer's Association (RWMA) alloy classifications or the electrode
manufacturer's classifications. Each electrode shall be identified
according to the RWMA category or manufacturer's classification, body
size, configuration, and tip size. Custom electrodes are allowed
however, the specific electrode materials and configuration shall be
considered an essential variable.

**5.1.4 Tooling and Fixtures**

Tooling required to locate or assist in the assembly of batteries to be
welded shall be designed to preclude any secondary current path that
will allow current to be shunted away from the electrodes or through
battery cells.

**5.1.5 Welding Equipment Qualification**

The welding equipment shall be qualified as a system that includes at a
minimum, the power supply, weld head, electrodes, and interconnecting
cables. Qualification of a Welding Procedure Specification also
qualifies the system. Otherwise, qualification of a system shall be per
6.2.2.

**5.1.6 Force GaUge**

Devices used to determine electrode force shall have a minimum accuracy
of ±5%.

# **6.0 PROCESS REQUIREMENTS**

All weldments shall be fabricated according to the requirements of this
process specification. The requirements of the applicable codes and
standards listed in Section 4.0 shall be met as specified by this PRC
based on the design and intended function of the hardware. Certain
paragraphs of this process specification are abbreviated re-statements
taken from the applicable standards and are included here for the
clarification. The remaining paragraphs of this process specification
may represent requirements imposed in addition to the basic requirements
of the applicable codes and standards.

All resistance welding shall be performed using Welding Procedure
Specifications (WPS) that have been qualified in accordance with the
requirements of Section 6.2.

## **6.1 PROCESS-SPECIFIC REQUIREMENTS**

**6.1.1 Weld SYSTEM INSPECTION AND CHECK OUT**

Prior to the start of each qualification, preproduction, production, or
requalification lot, and at any interval(s) deemed necessary by the
operator or engineering, the following items shall be addressed and any
discrepant condition corrected as required. Weld circuit
interconnections shall be inspected to ensure that they are tight, clean
and corrosion free. Electrode alignment shall be checked per the WPS
requirements and adjusted. Electrode tips and contact surface condition
shall be inspected and continuously monitored for conditions which may
impede welding techniques and/or weld quality. The electrodes and
related essential components shall be cleaned, dressed, or replaced.
Electrodes shall be dressed with number 600 or finer grit abrasive paper
or equivalent. Electrode force shall be checked quantitatively by a
calibrated force gauge and adjusted. For applications where each
electrode is controlled individually (e.g., series welding), the force
of each electrode shall be determined and adjusted individually.

## **6.2 Weld Qualification**

A Welding Procedure Specification (WPS) shall be qualified for each
unique weld type to be produced by conforming to the requirements below,
before the production welds are made. An existing qualified WPS for one
unique weld type may be used for a new engineering drawing provided the
resistivity determined during qualification meet the requirements of the
new drawing as applicable, and it is demonstrated that the essential
weld variables will be met. Demonstration shall constitute all the
requirements of Section 6.2.2 except that no additional documentation is
required (existing PQR and WPS records shall be acceptable
documentation).

**6.2.1 Qualification of WPS**

The actual welding variables, methods, practices, specific tooling
requirements, and test results used during WPS qualification shall be
recorded on a Procedure Qualification Record (PQR).

**6.2.2 Requalification of WPS**

Requalification of the WPS shall be required when any of the following
conditions exist:

a)  The weld system has been placed on a different external power source
    except when the power supply has a means for internal power
    regulation,

b)  A WPS is proposed to be used on a weld system or systems other than
    that used for the initial qualification,

c)  Major maintenance has been performed on the weld system. Major
    maintenance includes replacement of the power supply, major repair
    of the power supply requiring entrance into the controller or
    transformer cabinet, replacement of the weld head, or replacement or
    change in length by more than 10% of any of the interconnecting
    cables,

d)  Preproduction weld samples do not meet requirements and no
    assignable cause for the failure can be determined.

Requalification may be performed with less total test sample
requirements than that required for an initial qualification for a
unique weld type. For requalification, 5 total weld samples shall be
produced and submitted as a lot. All 5 samples shall be subjected to
visual inspection and conductivity and destructive peel testing and
shall meet the applicable requirements specified herein. No
requalification specimens from the 5 submitted shall fail any of the
requirements as stated herein. Requalification results shall be
documented on a PQR with a specific notation made indicating
"requalification". If the requalification activities result in any
welding parameter deviations that exceed the range specified in Table 1
for that parameter, then the level of testing in 6.2.4 shall be
required.

**6.2.3 Essential Variables**

All essential variables shall be addressed and identified on a qualified
WPS and the supporting PQR. These essential variables are listed in
Table 1 below. Other variables determined to be essential to maintaining
the quality of the process output may be required to be controlled, as
determined by the M&P organization.

[**Table 1** **Essential Welding Variables**]{.underline}

  ------------ ------------------------------------- ---------------------
  **NUMBER**   **ESSENTIAL VARIABLES**               **VARIABLE RANGE**

  1            A change in the input line voltage    NONE^(1)^
               source                                

  2            Power supply - make and model         NONE

  3            Weld head - make and model            NONE

  4            Interconnecting cable size and length ±10%

  5            Tab material type                     NONE

  6            Tab material metallurgical condition  NONE

  7            Tab material thickness                ±10%

  8            Battery material type                 NONE

  9            Battery material metallurgical        NONE
               condition                             

  10           Battery anode thickness               ±10%

  11           Battery cathode thickness             ±10%

  12           Component lead material type          NONE

  13           Component lead metallurgical          NONE
               condition                             

  14           Component lead diameter               ±10%

  15           Surface condition of base materials   NONE

  16           Electrode RWMA category or other      NONE
               classification                        

  17           Electrode configuration & dimensions  NONE

  18           Electrode tip spacing                 ±20%

  19           Electrode tip contact surface shape   NONE

  20           Electrode tip contact surface area    ±10%

  21           Process -- a change from opposed to   NONE
               series welding or vice versa          

  22           Weld % power or watt/sec (all pulses) ±10%

  23           Number of weld pulses                 NONE

  24           Weld pulse width                      NONE

  25           Electrode tip force (pounds)          ±10%

  26           Current type (AC or DC)               NONE

  27           DC polarity current direction         NONE
               (Opposed Welding only)                
  ------------ ------------------------------------- ---------------------

^(1)^ Unless the power supply has internally regulated voltage
capability.

**6.2.4 Qualification Samples**

**6.2.4.1 General**

The manufacturing organization is responsible for qualifying the welding
process. Actual cathode and anode ends for the same make, size, and
model/type battery used in the design shall be obtained for use as
qualification and preproduction control samples. Actual batteries may be
also used for qualification and/or preproduction control samples.
Wire/leads of the same material and construction as component leads, or
actual components used in the design, shall also be supplied when
appropriate.

**6.2.4.2 QUALIFICATION MATERIALS**

For each unique type of weld to be produced, a minimum of 15 sample
welded connections shall be produced for an initial procedure
qualification and submitted as a lot. For either of the following weld
conditions, an additional sample shall be produced and submitted for
metallurgical examination bringing the minimum total to 16: 1) the
faying surfaces at the weld joint are of essentially different
materials, or 2) where it is determined that any of the base materials
(plated or not) are known to experience significant degradation or other
problems caused by the weld heating. Weld control settings shall not be
varied nor shall any maintenance, except cleaning and/or polishing of
electrodes, be performed on the equipment during the production of the
qualification samples. The number of weld spots on each qualification
sample connection shall not exceed the minimum number required per the
engineering drawing or if not specified shall be no greater than 2 spots
per connection or that planned for production work. The qualification
sample set shall be acceptable to all of the following 4 levels of
quality control as applicable, for successful qualification: 1) visual
inspection, 2) conductivity (resistivity) testing, 3) destructive peel
testing, and 4) metallurgical examination (when required).

**6.2.4.3 Visual Inspection and Electrical Conductivity Testing**

All weld specimens shall be visually inspected per 7.3 and tested for
electrical conductivity (resistivity). The resistivity of each
connection shall meet the drawing requirements or if not specified by
the drawing, shall measure less than 1.0 mΩ. If any of the individual
samples from those submitted fail to pass the visual or resistivity
requirements, an additional sample shall be allowed to be welded and
submitted to replace it, one time only. If more than 2 samples from the
original lot fail the visual or resistivity requirements further weld
parameter development or process analysis to determine the cause for the
rejection(s) is required prior to submitting another lot of samples for
testing to the requirements of this specification.

**6.2.4.4 Destructive Peel Testing**

Fifteen (15) weld samples shall be peel tested. The edges of a spot
welded sample connection shall be gripped and pulled apart to failure.
The welded connection (lap joint) shall be pulled in tension at an
approximate 90^0^ angle to the plane of the faying joint surfaces. See
Figure 3. The length of the grip sections on the samples shall be long
enough to preclude any interference of the gripping hardware with the
welded connection. For a procedure qualification or preproduction
verification sample set to be considered acceptable, the result of the
peel test must be a plug pull-out in a minimum of 75% of the total
number of individual spots in the sample set for connections with 4 or
more spots, 85% for connections with 3 spots only, and 100% for
connections with 2 or less spots. If any of the individual samples from
the 15 peel tests fail to result in at least 2 plug pull-outs from the
total number of weld spots on the individual connection, 2 additional
welded sample connections may be welded and submitted for inspection and
testing as part of the initial sample set, one time only. These 2
samples shall then be factored into the above acceptance criteria. If
more than 2 samples from the original lot fail the peel test as
described above, further weld parameter development or process analysis
to determine the cause for the failure(s) is required prior to
submitting another 16 samples for testing to the requirements of this
specification. If the minimum plug pull-out requirement for the total
number of individual spots in the sample set (i.e., 75%, 85%, or 100%
for the respective condition) can not be met as described above, further
weld parameter development or process analysis to determine the cause
for the failure is required prior to submitting another lot of samples
for testing to the requirements of this specification.

![](media/image3.wmf)

![](media/image4.wmf){width="6.439583333333333in"
height="2.7152777777777777in"}

**6.2.4.5 Metallurgical Examination**

When required, one (1) of the 16 samples submitted shall be
cross-sectioned, mounted, polished, and etched for metallurgical
examination. For samples involving a wire or component leads, one each
weld spot on the connection will be cross sectioned transverse to the
wire diameter and longitudinal to the wire diameter axis and for Series
Welded samples, cross sections of both weld spots produced by one weld
cycle (welds produced under each electrode contact) shall be taken. See
Figure 4.

The welds shall be free of cracks or voids open to any exterior surface.
Pore and voids contained within the weld zone but not open to an
exterior surface, and are not determined to have sharp notch like
characteristics, shall be acceptable. When examining welds intended for
battery cells, any anomaly which is determined to be a potential for
breaching or degrading the battery housing and therefore potentially
causing a leak, shall be cause for rejection. In addition, a
metallurgical fusion bond shall be visible at each weld spot interface.
If this criteria cannot be met, further weld parameter development or
process analysis to determine the cause for the rejectable condition, is
required prior to submitting another lot of samples for testing to the
requirements of this specification. Photomicrographs shall be taken of
the prepared samples and retained with the PQR.

### 

### **7.0 [PROCESS VERIFICATION]{.underline}**

Process verification shall consist of visual examination and/or
nondestructive inspection, as described further in sections 7.1 to 7.3.
In addition, at the appropriate time during the fabrication activities,
the manufacturing activity shall assure the following items:

a)  The operator is certified for the specific welding operation,

b)  A valid WPS exists,

c)  The essential variable ranges for the WPS are being adhered to.

### 

### **7.1 Preproduction Welding VERIFICATION**

### Prior to the start of a production run, a minimum of 1 preproduction weld sample for each unique type of weld shall be prepared using the appropriate qualified WPS. Actual batteries and component leads or simulated ones, as described in section 6.2.4.1, shall be used for this preproduction weld sample. The sample shall be visually inspected, in accordance with Section 7.3, and peel tested, in accordance with Section 6.2.4.4. The preproduction sample shall be made and tested before the welding of the production welds and under the following conditions:

a)  At the start of a production shift or the change of production
    shifts,

b)  Upon replacement of either or both of the welding electrodes,

c)  Following metal expulsion or severe metal deposits on the electrode
    face(s),

d)  Following the misfire or no weld condition where a weld has been
    attempted but not made and no assignable cause can be determined,

e)  Following a delay in welding of more than 4 hours and where the
    welding system was required to be powered down during this period,

f)  Where a different operator was assigned to the workstation to
    continue a job.

Different WPSs may be alternated within a production welding session
provided the above requirements are met.

## **7.2 Weld Verification**

## 

Prior to encapsulation, potting, or any process which would preclude
inspection of the welds, all welds and workmanship shall be inspected
for conformance to the requirements of this standard and the engineering
drawing. If a nonconformance is identified it shall be documented
appropriately. If the welds of a completed welded module or assembly
cannot be inspected after the assembly is complete, the module or
assembly must be inspected at selected points during assembly to assure
inspection of each weld in the module.

**7.3 Visual Inspection**

All welds shall be inspected visually at a magnification of 30X. The
welds shall conform to the following visual inspection criteria:

a)  **Cracked Weld** - Any weld that exhibits a crack in the weld zone
    shall be rejected.

b)  **Pitted/Deformed Weld** - Any weld that exhibits pits, holes or
    voids open to the surface, in either of the materials being shall be
    rejected. Surface deformation or upset from electrode contact shall
    not be considered unless the area in question exhibits sharp notch
    like characteristics, severe oxidation due to overheating, or where
    either of the elements has been deformed/upset by more than 50% of
    the material thickness.

c)  **Metal Expulsion** - Any weld that exhibits metal expulsion where
    the molten metal has become separated from the weld area shall be
    rejected.

d)  **Electrode Deposit** - Significant deposits of the electrode tip
    being left on the weld surface shall be rejected. Topical shallow
    deposits and superficial marks shall not be considered.

e)  **Open Weld** - An open weld shall be rejected. An open weld is one
    in which a weld has been attempted but no bonding has occurred.

f)  **Missed Weld** - Any weld that has been specified on the drawings
    but has been overlooked by the welding operator shall be identified
    and welded to meet the drawing requirements.

**7.4 WELD REPAIRS AND REWORK**

Any weld that has been indicated as having a defect (with the exception
of an Open Weld or a Missed Weld) as listed in 7.3, or as not meeting
the requirements specified on the drawing, may be rewelded no more than
1 time at the same location where the original weld was attempted. An
Open or Missed Weld shall be reworked to provide an initial weld per the
engineering drawing. If a reweld attempt is unsuccessful, unless a
misfire condition occurs, a discrepancy report shall be generated and
shall require dispositioning by the responsible engineering
organization. Two unsuccessful reweld attempts shall require
dispositioning by the Material Review Board (MRB). The level of
documentation of repair welds shall, at a minimum, be consistent with
that required for the original production weld. All rewelds shall be
performed using the WPS used for the original weld or a specific
qualified WPS for that repair and shall meet all of the requirements of
the original drawing and any additional requirements that are documented
in the WPS.

# **8.0 PROCESS DOCUMENTATION REQUIREMENTS**

The WPS, PQR, and WOPQ shall be prepared and retained as a permanent
record and made available upon request to the NASA/JSC M&P organization
for review. These procedures must contain, at a minimum, all of the
essential welding parameters, an identification of the welding
equipment, and include any pertinent tooling information. One copy of
the WPS shall be maintained in the vicinity of the welding station and
shall be readily accessible by the welders, inspectors, supervision,
and/or engineering.

**8.1 WELDING PROCEDURE SPECIFICATION**

A Welding Procedure Specification (WPS) is a qualified written working
procedure that must be developed before beginning production for each
unique weld type to be produced. Qualification support documentation in
the form of a Procedure Qualification Record (PQR) shall be maintained
on file to show proof of process/procedure capability using the WPS. The
WPS shall be traceable by means of serialized nomenclature and shall
show traceability to the applicable PQR(s). The WPS used for production
welding shall meet the requirements of this process specification and
shall be certified by the responsible M&P organization at the operating
facility, prior to use in production. Appendix B is an example of a
Welding Procedure Specification however, any format is considered
acceptable provided all the information and data necessary to
successfully perform the welding activity is available and displayed
clearly.

**8.2 PROCEDURE QUALIFICATION RECORD**

A Procedure Qualification Record (PQR) is documentation to support the
welding procedure specification to show proof of process/procedure
capability. A PQR shall be unique and traceable, by means of serialized
nomenclature. The PQR shall be process specific and specific to a unique
weld type. Data required in the PQR shall include detailed descriptions
of the test coupon configurations and joint designs, all pertinent
material specifications, all pertinent essential process variables used,
all destructive and nondestructive test results from the qualification
sample set, and all required certifications from the approving
organization. The PQR shall be approved by the responsible M&P
organization at the operating facility. Appendix A is an example of a
Procedure Qualification Record however, any format is considered
acceptable provided all the information and data necessary to accurately
document the process is made available and displayed clearly.

## **8.3 WELDING OPERATOR PERFORMANCE QUALIFICATION**

A Welding Operator Performance Qualification (WOPQ) is documentation
that shows that a welder has been tested in accordance with this PRC and
shown competent to produce a sound weld for a specific welding
process/base material/equipment combination. Any format is considered
acceptable provided all the information and data necessary to accurately
document the operator's performance qualification is made available and
displayed clearly.

## 

## **8.4 DEVIATIONS AND WAIVERS**

Any deviations or waivers regarding the use of this process
specification shall be requested in writing by the outside vendor. This
request shall be directed to the NASA/JSC M&P organization with the
appropriate justification and rationale. A written response will be
provided upon such a request.

# 

# **9.0 TRAINING AND CERTIFICATION OF PERSONNEL**

## **9.1 TRAINING**

At JSC, if welding operator training is considered necessary prior to
qualification/requalification of existing JSC welding operator personnel
or the initial qualification of new hires, it shall be conducted in
accordance with TI-0000-04. For an outside JSC vendor, welding operator
training (when necessary) should consist of practice using the facility
welding equipment with a specific WPS to demonstrate proficiency, under
the supervision of a qualified/certified welding operator or designated
training personnel. Specific development of an appropriate training
program shall be the responsibility of the vendor. RSW is a potentially
hazardous joining process because of the high energies involved.
Training shall include adequate exposure to all spot welding equipment
manufacturer's instructions and applicable industry standards relating
to safety and where applicable, to the specific hazards related to
batteries. All JSC organizations and their contractors who engage in
handling batteries shall be trained in all approved guidelines and
procedures for working with and handling batteries. Safety related
documents listed in Section 4.0 of this PRC form a part of these safety
precautions and notes to the extent specified herein.

**9.2 WELDING OPERATOR QUALIFICATION**

Resistance spot welding of battery and related electronic assemblies
shall be performed by a welding operator qualified and certified in
accordance with NASA/JSC PRC-0009. Sufficiently detailed records shall
be maintained by the manufacturing organization executing the
process(es). These records shall be made available to the NASA/JSC M&P
organization upon request. Minimum requirements for
qualification/certification shall be demonstrated by either of the
following:

a)  the operator must have successfully performed a PQR qualification or
    requalification to a written WPS per this specification, or

b)  the operator must have been judged competent in the process and use
    of the equipment, by the responsible M&P engineering representative,
    by successfully demonstrating the application of a qualified WPS.
    This shall include demonstration to the qualifier (certifying
    representative), machine operation, schedule/parameter selection,
    electrode setup, and weld cycle execution.

**APPENDIX A**

![](media/image5.wmf){width="6.4944444444444445in"
height="8.477083333333333in"}

![](media/image6.wmf){width="6.498611111111111in"
height="8.652083333333334in"}

![](media/image7.wmf){width="6.496527777777778in"
height="8.691666666666666in"}

**APPENDIX B**

![](media/image8.wmf){width="6.492361111111111in"
height="8.572916666666666in"}